ihe680_032911

Occupational Safety and Health for Technologists, Engineers, and Managers By David L. Goetsch

© 2011, 2008, 2005, 2002, 1999 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

Chapter 1 - Safety and Health Movement, Then and Now

•  ISE 480/IHE 680: Occupational Safety and Health •  Schedule: T & R; 8:30 am – 10:10 am

–  Break: 9:20-9:30??? –  Coffee/Sodas light breakfast items OK

•  Encourage distance students to attend class when able –  Not “technical skill” course… but important info –  Participation is encouraged!

•  There is an Option to participation…

INTRODUCTION: Logistics




INTRODUCTION: Option to Participation

•  Death by PowerPoint!




INTRODUCTION: Me!

•  Bob Myers, Adjunct Instructor •  Retired in 2009 after 32 years in Auto Industry •  BS Electrical Engineering

–  (1982) General Motors Institute •  MS Engineering Innovation & Entrepreneurship

–  (2010) Wright State University •  Working on Ph.D in Engineering

–  Interest in Operations Research & Modeling in Healthcare –  Work full time for Wright State Research Institute




INTRODUCTION: My Experience

•  32 years in Automotive Industry –  Industrial Control System Engineer

•  Electrical, Hydraulic, Pneumatic controls •  Robotics and Automation

–  Manufacturing/Process Engineer •  Plastic Injection Molding, Extrusion, and Painting •  Automated and Manual Assembly Cells •  Lean/Six Sigma Practitioner •  Project Manager •  Quality Engineer

–  Electrical “Arc Flash” Subject Matter Expert •  19 years as Part-time Farmer (Top 5 Most Dangerous Jobs)




INTRODUCTION: YOU!!!

•  Who are you? –  Name –  University program/degree –  Work experience –  Why are you taking this class? –  Any specific interests in Safety and Health?

Distance Students: Assignment #1 Send me an email to [email protected] answering above…




INTRODUCTION: Why?

•  Why study Safety and Health?

Education is the foundation of Prevention…. … Don’t let this be you!




COURSE INFORMATION

•  Textbook: –  Goetsch, D.L. (2011). Occupational Safety and Health for

Technologists, Engineers, and Managers, 7th Edition. Columbus, OH: Pearson Prentice Hall.

•  Distant Student assignment due dates –  One week behind the normal class schedule for

homework, quizzes and midterm. Exceptions: final exam, graduate presentations, & term paper.




COURSE INFORMATION

•  Term Paper –  All students will complete a term paper on a topic they are

interested in related to Occupational Safety and Health. –  A “Topic Proposal” (less than one page) is due (via email)

by April 19th. Please see me if you need help choosing a topic.

–  Final papers (7-15 double spaced pages, including a 1 page Executive Summary) must be uploaded to Pilot by May 31st.

–  Content of Executive Summaries may be included in the course’s Final Exam. They will be available to all students for viewing via Pilot.




COURSE INFORMATION

•  Graduate Student Special Presentation –  Graduate students in IHE 680 will perform an in-class or

recorded presentation on a topic related to Occupational Safety and Health to be approved by the instructor. (Presentation Date: June 2nd)

–  Topics are to come from class content, and provide additional information to class on the topic. No written report is required, only upload of PowerPoint Slides to Pilot. Please notify instructor as soon as you have a topic.

–  The oral presentation should be no longer than 15 minutes. You will be graded on content and organization as well as oral presentation style. This presentation is worth 10% of your final grade.




•  The safety movement in the United States has developed steadily since the early 1900s. –  In 1907, more than 3,200 people were killed in mining

accidents.

•  Legislation, precedent, and public opinion all favored management. –  There were few protections for workers’ safety.

•  Working conditions for industrial employees today have improved significantly. –  Chance of worker death in an industrial accident

is less than half of what it was 60 years ago.

THE SAFETY AND HEALTH MOVEMENT




DEVELOPMENTS BEFORE THE INDUSTRIAL REVOLUTION •  Understanding the past can help safety & health

professionals examine the present and future with a sense of perspective and continuity.

•  Modern developments in health & safety are part of the long continuum of developments. –  Beginning in the days of the ancient Babylonians.

•  Circa 2000 BC, their ruler developed his Code of Hammurabi, which encompassed all the laws of the land at that time. –  Showed Hammurabi to be a just ruler, and set a

precedent followed by other Mesopotamian kings.




DEVELOPMENTS BEFORE THE INDUSTRIAL REVOLUTION •  To ensure maintenance of a workforce to build a

huge temple bearing his name, Rameses II created an industrial medical service to care for the workers. –  They were required to bathe daily in the Nile and given

regular medical examinations, & sick workers isolated. •  The Romans were vitally concerned with safety &

health, as seen from their construction projects. –  Aqueducts, sewerage systems, public baths, latrines,

and well-ventilated houses.




