8Jun, 2017

Hazard Analysis and Control

HAZARD CATEGORIES

Introduction – Hazard Analysis and Control

Hazard Analysis and Control – In the first module, we began a discussion of the concepts of “hazard” and “exposure” in preparation for a further look in this module. Here we will take a closer look at the five general hazard categories and 13 more specific hazard categories. All this will help you improve your knowledge and skills in proactive hazard identification to help eliminate hazards in the workplace.

Five General Hazard Areas – Hazard Analysis and Control

All workplace hazards exist in five general areas:

Materials – liquids, solids, gases, etc.
Equipment – includes machinery, tools, devices
Environment – noise, temperature, atmospheres, workstation design
People – anyone in the workplace (i.e., employees, guests, customers or contractors)
System – flawed policies, programs, plans, processes, procedures, and practices

“Recognized” Hazards – Hazard Analysis and Control

When you conduct a walkaround inspection you are usually looking for hazardous materials, equipment, and environmental factors. These first three hazard areas represent hazardous physical conditions (think of these as hazardous “states of being”) in the workplace which, according to various studies*, cause only about three percent of all accidents in the workplace. It’s interesting to note, that hazardous conditions are what OSHA inspectors primarily cite as violation. What does that mean? Well, OSHA is very good at uncovering the conditions that don’t cause many accidents. It’s a flawed system, but it’s all we have. That also explains why there is little correlation between the most frequently cited violations and the most frequent causes of injury.

Sober and Focused – Hazard Analysis and Control

The fourth category, “People,” refers to any employee (or others) at any level of the organization who may not be “sober and focused” on the work they’re doing. For example, an employee might be in a hazardous “state of being” if they are:

under the influence of legal/illegal drugs;
poorly trained or educated;
worried about a family illness; or
mentally or physically incapable of doing the job safely

Remember, an employee who is distracted in any way from the work they’re doing should also be considered a “walking” hazardous condition that increases the likelihood of an unsafe behavior. Unfortunately, OSHA does not usually “catch” employees working in an unsafe manner, so you don’t see unsafe behaviors described in OSHA citation reports too often.

Hazardous Materials – Hazard Analysis and Control

Nearly every production job involves the use of hazardous materials including chemicals for cleaning, stripping, or degreasing parts and equipment. Maintenance workers who enter enclosed or confined spaces are also exposed to toxic substances.

Solvents: Solvents are used to dissolve various materials. Those commonly used include:

trichloroethylene	toluene
acetone	methylene chloride
percholoroethylene	glycol ether
isopropyl alcohol	Chloroform
xylene	freon

Exposure occurs by inhalation, ingestion, and absorption primarily through skin contact. Skin exposure may result in dermatitis or skin rash, edema or swelling, and blistering. These exposures can result from chemical splashes and spills, from directly immersing one’s hands into solvents and chemicals, from contact with solvent-soaked clothing or solvent-wet objects, and from the use of improper personal protective equipment. Solvents can dissolve the body’s natural protective barrier of fats and oils leaving the skin unprotected against further irritation.

In addition, inhaling or ingesting solvents may affect the central nervous system, acting as depressants and anesthetics causing headaches, nausea, drowsiness, dizziness, complaints of irritation, abnormal behavior, general ill-feeling, and even unconsciousness. These symptoms should be viewed as visible signs of potential disease. Excessive and continued exposure to certain solvents may result in liver, lung, kidney, and reproductive damage, as well as cancer.

Acids and Alkalis: Acids and alkalis may cause serious burns if they are splash into the eyes or onto the skin. If vapors or mists are inhaled, they may result in a burning of the linings of the nose, mouth, throat, and lungs.

Metals: Employees are exposed to metals primarily by skin contact and by inhalation of metal dusts and fumes. Exposure may cause headaches, general ill-feeling, anemia, central nervous system and kidney damage, and reproductive problems, as well as cancer.

Gases: Gases are used in many operations and may combine with other substances to produce toxic gases such as phosgene, ozone, and carbon monoxide. Workers can be exposed to these and other gases during work. Potential exposure to gases occurs through inhalation. Such exposure may produce eye damage, headaches, shivering, tiredness, nausea, and possible kidney and liver damage.

Plastics and Resins: Inhalation or skin contact may occur when curing resins; cutting, heating, or stripping wires; or cutting, grinding, or sawing a hardened product. Exposure to these substances may result in skin rash and upper respiratory irritation.

Polychlorinated Biphenyls (PCBs): PCBs are used as insulators in some electrical equipment and present a potential hazard to workers. Exposures to PCBs may cause skin disorders, digestive problems, headaches, upper respiratory irritations, reproductive problems, and cancer.

Fiberglass and Asbestos: Fiberglass and asbestos are also used as fillers in epoxy resins and other plastics, in wire coatings or electrical insulation, and in printed circuit boards. Uncontrolled exposures may produce skin and upper respiratory irritations and, in the case of asbestos, cancer.

Solids: Solids like metal, wood, plastics. Raw materials used to manufacture products are usually bought in large quantities, and can cause injuries or fatalities in many ways.

Gases: Gases like hydrogen sulfide, methane, etc. Gas may be extremely hazardous if leaked into the atmosphere. Employees should know the signs and symptoms related to hazardous gases in the workplace.

Hazardous Equipment – Hazard Analysis and Control

Hazardous equipment includes machinery and tools.

Hazardous equipment should be properly guarded so that it’s virtually impossible for a worker to be placed in a danger zone around moving parts that could cause injury or death. A preventive maintenance program should be in place to make sure equipment operates properly. A corrective maintenance program is needed to make sure equipment that is broken, causing a safety hazard, is fixed immediately.
Tools need to be in good working order, properly repaired, and used for their intended purpose only. Any maintenance person will tell you that an accident can easily occur if tools are not used correctly. Tools that are used while broken are also very dangerous.

Hazardous Work Environments – Hazard Analysis and Control

Are there areas in your workplace that are too bright, dark, hot, cold, dusty, dirty, messy, wet, etc.? Is it too noisy, or are dangerous gases, vapors, liquids, fumes, etc., present? Do you see short people working at workstations designed for tall people? Such factors all contribute to an unsafe environment. You can bet a messy workplace is NOT a safe workplace!

