Industrial Safety - a PDH Online Course for Engineers, Surveyors and Architects

Industrial Safety

Course Outline

This six (6) hour course addresses major needs relative to creating and maintaining a safe manufacturing facility and a safe manufacturing environment. I might also state several elements of this course also apply to most working environments. The following course content is presented:

INTRODUCTION
SAFETY BENEFITS TO EMPLOYEERS and EMPLOYEES
OSHA STATISTICS

Worker Injuries, Fatalities and Illnesses
Construction’s Fatal Four
Ten Most Frequently Cited OSHA Standards Violations (2013)
OSHA Investigation Sample Document

NON-OSHA WORKPLACE INJURIES
TYPICAL OSHA INVESTIGATION DOCUMENT
GENERAL WORKPLACE AND FACTORY RULES
KEY STEPS IN STRUCTURING A SAFETY PROGRAM

Conduct a Needs Assessment
Organize a Safety Leadership Team
Establish a Workplace Charter

TRAINING
DOCUMENTATION
FIRST AID AND CPR OVERVIEW
BLOOD-BORNE PATHOGENS
FIRE PROTECTION
PERSONAL PROTECTION EQUIPMENT (PPE)
COMPLYING WITH OSHA’S HAZARDOUS MATERIAL REQUIREMENTS
MECHANICAL COMPONENTS AND ROTATING ASSEMBLIES-GUARDING TECHNIQUES
SAFETY WHEN USING FORK-LIFT EQUIPMENT
SAFTY WHEN USING POWERED MECHANICAL PRESSES
MECHANICAL COMPONENTS AND ROTATING ASSEMBLIES
SAFETY WHEN USING FORK-LIFT EQUIPMENT
SAFETY AND ROBOTIC SYSTEMS
APPENDIX

Self-Inspection Checklist
References

We definitely need to direct your attention to the checklist found in the appendix and the General Workplace Safety Rules.

This course includes a multiple choice quiz at the end, which is designed to enhance the understanding of the course materials.

Learning Objective

Upon completion of this course the student will have an understanding and working knowledge of the following areas relating to INDUSTRIAL SAFETY:

General rules governing factory and facility safety;
Information relative to injury, illness and deaths due to unsafe working conditions for factories and construction sites. This included OSHA and non-OSHA related incidences;
Will be shown the format for OSHA incident reporting templates with descriptions of each block within the investigative template;
Will be given a complete self-inspection checklist for many situations found in industry. This checklist is comprehensive and governs specific elements including lockout/tagout, entry into confined spaces, personal protection equipment (PPE) and many others;
Will be given key steps in structuring a viable safety program;
Will gain a complete understanding of hazardous material data sheets, i.e. MSDS and how to read those sheets;
Will receive basic instructions on safeguarding robotic systems to insure operator safety;
Will receive basic safety instructions for presses and metal stamping operations;
Will be given the basics regarding how to provide workable guards for mechanical and robotic equipment;
Will discuss safety regarding mechanical components and rotating mechanisms;
Will be given “best practices” for handling bloodborne and air-borne pathogens;
Will study “best practices” for first aid, CPR, AED ( Automated External Defibrillator), Treatment of Wounds, legal issues involving in-house treatment and first aid;
Will list the major codes and standards relative to industrial safety. (NOTE: these codes and standards are included within the text and not listed separately.);
Will be given text covering personal protection equipment (PPE), when that equipment is necessary, discussions on maintaining equipment and disposal of that equipment when necessary;
Will receive instructions for lockout/tagout methodology;
Documentation relative to safety and archival of reporting will be discussed;
Will be advised as to necessary precautions for exit, entry and confined spaces;
Will discuss at length fire protection and cautions to be taken within an industrial setting to prevent fires. An extensive checklist is presented for this purpose; and
Will be given an extensive checklist covering general rules governing the use of forklift and power lift equipment.

Intended Audience

This course is intended to give in-depth information relative to Industrial Safety. Specifically, what actions MUST be taken to insure a safe, yet productive, working environment. Our aim is the “shop floor”, although topics presented can certainly apply to office areas as well. As you might suspect, OSHA (Occupational Safety and Health Administration) as well as city, county and state codes play directly into efforts insuring workplace safety. With this in mind, people with the following disciplines would enjoy and benefit from taking this course:

Engineers given the task of overseeing safety for an industrial area.
Engineers designing equipment to automate manufacturing processes
First responders
911 operators and management staff
On-site medical practitioners
Industrial engineers
Department managers with oversight for production and assembly personnel
Chief operating officers
Human resource managers
Individuals responsible for financial allotments within commercial concerns
Laboratory managers; i.e., evaluation lab, reliability lab, HALT (Highly Accelerated Life Test )and HASS (Highly Accelerated Stress Screening) installations
Model shop managers within an industrial environment
Machine shop personnel and owners
Individuals responsible for oversight of EPA regulations and company mandates
Any individual concerned with industrial safety with the intent of improving a work cell or work area. This certainly includes line supervisors.