DEVELOPMENTS BEFORE THE INDUSTRIAL REVOLUTION •  In 1567, Philippus Aureolus produced a treatise

on the pulmonary diseases of miners. –  Covered diseases of smelter workers & metallurgists.

•  Diseases associated with handling/exposure to mercury.

•  Around the same time, Georgius Agricola published De Re Metallica, emphasizing need for ventilation in mines, showing devices to bring fresh air into mines.

•  The eighteenth century saw Bernardino Ramazzini, who wrote Discourse on the Diseases of Workers. –  Drew conclusive parallels between diseases suffered

by workers and their occupations.




DEVELOPMENTS BEFORE THE INDUSTRIAL REVOLUTION •  The changes of the Industrial Revolution

necessitated a greater focusing of attention on the safety and health of workers. –  Steam power increased markedly the potential for

life-threatening injuries, as did machines. –  The new methods used for converting raw materials

also introduced new risks of injuries and diseases. –  Specialization, by increasing the likelihood of boredom

and inattentiveness, also made the workplace a more dangerous environment.




MILESTONES IN THE SAFETY MOVEMENT

•  The safety movement traces its roots to England. •  After an outbreak of fever among children working

in their cotton mills, people of Manchester, England, demanded better factory working conditions. –  In 1802 the Health & Morals of Apprentices Act

passed. •  Marked the beginning of governmental

involvement in workplace safety.





•  When the industrial sector began to grow in the US, hazardous working conditions were commonplace. –  In 1868, the first barrier safeguard was patented. –  In 1869, the Pennsylvania legislature passed a mine

safety law requiring two exits from all mines. –  In 1877, the Massachusetts legislature passed a law

requiring safeguards for hazardous machinery. –  1877 also saw passage of the Employer’s Liability

Law, establishing potential for employer liability in workplace accidents.





•  Around 1900, Frederick Taylor began studying efficiency in manufacturing, and drew a connection between lost personnel time & management policies and procedures.





•  Workers’ compensation actually had its beginnings in Germany, and soon spread through Europe.

•  Workers’ compensation made great strides in the US when Wisconsin passed the first effective workers’ compensation law in 1911. – Today, all 50 states have some form of

workers’ compensation.




TRAGEDIES THAT HAVE CHANGED THE SAFETY MOVEMENT •  Hawk’s Nest Tragedy (aka Gauley Bridge

Disaster ) - solidified public opinion in favor of protecting workers from the debilitating disease silicosis. (1920s)

•  A company contracted to drill a passage through a mountain in the Hawk’s Nest region of West Virginia. –  Workers spent as many as 10 hours per day breathing

dust created by drilling and blasting. •  This mountain had an unusually high silica content.

•  Silicosis normally takes 10 to 30 years to show up. –  Hawk’s Nest workers began dying in as little as a year.

•  By the time the project was completed, hundreds had died.




TRAGEDIES THAT HAVE CHANGED THE SAFETY MOVEMENT •  Asbestos Menace - in 1964, Dr. Irving J. Selikoff

told a conference on biological effects of asbestos that the widely used material was killing workers. –  Asbestos was once considered a “miracle” fiber.

•  At the time of Selikoff’s findings, asbestos was one of the most widely used materials in the US. –  Found in homes, schools, offices, factories, ships, and

even in the filters of cigarettes.

•  This conference changed how Americans viewed not just asbestos, but workplace hazards in general. –  Selikoff was the first to link asbestos to lung cancer and

respiratory diseases.




TRAGEDIES THAT HAVE CHANGED THE SAFETY MOVEMENT •  Bhopal Tragedy - On Dec. 3, 1984, over 40 tons

of methyl isocyanate (MIC) & other gases, including hydrogen cyanide, leaked into north Bhopal, India. –  Killing more than 3,000 people in its aftermath.

•  It was discovered the protective equipment that could have halted impending disaster was not in full working order.

•  In February 1989, India’s Supreme Court ordered Union Carbide India Ltd., to pay $470 million in compensatory damages. –  Funds were paid to the Indian government to be

used to compensate the victims.




TRAGEDIES THAT HAVE CHANGED THE SAFETY MOVEMENT •  Bhopal Tragedy

Factors leading to the magnitude of the gas leak include: • Storing MIC in large tanks and filling beyond recommended levels • Poor maintenance after the plant ceased MIC production at the end of 1984 • Failure of several safety systems (due to poor maintenance) • Safety systems being switched off to save money—including the MIC tank refrigeration system which could have mitigated the disaster severity




ROLE OF SPECIFIC HEALTH PROBLEMS

•  Specific health problems tied to workplace hazards have played significant roles in the development of the modern safety and health movement.