Noise Exposure: Many work places are inherently noisy and potentially hazardous to employees. Continuous noise and instantaneous noise bursts can damage the hearing of employees. A hearing conservation program should be established if you think noise levels are a potential threat to the health of your employees. OSHA consultants, your insurer, or a private consultant are all available to help you determine noise levels in the workplace.

Electric Shock: Electricity travels in closed circuits, normally through a conductor. Shock occurs when the body becomes part of the electric circuit. The current must enter the body at one point and leave at another. Shock normally occurs in one of three ways. The person must come in contact with:

both wires of an electric circuit,
one wire of an energized circuit and the ground, or
a metallic part that has become “hot” by being in contact with an energized wire or conductor, while the person is also in contact with the ground.

Illumination: It’s important to make sure illumination is adequate for the job being performed. Too much direct or indirect glare can, over time, cause eye strain. Too little light can result in an injury. More on this topic in course 711, Introduction to Ergonomics.

Informal Observation and Formal Observation Programs – Hazard Analysis and Control

An informal observation process is nothing more than being watchful for hazards and unsafe behaviors throughout the work shift. No special procedure is involved. All employees should be expected to look over their work areas once in a while.

One of the most effective proactive methods to collect useful data about the hazards and unsafe behaviors in your workplace is the formal observation program because it includes a written plan and procedures. For example, safety committee members or other employees who may be assigned to complete a minimum number of observations of safe/unsafe behaviors during a given period of time. This data is gathered and analyzed to produce graphs and charts reflecting the current status and trends in employee behaviors. Posting the results of these observations tends to increase awareness and lower injury rates. But, more importantly, the data gives valuable clues about safety management system weaknesses.

Observation is important because it can be a great tool to effectively identify behaviors that account for 95 percent of all workplace injuries. The walkaround inspection, as a method for identifying hazards, may not be as effective as observation in identifying unsafe behaviors.

Note: An important policy for successful formal observation procedures is that they are not, in any way, linked to discipline. Observers should not discipline or “snitch” on employees: To do so ensures any observation program will fail as an accurate fact-finding tool. I recommend using only employees who do not have authority to discipline as observers in the program. If you must use managers or supervisors, make sure they do not observe in their own areas of responsibility, and make sure they understand the policy regarding “no discipline” as a consequence of an observation. It is also important for observers to express appreciation when safe behaviors are observed, and remind or warn employees to use safe practices if they are not performing a task safely.

Comprehensive Surveys

Comprehensive surveys are not the same as interviews or inspections. An interview is a verbal exchange conducted one-on-one, preferably in private, and has the potential to gather more information. An inspection is often done by employees at the workplace who walk around observing the workplace and asking questions in public.

Comprehensive surveys ideally should be performed by people who can bring to your worksite fresh vision and extensive knowledge of safety, health, or industrial hygiene. Because there are few professional consultants equipped to do comprehensive surveys in all three areas, the best approach is to use a team consisting of outside specialists: a safety professional and an industrial hygienist.

We encourage you to take advantage of OSHA’s safety and health consultative services if available in your state. Just call your local OSHA field office and schedule a visit. Workers’ compensation insurance providers and other insurance companies offer expert services to help their clients evaluate safety and health hazards. Private consultants may also provide excellent specialized services to help determine workplace hazards.

For an industrial hygiene survey you should, at a minimum, inventory all chemicals and hazardous materials in the plant, review your hazard communication program, and analyze air samples. For many industries, a survey of noise levels and a review of the respirator program also will be vital. Companies participating in OSHA’s SHARP and VPP must conduct initial comprehensive surveys.

Interviewing Employees

Interviews differ from surveys. Whereas surveys ask many people the same questions, an interview is a one-on-one process that asks unique questions. Outside experts may or may not conduct interviews during comprehensive surveys. If they do, that’s great. If they don’t, it becomes important for someone in-house conduct the interviews. A wealth of information, over and above what might be possible from a survey, may be obtained by conducting interviews with employees.

When conducting the interview keep the following tips in mind:

Put the person at ease.
Keep the purpose of the interview in mind: It’s to get the employee’s help in determining the types of hazards that exist in his or her work area. Go to the work area to conduct the interview. Just because you are familiar with the location or the employee’s job, don’t assume that things are always the same.
Explain the purpose and your role. Tell the employee exactly why you are conducting the interview to reduce any initial reluctance to participate.
Stress that the information given is important. It may help eliminate hazards that have the potential to kill, injure or produce illness. Information given may also help to make the work procedure more efficient too.
Be friendly, understanding, and open minded. Try to keep the interview informal. Your approach is important. Make sure they sense that you care about their safety.
Be calm and unhurried. If you are agitated, or in a hurry to get the interview over, you’ll be sending a negative message that the employee will see.
Let the individual talk. Don’t interrupt while they are talking. It’s easy to think you have all the information. Many important facts may not be uncovered if you cut them off.
Ask background information, name, job, etc . . . This just helps to smoothly transition into the actual interview. Small talk…then get to business.
The key initial statement. Ask the witness to tell you about the hazards they are aware of. Don’t ask them if they know of any hazards: they could easily just say “no.”
Don’t ask leading questions. They are not on trial.
Ask follow-up questions. This will help to clarify particular areas or get specifics.
Do not put the person on the defensive. If there are hazards present, don’t in any way question the employee in a manner that might accuse or blame them of wrong doing.
Try to avoid yes and no answer questions. Ask open-ended questions. One effective question is…”Tell me about the procedures for…”
Actively listen. Repeat the information given. Rephrase. Communicate to understand.
Take notes. Notes should be taken very carefully, and as casually as possible. Let the individual read them if desired.
Use a tape recorder. But always get permission from the employee first. Offer to give them a copy of the tape if they hesitate.
Thank the employee. Conclude the interview with a statement of appreciation for their contribution.
Be available. Ask them to contact you if they think of anything else.
Provide feedback. If possible, advise the person the outcome of the interview.