Benefit to Attendees

This six (6) hour course is designed to provide an in-depth survey of safety practices determined to be most important relative to insuring workplace safety. Benefits to attendees will be derived from discussing the following areas:

General Plant Safety Rules.
Basic employee conduct.
Personal protective equipment (PPE).
Lockout/tagout procedures.
Physical site hazards.
Necessary workplace permits.
Applicable vendor and contractor procedures.
A checklist for addressing facility safety and equipment used within a manufacturing or industrial environment.
The basic requirements for administering first aid training. What training is needed for first-class safety training and who should administer that training.
Hazardous Material Data Sheets (HAZMAT)—What are they? Their use? How to read a HAZMAT sheet. The significance of a HAZMAT sheet.
Bio-hazards and bloodborne pathogens. How to handle and dispose of pathogens.
Safety measures for robotic systems.
Safety measures for mechanical systems and rotating mechanical systems.
An understanding of elements needed for a viable safety program.

As you might suspect, different commercial concerns will, by necessity, have requirements specific to the tasks at hand. These requirements must be developed with that in mind. Safety rules for the Y-12 Plant at Oak Ridge will differ in comparison to rules for fabrication shops, range manufacturing facilities, chemical plants, assembly facilities, hospitals etc. “In-house” requirements follow proven methodology. We will be addressing industrial safety only because that area is where most injuries occur.

Course Introduction

A safe working environment does not just happen. It must be made to happen. For the most part, offices, retail establishments, car dealerships, movie theaters, and many others establishments are inherently safe and maybe very safe. Industrial environments where fabrication, welding, assembly processes, handling metal components, transporting finished goods, warehousing, etc. represent a challenge quite different than those just mentioned. There are definite areas that require constant vigilance relative to safe operating methodology. This course will address only INDUSTRIAL SAFETY, but most of the tenants provided can be applied to other commercial activities.

The first and most important benefit of safety training is to save lives and prevent injury. No one wants to get hurt! With proper coaching and instruction an individual or work-cell team can perform their specified functions safely and effectively without worrying about injuries. Many companies have committees working with management, dedicated to developing workplace standards in addition to those mandated by OSHA and local codes. In larger companies, it is not uncommon to find varying safety requirements relating specifically to departments and not the facility in general. “In-house documents” often entail injury- free rewards systems. One example might be offering a twenty-five dollar gift certificate to those core team members remaining accident-free for a period of six months. This helps workers stay motivated and aware, thus preventing injury, and also keeps work areas safe and productive.

I don’t want to be pedestrian about this but a second reason for safety is to save insurance costs for the employers. If you provide assurance your company does indeed practice safety in the workplace, insurance costs could result in a savings passed on to the employer as well as the employee. Nobody receives immunity where safety is concerned. Everyone has to participate in the safety program.

Third, one other important thing to remember is, a safe place to work means more production. If you have injuries resulting in down-time or employees off work, you may not achieve production goals. If you have machines, lift trucks, conveyor lines, robotic systems, or any operation that could cause serious injury, you need to employ safety measures to ensure continued production AND a safe work environment. Every job is different and may require a different structure for training and teaching safety.

Course Content

The course content is in a PDF file:

Industrial Safety

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Course Summary

Industrial safety is absolutely critical to manufacturing and factory facilities. It is imperative that safety and environmental conditions be of utmost concern for management and supervisory personnel. Looking at OSHA records, we see the following:

4,383 workers were killed in 2012. This equates to eighty four (84) deaths per week and twelve (12) deaths per day.
Of the 3,945 fatalities in private industry, 19.6% were in construction environments.
The leading causes of worker deaths on construction sites were falls, followed by struck by object, electrocution, and caught-in/between. Eliminating the Fatal Four would save 435 workers' lives in America every year.

Falls – 278 out of 775 total deaths in construction in CY 2012 (36%)
Struck by Object – 78 (10%)
Electrocutions – 66 (9%)
Caught-in/between – 13 (2%)

Any course involving safety would not be complete without discussions concerning:

The basic tenants of CPR
First Aid
MSDA and hazardous materials

We also present 1.) A very complete safety checklist and 2.) General rules regarding safety within in the workplace. (Please note: these general rules for safety can and should be applied to any workplace, not only manufacturing but office environment as well.) We strive to present methodologies aimed at maintaining safety within areas used by ALL employees.

Quiz

Once you finish studying the above course content, you need to take a quiz to obtain the PDH credits.

DISCLAIMER: The materials contained in the online course are not intended as a representation or warranty on the part of PDH Center or any other person/organization named herein. The materials are for general information only. They are not a substitute for competent professional advice. Application of this information to a specific project should be reviewed by a registered architect and/or professional engineer/surveyor. Anyone making use of the information set forth herein does so at their own risk and assumes any and all resulting liability arising therefrom.