Domain 1: Safety Awareness Section 2: Managing Safety Programs

Foundations of Manufacturing

PRESENTED BY ORLANDO MORENO

+1 770.354.3072

OMORENO@HOTMAIL.COM

UNIVERSITY OF CALIFORNIA AT BERKELEY

Effective Safety Programs

It has been found that effective management of worker safety programs– Reduces the extent and severity of work

related injuries and illnesses– Improves employee morale and productivity– Reduces workers’ compensation costs

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Common Characteristics of Exemplary Workplaces

• Use organized and systematic methods to– Assign responsibility to managers, supervisors,

and employees– Inspect regularly for and control hazards– Orient and train all employees to eliminate or

avoid hazards

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The Guidelines - General

• An effective program– Includes provisions for systematic identification,

evaluation and prevention or control of hazards– Goes beyond specific requirements of the law to

address all hazards• Written program– “In writing” less important than its effectiveness– As size and complexity of worksite or process

increases, so does need for written guidance

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Major Elements

An effective occupational safety program will include the following four elements–Management commitment and employee

involvement–Worksite analysis– Hazard prevention and control– Safety training

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Management Commitment and Employee Involvement

• Management commitment and employee involvement are complementary

• Management commitment provides the motivating force and resources for organizing and controlling activities within an organization

• Employee involvement provides the means through which workers develop and express their own commitment to safety protection

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Management Commitment and Employee Involvement (Cont’d.)

Recommended Actions:• State clearly a worksite safety policy• Establish and communicate a clear goal and

objective for the safety program • Provide visible top management involvement

in implementing the program

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Management Commitment and Employee Involvement (Cont’d.)

Recommended Actions:• Encourage employee involvement in the

program and in decisions that affect their safety (e.g., inspection or hazard analysis teams; developing or revising safe work rules; training new hires or co-workers; assisting in accident investigations)

• Assign and communicate responsibility for all aspects of the program

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Management Commitment and Employee Involvement (Cont’d.)

Recommended Actions:• Provide adequate authority and

resources to responsible parties• Hold managers, supervisors, and employees

accountable for meeting their responsibilities• Review program operations at least annually,

to evaluate, identify deficiencies, and revise,as needed

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Worksite Analysis

• Worksite analysis involves a variety of worksite examinations, to identify not only existing hazards, but also conditions and operations where changes might occur to create hazards

• Effective management actively analyzes the work and the worksite to anticipate and prevent harmful occurrences

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Worksite Analysis (Cont’d.)

Recommended Actions:So that all hazards are identified-– Conduct comprehensive baseline and

periodic surveys for safety and health – Analyze planned and new facilities,

processes, materials, and equipment– Perform routine job hazard analyses

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Worksite Analysis (Cont’d.)

Recommended Actions:• Provide for regular site safety inspections• Provide a reliable system for employees,

without fear of reprisal, to notify management about apparent hazardous conditions and to receive timely and appropriate responses

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Worksite Analysis (Cont’d.)Recommended Actions:• Provide for investigation of accidents and

“near miss” incidents, so that their causes and means for prevention are identified. A “near miss” is an accident without injury

• Analyze injury and illness trends over time, so that patterns with common causes can be identified and prevented

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Hazard Prevention and Control

• Triggered by a determination that a hazard or potential hazard exists

• Where feasible, prevent hazards by effective design of job or job site

• Where elimination is not feasible, control hazards to prevent unsafe and unhealthful exposure

• Elimination or control must be accomplished in a timely manner

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Hazard Prevention and Control (Cont’d.)Recommended Actions:Establish procedures for timely correction or control of hazards, including– Engineering techniques, where feasible and appropriate– Procedures for safe work which are understood and

followed as a result of training, positive reinforcement, correction of unsafe performance, and enforcement

– Provision of personal protective equipment– Administrative controls

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Hazard Prevention and Control (Cont’d.)

Recommended Actions:• Provide for facility and equipment

maintenance• Plan and prepare for emergencies– Training and drills, as needed

• Establish a medical program– First aid on site– Physician and emergency care nearby

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Safety Training

• Addresses the safety responsibilities of all personnel, whether salaried or hourly

• Most effective when incorporated into other training about performance requirements and job practices

• Complexity depends on size and complexity of worksite and nature of hazards

Forklift Safety

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Safety Training (Cont’d.)