Workplace Inspections

Inspections are the best understood and most frequently used tool to assess the workplace for hazards. Much has been written about them, and many inspection checklists are available in various OSHA publications. The term “inspection” means a general walk-around examination of every part of the worksite to locate conditions that do not comply with safety standards. This includes routine industrial hygiene monitoring and sampling.

Sometimes the term, “audit” is substituted for the term “inspection.” Actually, an audit is a little different. The audit is actually an evaluation tool because the process involves giving a numerical rating of some kind to items that are being audited. While inspections involve locating hazardous conditions, audits more generally involve locating ineffective or missing safety programs.

Inspection Frequency

The regular site inspection should be done at specified intervals. The employer should inspect as often as the type of operation or character of equipment requires. Think about the most hazardous operation or location in your company. How often are safety inspections conducted there?

OSHA expects all places of employment to be inspected by a qualified person or persons as often as the type of operation or the character of the equipment requires. Defective equipment or unsafe conditions found by these inspections should be replaced or repaired or remedied promptly.

Safety committees can play an important role in the success of the hazard identification and control program. The safety committee can assist the employer in evaluating the employer’s accident and illness prevention program, and submit valuable written recommendations to improve the program where applicable. In addition, the safety committee can:

(i) Establish procedures for workplace inspections by the safety committee inspection team to locate and identify safety and health hazards;

(ii) Conduct regular workplace inspections; and

(iii) Recommend to the employer how to eliminate hazards and unsafe work practices in the workplace.

The inspection team can document in writing the location and identity of the hazards and make recommendations to the employer regarding correction of the hazards. Regular inspections of satellite locations should be conducted by the committee team or by a person designated at the location.

I’m sure you can see from the above discussion that a regular inspection by the safety committee may not be sufficient to ensure hazards are effectively identified. The frequency of the safety inspection is really a judgment call for the employer, but at a minimum, medium and large fixed worksites should be inspected completely at least every quarter, with some part of the inspection occurring each month. The frequency of a safety inspection depends on the nature of the work and workplace. More frequent change and higher probability for serious injury or illness requires more frequent inspection. For construction sites, daily inspections are a must because of the rapidly changing nature of the site and its hazards.

At small fixed worksites, the entire site should be inspected at one time. And even for the smallest worksite, inspections should be done at least quarterly. If the small worksite uses hazardous materials or involves hazardous procedures or conditions that change frequently, inspections should be done more often.

Sound Safety Inspection Policy: All employees should inspect their area of responsibility at the beginning and end of each shift, and bridge the inspections with continual observation. If a hazardous condition is observed, eliminate it if you safely can, or report it immediately.

What Should We Inspect?

A methodical inspection will follow a checklist based on the inventory of hazards and the preventive actions and controls designed to reduce or eliminate worker exposure. Regular site inspections should be designed to check each one of those controls to make sure that hazards are contained.

Do not overlook areas outside of the production mainstream. Your search for common hazards and OSHA standards violations should cover the entire worksite, including all office areas.

Who Should Inspect?

From your reading earlier, you already know that the safety committee may be responsible for conducting regular safety inspections. But that is where it ends, and that should not be. Supervisors and other employees should be conducting safety inspections on a regular basis.

Supervisors.: Employers should make it the supervisor’s responsibility to inspect his/her work area at the beginning of every shift to ensure equipment and personnel are ready to work safely. This can be particularly helpful when other shifts use the same area and equipment or when after-hours maintenance and cleaning are routinely done.

Employees: Involving employees in all aspects of the safety and health program, including hazard identification and control, is smart business. Get as many employees involved as you can.

Get Educated in Hazard Identification

Safety and health staff: Employees who specialize in safety and health can be an excellent source of help in providing the necessary education and training on hazard identification. In a small business, the specialist may be a Production/Quality Control manager or another member of management with many important duties in addition to safety and health.

Inspector Training Options

Employees: All employees should have training in the hazards that they may be exposed to during work. When they are responsible for workstation inspections, employees also should have specific training in how to inspect. On-the-job training with the supervisor can be an excellent strategy to ensure adequate education (understanding of consequences) and training (the how-to) is conducted.

Supervisors: All supervisors should be properly educated about their safety responsibilities. They should have training in identifying and controlling the hazards that workers under their supervision are likely to encounter. When they are responsible for area inspections, supervisors should have specific training on how to conduct safety inspections. Formal course work may not be necessary, but the training should be provided by someone who is competent (has experience and training).

Safety committee members and employees: All safety committee members and employees should understand the potential hazards to which they might be exposed and the ways they can protect themselves and their fellow workers. Those who are involved in inspections need training in recognizing and controlling all the potential hazards of the worksite. They will also need written guidance, tips for inspecting, and some on-the-job training by safety and health staff or other specialists.

Written Inspection Reports

In all but the smallest and least dangerous of workplaces, written inspection reports are necessary to record hazards discovered, responsibility assigned for correction, and tracking of correction to completion. Formal safety inspections should include a written report with recommendations for corrective action.

A written record will help ensure:

Assignment of responsibility for hazard correction.
Tracking of correction to completion.
Identification of problems in the controls system when the same types of hazards keep appearing even after correction is verified.
Identification of problems in the accountability system.
Identification of hazards for which no prevention or control has been planned.

Of course, having such written records will be most helpful if they are read by someone knowledgeable in the safety and health program. This person then can provide top managers with summaries of problems.

Beware of “Tunnel Vision”

If you use experts from within your company, be on guard for “tunnel vision,” which can lead to a failure to spot hazards in areas not directly related to your firm’s primary function. You want your maintenance shop, for example, to be just as safe as your production line. OSHA frequently finds unguarded saws and grinders, non-code electrical wiring, and other basic safety hazards in areas that are outside the main production process but regularly used by employees.

Review Documents

Assessing the workplace would not be complete without thoroughly reviewing existing documents to determine what kinds of hazards have existed in the workplace prior to the assessment. Actually, document review may be considered both an assessment tool and an analysis tool. Not only are we able to determine the hazards that have caused accidents in the past, we can analyze to uncover trends in the types, locations, date/time, etc. for accidents.

