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Purpose

Describes the award‐winning Zero Injuries training program at car‐manufacturer Nissan's Sunderland plant in the UK.

Design/methodology/approach

Explains the reasons for the program, the way in which it was developed, how it is delivered and the results it has achieved.

Findings

Reveals that the number of accidents at the plant has fallen by 60 percent in the four years since the program was introduced.

Practical implications

Highlights how the program has changed the mindset of the workforce and visitors, and has resulted in a major cost saving for the plant.

Social implications

Explains that the program has helped to bring about improved job satisfaction, morale, safety awareness and communication.

Originality/value

Shows how well‐designed safety training can prove to be cost effective.

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