Recommended Actions:Ensure that all employees understand the hazards to which they may be exposed and how to prevent harm to themselves and others from exposure to these hazards

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Safety Training (Cont’d.)Recommended Actions:Ensure that supervisors carry out their safety and health responsibilities, including– Analyzing the work under their supervision to

identify unrecognized potential hazards–Maintaining physical protections in work areas– Reinforcing employee training through continual

performance feedback and, if needed, enforcement of safe work practices

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Safety Training (Cont’d.)

Recommended Actions:Ensure that managers understand their safety and health responsibilities, as described under the Management Commitment and Employee Involvement element of the guidelines

AA Co.Safety &Health Policy

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Safety Training (Cont’d.)

• Training is required due to changes in people and processes

• Cross-trained employees adds flexibility to managers in assigning workers to specific jobs

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Training Documentation

• Initial safety training must be provided at time of employee’s initial assignment

• In general, refresher training is required annually• All OSHA required training includes providing workers

a copy of the OSHA standard referred to in the training.

• Training documentation is done in accordance with company policy

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Training Safety Orientation• It is important to include the process on how to

communicate safety concerns• Training material should be at a level appropriate for

the audience• Hand-on post training activities are a good way to see if

training is effective• Interactive activities are effective ways to maintain

employee interest in safety training programs

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OSHA Hazard Colors

The Occupational Safety and Health Act (OSHA) stipulates that industrial plants provide color coded safety equipment and hazard areas. The list identifies the OSHA-designated colors and their meaning.

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Hazards• Hazard:aconditionthatmaypresent,ordefinitelypresents,athreattohealth,safety,ortheenvironment

• Ahazardcombinedwithapersonperformingtheirworkinawaythatexposesthehazardcanoftenresultinaninjury

• OSHAprovidesatoolforidentifyingworkhazards:OSHA3071-JobHazardAnalysisbooklet

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Identifying Hazards• Evaluate your workplace.

• Talk to employees.

• Develop a checklist.

• Inspect your workplace regularly.

• DO NOT put yourself or someone else into a dangerous situation. DO NOT proceed until the danger is removed

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Identifying Hazards (Cont’d.)

• Job Safety Analysis – (Hazard Analysis)

• Defined as planning the best method of integrating safety into the way a job is done

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Internal Hazard Analysis ReportProcessusedtoreducetheriskofhazards

• performedannually

• performedwhennewequipmentisinstalled

• Performedbyteamsclosesttotheprocess(notbyOSHA)

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Tracking Safety Concerns Until Corrected

Hazards must be identified, described, dated for both reporting and resolution, and responsible parties identified.

Safetyinspectionrecordsstorageisdeterminedbycompanypolicy

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Hazard Response

• Eliminate hazard by designing out of the process.

• Provide Engineering controls – ventilation, guards, circuit breakers.

• Use PPE to reduce worker exposure.

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Safety Committees

• Critical for implementing corrective actions by combining management, employees, and experts as needed to solve hazards• Can assist with:– Establishing inspection procedures and recording steps– Inspecting plants from quarterly to yearly– Generating recommendations for mitigating hazards– Conducting after accident analysis and create reports

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Safety Committee

• The primary responsibility of a safety committee is to respond to worker safety concerns.

• Performance of routine safety inspections can help determine what improvements may be needed or if safety methods are working

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Approval Process for Corrective Action• Risk assessment defines hazard

• Committee considers control actions

• Management approves recommendations

• Corrective actions approved and implemented or possible safety agencies notified

• Process documented in hazard control log

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Corrective Actions Must be Prompt

• Emergency procedures must be followed for imminent health or safety conditions that are serious or life threatening; immediate corrective actions required

• Non-emergency procedures are for hazards that are not immediately serious or life threatening; reasonable time frames are allowed for resolving these hazards; OSHA can enforce actions if the company is not responsive

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Secrets to Successful Safety Practices

• Teamwork – everyone working together for a common goal

• Group problem solving - Team members discuss making decisions and solving problems as a group

• Accepting consensus – all team member accept the same decision even if it is not their first choice

• Team leader – only makes decisions when team is deadlocked

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QUESTIONS ?

OrlandoMoreno+1770.354.3072omoreno@hotmail.com