You need to review these documents to assess workplace hazards:

OSHA 300 Log (of course)
OSHA Form 301, Injury and Illness Incident Report
Maintenance work orders
Accident reports
Safety committee minutes
Safety suggestions
Training evaluations

7Jun, 2017

Safe Forklift Operations

A forklift is a powerful tool that allows one person to precisely lift and place large heavy loads with little effort. Using a tool such as a forklift, cart or hand truck instead of lifting and carrying items by hand can reduce the risk that you will suffer a back injury.

operations

However, there is great risk of injury or death when a forklift operator:

has not been trained in the principles of physics that allows a forklift to lift heavy loads
is not familiar with how a particular forklift operates
operates the forklift carelessly
uses a forklift that is not safe due to malfunctioning or missing parts

Pre-Use Inspection

The forklift should be checked for defects before initial use, usually by the operator before beginning a work shift. If someone else has used the forklift during a shift, it’s a good idea to check it for defects again.

Even if you operate a forklift safely, a defect can cause or contribute to a serious accident. Any defects that would affect safety must be corrected before the forklift is returned to service.

Look at the following items for things to look for during an expection:

Is the horn working? Sound the horn at intersections and wherever vision is obstructed.
Are there hydraulic leaks in the mast or elsewhere? These could cause slipping hazards or lead to hydraulic failure.
Are fuel connections tight and battery terminals covered? Dropping a piece of metal across battery terminals can cause an explosion.
Is there a lot of lint, grease, oil or other material on the forklift that could catch on fire?
Do sparks or flames come out from the exhaust system?
Does the engine show signs of overheating?
Are tires at proper pressure and free of damage? A tire with low pressure or a tire failure can cause a forklift to tip or fall when a load is high.
Do all controls such as lift, lower, and tilt work smoothly? Are they labeled?
Is there any deformation or cracks in the forks, mast, overhead guard, or backrest?
Are lights operating if used at night or in dark locations?
Is steering responsive? A lot of play or hard steering will reduce your control.
Do brakes stop smoothly and reliably? Sudden stops can cause tipping.
Does the parking brake hold the forklift on an incline?
Are seat belts (if equipped) working and accessible?
Is the load capacity plate readable?

Traveling

Precautions and best practices while traveling in a forklift include:

- The most basic rule for traveling is that you maintain control of your forklift at all times.
- Operate a forklift only while in the seat or operator’s station.
- Never start it or operate the controls while standing beside the forklift.
- Never allow passengers unless the forklift was designed for a passenger.
- Do not put any part of your body between the uprights of the mast or when traveling, outside of the forklift frame.
- Never drive with wet or greasy hands. If necessary, keep a towel or rag handy at all times.
- Whether loaded or empty, carry forks and platforms on lift trucks as low as possible. This lowers the center of gravity and reduces the possibility of overturning the truck or dumping the load.

Always look in the direction of travel and keep a clear view of the travel path. Travel in reverse if the load blocks your view.
Always observe posted speed limits (usually 5 mph) at your workplace. A forklift should not be driven faster than a quick walking pace.
Keep a distance of at least three forklift lengths between you and any forklift traveling in front of you.
Do not pass a forklift traveling in the same direction if it is at a blind spot, intersection or other dangerous location.
Never drive a forklift up to anyone in front of a bench or other fixed object.
Never allow anyone to walk or stand under the elevated forks—even if the forks are not carrying a load.
Check that there is adequate clearance under beams, lights, sprinklers, and pipes for the forklift and load to pass.
Never engage in stunt driving or horseplay.

Driving on Ramps and Grades

Forklift operators should follow certain general rules of the road when traveling on ramps and other inclines. Traveling up and down ramps and grades can be quite dangerous because the forklift can more easily tip over. Be sure to follow these safety practices when operating the forklift on ramps and grades:

Always look in the direction of travel.
Never turn on a ramp or incline. Turn prior to the ramp or incline to place forks in proper direction.
Keep a safe distance from the edge of a ramp.
Do not travel on ramps with slopes or other conditions that exceed the manufacturer’s recommendation.
When traveling with a load, the load should point up the incline, regardless of direction of travel.
When traveling without a load, the forks should point downgrade, regardless of direction of travel.

Driving onto Trucks, Trailers, and Railroad Cars

Forklifts are often driven onto trucks, trailers, or railroad cars over a dock board (also known as a bridge plate) at loading docks. If the truck, trailer or car is not secured to the dock or otherwise chocked, it may move forward. The dock board can then fall between the trailer and the dock as the forklift crosses it.

You can secure wheel chocks with chains at each loading dock bay and tell truck drivers that they must place them in front of the rear wheels. Another way of securing the trailer is to use a vehicle restraint system mounted to the dock that clamps onto a bar below the trailer as it backs into place. This system will signal when the restraint is engaged or if there is a problem.

The pavement at some loading docks slopes downhill toward the loading dock. This is not a substitute for chocking wheels.

Sometimes a trailer is left at a loading dock without the tractor attached. Use trailer jacks to prevent the trailer from up-ending when a forklift drives to the front of the trailer to load or unload. Here are some additional loading and unloading procedures:

Inspect the floor of the trailer to be sure that it will support the forklift and load.
Ensure that the height of the entry door is adequate to clear the height of your vehicle, taking into consideration the height of the loading platform.
Drive straight across the bridge plates when entering or exiting the truck trailer or railroad car.
Use dock lights and headlights when working in a dark trailer.
Sound the horn when entering or exiting the trailer.
In determining the capacity of the trailer floor to support a forklift, consider various factors, including floor thickness and cross-member spacing or unsupported floor area. In general, the larger the unsupported area, the lower the forklift capacity the trailer will have for the same floor thickness.
Never use the forklift to open railroad car doors unless:
- It has a device designed for that purpose.
- The operator is trained in the use of the device.
- All other employees stand clear.

- Keep a safe distance from the edge of a loading dock or a ramp. The edge must be painted yellow or with alternating yellow and black diagonal stripes to warn of both the fall hazard and the potential to be crushed by a trailer backing into the dock.

- A portable dock board must be secured in place to prevent it from moving. Some boards have pins that are inserted into the sides and project below the board. This prevents the board from moving toward the dock or toward the trailer. To prevent crushed fingers and make for safe handling, a portable dock board must also have handholds or lugs that allow the forklift to pick it up.
- Some loading docks have a bull rail that prevents a wheel from slipping off the sides of ramps or edges of the dock where a forklift would not have to cross to enter a trailer.

Any part of the dock edge that is four feet or more above the adjacent surface must have a standard guardrail. Removable rails (such as chain rails) and posts can be used at the place where trucks or trailers will be loaded.
Use rail mounted chocks to secure a railroad car. Also, prevent anyone from moving the rail car while the forklift is working. A blue sign with the word “STOP” attached to the track is one way of signaling that the car must not be moved. A special attachment must be used if a forklift is used to open a rail car door.

Loading and Unloading the Forklift

Because of the wide variety of equipment used and the different kinds of stock and materials handled, each company must form additional rules for loading and unloading to fit the needs of its facilities. Know the maximum load that each truck can carry safely; do not overload it. An overloaded truck will not operate in a safe manner.

Answer the following questions and check the load before you pick it up.

stacking

Common pallet stacking patterns

Do the dimensions and weight of the load fall within the capacity rating of the forklift at the highest elevation and maximum extension you will handle the load? If not, can you break the load into smaller parts?
Is it stable or will parts slide or fall during transit? Secure it as necessary. The illustrations to the right show some common pallet stacking patterns

When you pick up the load:

picking up

Make sure your view is not obstructed.
Move squarely into position in front of the load.
Do not permit anyone to stand under or too close to a load that is being hoisted or lowered.
Position the forks wide apart to keep the load balanced.
Drive the forks fully under the load.
Tilt the mast backward slightly to stabilize the load and lift. Check the destination before you place the load.

Check out the destination:

- Is the destination flat and stable—or, will the load rock, tilt or lean?
- Never place heavy loads on top of light loads.
- Observe maximum stacking quantities and orientation if printed on cartons.
- Do you know the load bearing capacity of your rack or storage loft destination?

- Are rack legs or support members bent or disconnected? The load bearing capacity of a damaged rack is unknown. Wait until the damaged component has been replaced before loading.
- Are racks arranged back to back with a stock behind where you will place the load? Someone may need to be in the next aisle to control access while you place the load.
- Are wooden stringers or decking laid between front and rear rack beams in good condition? They may support the load if the pallet is not properly placed on both front and rear rails.
- If you are stacking, are other pallets in the stack in good condition and capable of supporting the load in addition to what they are already supporting?

When you place the load at its destination:

Move squarely into position in front of the rack or stack where the load will be placed.
When ready to place the load, tilt the mast to level. Only tilt forward when the load is over the spot where it will be placed.
Lower the forks and back away.
Visually verify that the load is stable.

Leaving a Forklift Unattended

traveling

Do not leave the forklift unattended.
Click to Enlarge

A forklift is considered to be unattended when it is not in view of the operator or if it is in view, the operator is 25 feet or more away.

If you leave a forklift unattended:

Lower the forks to the ground.
Set the controls to neutral.
Turn off the power.
Set the brakes.
If the forklift is on an incline, block the wheels.
If you dismount a forklift and stay within 25 feet, you must at least lower the forks to the ground, set the controls to neutral, and set the brakes.

Lifting and Lowering People

Lifting or lowering a person on forks or a pallet can result in a fall injury or fingers caught in moving parts of the mast.

No worker should be allowed to be lifted while standing on the forks or on a pallet lifted by the forks. The image to the right is a good example of what should never be done. These workers in the photo are lucky they did not get hurt or killed.

If you want to use a forklift to raise an employee to an elevated position, use a platform or structure specifically built for this purpose that meets the conditions described below.

- The platform must have standard guardrails which include a top rail 36” to 42” above the platform (39” to 45” on a construction site), midrail and toeboard. It must also prevent contact with chains and shear points on the mast. See the illustration for an example.
- The platform must be securely attached to the forks such as by a clamp or chain.
- Check with the forklift manufacturer to verify that the hydraulic system will not allow the lift mechanism to drop faster than 135 feet per minute in the event of a system failure. Identify the forklift as approved for use with the platform.
- Lock or secure the tilt control to prevent the boom from tilting.
- A forklift operator must be at the normal operating position when lifting and lowering the platform. The operator must be near the forklift while a worker is elevated.
- Except to inch forward/backward or maneuver at low speeds, do not move the forklift between two points when a worker is on the platform.

Order picker forklifts are designed to allow the operator to be lifted along with the controls to an elevated location. However, if the operator station does not have standard guardrails on all open sides, then the operator must wear a full body harness with lanyard attached to a manufacturer approved anchor.

Traffic Patterns

The first step to prevent powered industrial truck accidents in a facility is to establish a traffic pattern. This is management’s responsibility.

Management must ensure:

Aisles are well-lighted and free from obstructions.
Floors are sound and in good shape. Wet, oily or icy surfaces should be avoided. Clean them up as soon as possible.
Aisles are marked clearly. When they are wide enough for two trucks to pass each other, the center of the aisle and the two extreme edges should be marked with painted lines. In some plants, the aisles are wide enough for two truck lanes and a pedestrian lane.
Do not allow for two trucks to run side by side in the same direction.
A truck must never pass another truck at an intersection, blind spot or other dangerous location. In areas where there is high concentration of truck traffic, it may be best to have one-way aisles.
Speed limits are set and strictly enforced. A few speed limit signs at strategic points serve as constant reminders to truck operations.
Prominently display stop signs at all crossings. These may be regular stop signs or signs painted or set into the floor. You can also use stripes and discs as indicators.
Each plant must set up its own rules regarding traffic control, but a required four-way stop at every intersection is a wise way to avoid collisions. Plants that have adopted the four-way stop requirements have found that no significant time is lost by this extra precautionary measure.

Workplace Conditions

Workplace surface and overhead conditions are an important part of safe lift truck operation. Operating surfaces must be strong enough to support the forklift, its load and its operator. They must also be free of holes, grease, oil or obstructions that could cause the lift truck to skid, bounce, and/or possibly tip over.

Workplace surface and overhead conditions and factors to consider when traveling include:

Slippery Conditions: There is a danger of skidding when traveling on oil, grease, water or other spills. A forklift could tip over when traveling on ice, snow, mud, gravel and uneven areas.
Obstructions and Uneven Surfaces: There is a danger of tip over when traveling over obstructions, holes and bumps.
Floor Loading Limits: There is a danger of the floor collapsing if it’s unable to support the weight of the forklift, load, and operator.
Overhead Clearance: There is a chance of damage to lights, stacks, doors, sprinklers and pipes. Damage to the load may also occur, and the forklift may tip over when traveling and hitting an overhead obstruction.

Housekeeping

Develop a model for good housekeeping. Develop specific procedures for storing tools and material in the proper location. Items to consider for proper housekeeping include the following:

uncluttered and well-marked aisles
a corner mirror for traffic safety at the intersection
adequate lighting

Other standard precautions, which management should consider, include guardrails or flashing lights in front of doors that open into aisles; curbs around docks, pits or drop areas; and mirrors at intersections.

Carbon Monoxide

Internal combustion engines produce carbon monoxide. This gas can rapidly build up in any indoor area. Once inhaled, carbon monoxide decreases the ability of the blood to carry oxygen to the brain and other vital organs. Even low levels of carbon monoxide can set off chest pains and heart attacks in people with coronary artery disease.

Workers can be overcome without even realizing they are being exposed. Confusion, headache, dizziness, fatigue, and weakness may set in too quickly for victims to save themselves. Carbon monoxide poisoning can cause permanent brain damage, including changes in personality and memory.

Gasoline powered forklifts should not be used indoors. Propane forklifts also produce carbon monoxide and must be regularly inspected and maintained. If you are concerned about the exposure level in an enclosed area where a forklift operates, contact a qualified industrial hygienist to make measurements and recommendations to improve ventilation.

Maintenance Records

It is very important to maintain accurate records of all corrective and preventative maintenance for a substantial period of time. Doing so will help in conducting accident investigations by providing a maintenance history for analysis. It will also make it easier to establish trends in maintenance needs.

Source: OSHAcademy

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5Jun, 2017

BASICS OF MACHINE SAFEGUARDING

Introduction

Crushed hands and arms, severed fingers, blindness — the list of possible machinery-related injuries is as long as it is horrifying. There seem to be as many hazards created by moving machine parts as there are types of machines. Safeguards are essential for protecting workers from needless and preventable injuries.

A good rule to remember is: Any machine part, function, or process which may cause injury must be safeguarded. When the operation of a machine or accidental contact with it can injure the operator or others in the vicinity, the hazards must be either controlled or eliminated.

This course describes the various hazards of mechanical motion and presents some techniques for protecting workers from these hazards. General information covered in this chapter includes — where mechanical hazards occur, the hazards created by different kinds of motions and the requirements for effective safeguards, as well as a brief discussion of non-mechanical hazards.

Where Mechanical Hazards Occur

Dangerous moving parts in three basic areas require safeguarding:

The point of operation: that point where work is performed on the material, such as cutting, shaping, boring, or forming of stock.

Power transmission apparatus: all components of the mechanical system which transmit energy to the part of the machine performing the work. These components include flywheels, pulleys, belts, connecting rods, couplings, cams, spindles, chains, cranks, and gears.

Other moving parts: all parts of the machine which move while the machine is working. These can include reciprocating, rotating, and transverse moving parts, as well as feed mechanisms and auxiliary parts of the machine.

Hazardous Mechanical Motions and Actions

A wide variety of mechanical motions and actions may present hazards to the worker. These can include the movement of rotating members, reciprocating arms, moving belts, meshing gears, cutting teeth, and any parts that impact or shear. These different types of hazardous mechanical motions and actions are basic in varying combinations to nearly all machines, and recognizing them is the first step toward protecting workers from the danger they present.

The basic types of hazardous mechanical motions and actions are:

nippoint

A wide variety of mechanical motions and actions may present hazards to the worker.

Motions

rotating (including in-running nip points)
reciprocating
transversing

Actions

cutting
punching
shearing
bending

Motions

Rotating motion can be dangerous; even smooth, slowly rotating shafts can grip clothing, and through mere skin contact force an arm or hand into a dangerous position. Injuries due to contact with rotating parts can be severe.

Collars, couplings, cams, clutches, flywheels, shaft ends, spindles, meshing gears, and horizontal or vertical shafting are some examples of common rotating mechanisms which may be hazardous. The danger increases when projections such as set screws, bolts, nicks, abrasions, and projecting keys or set screws are exposed on rotating parts, as shown in the figure to the right.

In-running nip point hazards are caused by the rotating parts on machinery. There are three main types of in-running nips.

Parts can rotate in opposite directions while their axes are parallel to each other. These parts may be in contact (producing a “nip point”) or in close proximity. In the latter case the stock fed between the rolls produces the nip points. This danger is common on machines with intermeshing gears, rolling mills, and calendars. See the figure to the left.

Nip points are also created between rotating and tangentially moving parts. Some examples would be: the point of contact between a power transmission belt and its pulley, a chain and a sprocket, and a rack and pinion. See figure to the right.

Big idea: Kevin K., one of our students, uses the term, “Blood Points” instead of pinch, nip, or crush points, as a meaningful deterrent, and not a temptation, because it reminds employees of the immediate consequence – a lot of blood. He’s experienced in machining, and knows enough about machines to understand that machines do not think, have a lot of force, and they do not stop. The result is typically a fatal amount of blood, so he keeps his hands away from the “Blood Points” for the obvious reasons. You may want to use this idea to help your employees remember the dangers associated with machines in motion.

Rotating and fixed parts

Nip points can occur between rotating and fixed parts which create a shearing, crushing, or abrading action. Examples are: spoked handwheels or flywheels, screw conveyors, or the periphery of an abrasive wheel and an incorrectly adjusted work rest. See figure the to the right.

Reciprocating motions may be hazardous

Reciprocating motions may be hazardous because, during the back-and-forth or up-and-down motion, a worker may be struck by or caught between a moving and a stationary part. See the figure immediately to the left for an example of a reciprocating motion.

Transverse motion

Transverse motion (movement in a straight, continuous line) creates a hazard because a worker may be struck or caught in a pinch or shear point by the moving part. See figure to the right.

Actions

Cutting Action

Cutting action may involve rotating, reciprocating, or transverse motion. The danger of cutting action exists at the point of operation where finger, arm and body injuries can occur and where flying chips or scrap material can strike the head, particularly in the area of the eyes or face. Such hazards are present at the point of operation in cutting wood, metal, or other materials.

Examples of mechanisms involving cutting hazards include band saws, circular saws, boring or drilling machines, turning machines (lathes), or milling machines. See figure to the right.

Punching Action

Punching action results when power is applied to a slide (ram) for the purpose of blanking, drawing, or stamping metal or other materials. The danger of this type of action occurs at the point of operation where stock is inserted, held, and withdrawn by hand.

Typical machines used for punching operations are power presses and iron workers. See figure to the left.

Shearing Action

Shearing action involves applying power to a slide or knife in order to trim or shear metal or other materials. A hazard occurs at the point of operation where stock is actually inserted, held, and withdrawn.

Examples of machines used for shearing operations are mechanically, hydraulically, or pneumatically powered shears. See figure to the right.

Bending Action

Bending action results when power is applied to a slide in order to draw or stamp metal or other materials. A hazard occurs at the point of operation where stock is inserted, held, and withdrawn.

Equipment that uses bending action includes power presses, press brakes, and tubing benders. See Figure below.

Requirements for Safeguards

What must a safeguard do to protect workers against mechanical hazards? Safeguards must meet these minimum general requirements:

Prevent contact: The safeguard must prevent hands, arms, and any other part of a worker’s body from making contact with dangerous moving parts. A good safeguarding system eliminates the possibility of the operator or another worker placing parts of their bodies near hazardous moving parts.
Secure: Workers should not be able to easily remove or tamper with the safeguard, because a safeguard that can easily be made ineffective is no safeguard at all. Guards and safety devices should be made of durable material that will withstand the conditions of normal use. They must be firmly secured to the machine.
Protect from falling objects: The safeguard should ensure that no objects can fall into moving parts. A small tool which is dropped into a cycling machine could easily become a projectile that could strike and injure someone.
Create no new hazards: A safeguard defeats its own purpose if it creates a hazard of its own such as a shear point, a jagged edge, or an unfinished surface which can cause a laceration. The edges of guards, for instance, should be rolled or bolted in such a way that they eliminate sharp edges.
Create no interference: Any safeguard which impedes a worker from performing the job quickly and comfortably might soon be overridden or disregarded. Proper safeguarding can actually enhance efficiency since it can relieve the worker’s apprehensions about injury.
Allow safe lubrication: If possible, one should be able to lubricate the machine without removing the safeguards. Locating oil reservoirs outside the guard, with a line leading to the lubrication point, will reduce the need for the operator or maintenance worker to enter the hazardous area.

Non-Mechanical Hazards

While this course concentrates attention on concepts and techniques for safeguarding mechanical motion, machines obviously present a variety of other hazards which cannot be ignored. Full discussion of these matters is beyond the scope of this course, but some non-mechanical hazards are briefly mentioned below to remind you of things other than safeguarding moving parts that can affect the safe operation of machines.

All power sources for machines are potential sources of danger.

When using electrically powered or controlled machines, for instance, the equipment as well as the electrical system itself must be properly grounded. Replacing frayed, exposed, or old wiring will also help to protect the operator and others from electrical shocks or electrocution. High pressure systems, too, need careful inspection and maintenance to prevent possible failure from pulsation, vibration, or leaks. Such a failure could cause, among other things, explosions or flying objects.

Machines often produce noise (unwanted sound) which can result in a number of hazards to workers.

Noise can startle and disrupt concentration, and can interfere with communications, thus hindering the worker’s safe job performance. Research has linked noise to a whole range of harmful health effects, from hearing loss and aural pain to nausea, fatigue, reduced muscle control, and emotional disturbance. Engineering controls such as the use of sound-dampening materials, and personal protective equipment, such as ear plugs and muffs, can help control the harmful effects of noise. Also, administrative controls that involve removing the worker from the noise source can be an effective measure when feasible.

Examples of Engineering Controls

Because some machines require the use of cutting fluids, coolants, and other potentially harmful substances, operators, maintenance workers, and others in the vicinity may need protection.

These substances can cause ailments ranging from dermatitis to serious illnesses and disease. Specially constructed safeguards, ventilation, and protective equipment and clothing are possible temporary solutions to the problem of machinery-related chemical hazards until these hazards can be better controlled or eliminated from the workplace.

Training

a description and identification of the hazards associated with particular machines;
the safeguards themselves, how they provide protection, and the hazards for which they are intended;
how to use the safeguards and why;
how and under what circumstances safeguards can be removed, and by whom (in most cases, repair or maintenance personnel only); and
what to do (e.g., contact the supervisor) if a safeguard is damaged, missing, or unable to provide adequate protection.

This kind of safety training is necessary for new operators and maintenance or setup personnel, when any new or altered safeguards are put in service, or when workers are assigned to a new machine or operation.

An effective training technique is to present a summary of an actual machine guarding accident, how it happened, and what would have prevented it.

Check out the sample below:

A paper mill employee was killed after he became entangled in a rotating shaft at the company’s paper mill. The worker, employed at the company for less than two weeks, was buffing the shaft when his clothing got caught on the rotating bolt heads of the shaft.

After the bolts on this shaft caused a fatal injury, the employer built a machine guard.

A worker’s loose clothing caught on this rotating shaft bolts causing a fatality.

Protective Clothing and Personal Protective Equipment

Using engineering controls to eliminate the hazard at the source, and not relying on the worker’s behavior, offer the best and most reliable means of safeguarding. Therefore, engineering controls must be the employer’s first choice for eliminating machine hazards. But whenever engineering controls are not available or are not fully capable of protecting the employee (an extra measure of protection is necessary), operators must wear protective clothing or personal protective equipment.

appropriate for the particular hazards;
maintained in good condition;
properly stored when not in use, to prevent damage or loss; and
kept clean, fully functional, and sanitary.

Protective clothing is, of course, available for different parts of the body. Hard hats can protect the head from the impact of bumps and falling objects; caps and hair nets can help keep the worker’s hair from being caught in machinery. If machine coolants could splash or particles could fly into the operator’s eyes or face, face shields, safety goggles, glasses, or similar kinds of protection may be necessary. Hearing protection may be needed when workers operate noisy machines. To guard the trunk of the body from cuts or impacts, there are certain protective coveralls, jackets, vests, aprons, and full-body suits. Workers can protect their hands and arms from the same kinds of injury with special sleeves and gloves. Safety shoes and boots, or other acceptable foot guards, can shield the feet against injury in case the worker needs to handle heavy objects which might drop on their feet.

It is important to note that protective clothing and equipment can create hazards. A protective glove which can become caught between rotating parts, or a respirator facepiece which hinders the wearer’s vision, for example, require alertness and continued attentiveness whenever they are used.

Other parts of the worker’s clothing may present additional safety hazards. For example, loose-fitting shirts might possibly become entangled in rotating spindles or other kinds of moving machinery. Jewelry, such as bracelets and rings, can catch on machine parts or stock and lead to serious injury by pulling a hand into the danger area.

2Jun, 2017

Oil Spill Cleanup

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OIL SPILL CLEANUP EQUIPMENT

When an oil spill occurs, there are many ways to clean it up. One method includes mechanical means to contain and clean up the oil. Let’s take a look at some of the equipment needed:

Containment Boom

A containment boom is a flexible, fence-type, water-borne pollutant containment barrier that floats on the water.

Containment Boom Usage

Used to contain oil slicks and lift the oil off the water.
Boom is reusable and must be decontaminated after use.
It is very heavy to carry and difficult to work with.

A containment boom is a flexible, fence-like, water-borne pollutant containment barrier.

Oil Skimmer

Oil Skimmers are a floating device used to skim oil off the surface of water or liquid. Many skimmers use oil-attracting materials to help draw the oil to the system and facilitate a more complete cleanup.

Skimmers can be towed, self-propelled, moored in river currents, or even used from shore. Many types of skimmers are available for use, depending on the kind of oil spilled and the weather conditions.There are three common types of skimmers:

Weir skimmers function by allowing the oil floating on the surface of the water to flow over a weir. The height of the weir may be adjustable.
Drum skimmers function by using a rotating element such as a drum, to which the oil adheres. The oil is wiped from the surface of the drum and collected.
Oleophilic skimmers use ropes, discs, or drums that are treated with a substance or otherwise manufactured to adhere to oil.

Other Equipment

Other equipment used for oil spill cleanup include the following:

Vacuums and Centrifuges

Oil can be sucked up along with the water, and then a centrifuge can be used to separate the oil from the water, allowing a tanker to be filled with near pure oil. Usually, the water is returned to the sea, making the process more efficient, but allowing small amounts of oil to go back as well.

Shovels and Other Road Equipment

Shovels are used to clean up oil on beaches.

Sorbents

These are large absorbents that absorb oil. To be useful in combating oil spills, sorbents need to be both oleophilic (oil-attracting) and hydrophobic (water-repellent). Although they may be used as the sole cleanup method in small spills, sorbents are most often used to remove final traces of oil or in areas that cannot be reached by skimmers. Sorbent materials used to recover oil must be disposed of in accordance with approved local, state, and federal regulations. Any oil that is removed from sorbent materials must also be properly disposed of or recycled. (EPA)

Sorbents can be divided into three basic categories:

Natural organic sorbents include peat moss, straw, hay, sawdust, ground corncobs, feathers, and other readily available carbon-based products.
Natural inorganic sorbents consist of clay, perlite, vermiculite, glass wool, sand, or volcanic ash. They can adsorb from 4 to 20 times their weight in oil.
Synthetic sorbents include man-made materials that are similar to plastics, such as polyurethane, polyethylene, and polypropylene and are designed to adsorb liquids onto their surfaces.

Bioremediation

Studies by the U.S. Geological Survey (USGS) have shown microorganisms naturally present in the soils actively consume fuel-derived toxic compounds and transform them into harmless carbon dioxide. Furthermore, these studies have shown that the rate of these biotransformations could be greatly increased by the addition of nutrients. By “stimulating” the natural microbial community through nutrient addition, it is theoretically possible to increase rates of biodegradation and thereby shield the residential area from further contamination.

Bioremediation Accelerator

A bioremediation accelerator is a chemical containing no bacteria which bonds to soluble and insoluble hydrocarbons. Characteristics of bioremediation accelerators include the following:

They chemically and physically bond to both soluble and insoluble hydrocarbons.
They act as a herding agent in water and on the surface and the accelerator causes molecules to float to the surface of the water.
These are usually chemical products with hazardous properties.
Workers need additional training in their safe use and perhaps additional PPE. Check with your site supervisor for SDSs.

Controlled Burning

Controlled (In-situ) burning is the term given to the process of burning oil slicks at sea, at or close to the site of a spill. Burning may be seen as a simple method which has the potential to remove large amounts of oil from the sea surface. Controlled burns:

burn the oil off of the water
can effectively reduce the amount of oil in water
can only be done in low wind
can cause air pollution and respiratory ailments

There are a number of problems which limit the viability of this response technique. These include:

the ignition of the oil
maintaining combustion of the slick
the generation of large quantities of smoke
the formation and possible sinking of extremely viscous and dense residues
safety concerns

A controlled burn to clear marsh grasses can also be used BEFORE the oil reaches the shore.

Controlled burning is the term given to the process of burning oil slicks at sea.

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Monthly Archives: June 2017