•  Lung disease in coal miners was a major problem in the 1800s, particularly in Great Britain, where much of the Western world’s coal was mined.

•  An West Virginia coal mine explosion that killed 78 miners focused attention on mining health & safety. –  Congress passes Coal Mine Health & Safety Act, 1969.

•  Mercury poisoning was first noticed in a Japanese fishing village in the early 1930s. –  A chemical plant near the village Minamata periodically

dumped methyl mercury into the bay. Citizens ingested hazardous dosages of mercury every time they ate fish from the bay.





•  Mercury poisoning became an issue in the US after a 1940s study on New York’s hat-making industry. (Phrase: Mad as a hatter?)

•  By the time it was determined that asbestos is a hazardous material, the fibers of which can cause asbestosis or lung cancer (mesothelioma), thousands of buildings contained the substance.

•  The fibers are so hazardous that removing asbestos from old buildings has become a highly specialized task requiring special equipment & training.




DEVELOPMENT OF ACCIDENT PREVENTION PROGRAMS •  Individual components of broader safety

programs have evolved since the late 1800s. –  Early employers had little concern for worker safety. …and little incentive to be concerned.

–  Between World War I & World War II, industry discovered the connection between quality & safety.

–  World War II labor shortages created a greater openness toward giving safety the serious consideration it deserved.




SAFETY AND HEALTH MOVEMENT TODAY

•  Today, there is widespread understanding of the importance of providing a safe & healthy workplace. –  After World War II, practitioners of occupational health

& safety began to see the need for cooperative efforts.




DEVELOPMENT OF ACCIDENT PREVENTION PROGRAMS •  Early safety programs were based

on the three E’s of safety: –  Engineering. –  Education. –  Enforcement.




DEVELOPMENT OF ACCIDENT PREVENTION PROGRAMS •  Engineering aspects of a safety program involve

design improvements to both product & process. •  Manufacturing processes can be engineered to

decrease potential hazards associated with them. •  Education ensures that employees know how to

work safely, why it is important to do so, and that safety is expected by management.

•  Enforcement involves making sure employees abide by safety policies, rules, regulations, practices, and procedures.




DEVELOPMENT OF SAFETY ORGANIZATIONS •  The Occupational Safety & Health Administration

(OSHA) is the government’s administrative arm for the Occupational Safety & Health Act of 1970.

•  OSHA sets/revokes safety & health standards, conducts inspections, investigates problems… –  Issues citations & assesses penalties. –  Petitions courts to take action against unsafe employers. –  Provides safety training & injury prevention consultation. –  Maintains a database of health and safety statistics.




DEVELOPMENT OF SAFETY ORGANIZATIONS •  The National Institute for Occupational Safety and

Health (NIOSH) is part of the Centers for Disease Control and Prevention (CDC) of the Department of Health and Human Services. –  NIOSH is required to publish annually a comprehensive

list of all known toxic substances. –  NIOSH will also provide on-site tests of potentially toxic

substances so that companies know what they are handling and what precautions to take.




INTEGRATED APPROACH TO SAFETY AND HEALTH

•  OSHA reinforces the integrated approach by requiring companies to have a plan for: –  Providing appropriate medical treatment for injured

or ill workers. –  Regularly examining workers who are exposed to

toxic substances. –  Having a qualified first-aid person available during

all working hours. •  Larger companies often maintain a staff of safety

& health professionals. –  Smaller companies may contract out fulfillment of these

requirements.




INTEGRATED APPROACH TO SAFETY AND HEALTH

•  Health & safety staff in a modern industrial company may include the following positions: –  Industrial hygiene chemist and/or engineer -

companies that use toxic substances may employ industrial hygiene chemists to test work environment & people working in it.

–  Radiation control specialist - monitor radiation levels to which workers may be exposed, test for levels of exposure, respond to radiation accidents, develop company-wide plans for handling radiation accidents.

–  Industrial safety engineer or manager - safety & health generalists with specialized education and training.




END




ACCIDENTS AND THEIR EFFECTS

•  Accidents are the 4th leading cause of death in this country after heart disease, cancer, and strokes.

•  There is a long history of debate on the effect of accidents on industry (workers and companies). –  Historically, the prevailing view was that accident

prevention programs were too costly. –  The contemporary view is that accidents are too costly

and accident prevention makes sense economically.

•  Accident prevention, which had been advocated on a moral basis, is now justified in economic terms.




COSTS OF ACCIDENTS

•  Overall cost of accidents in the US is about $150 billion.

Figure 2-1 Accident costs by accident type (in billions, in a typical year).

Figure 2-2 Accident costs by categories (in billions, in a typical year).

Accidents on and off the job cost US industry dearly.




ACCIDENTAL VS OTHER CAUSES OF DEATH

•  There are more yearly deaths of heart disease, cancer & strokes than from accidents. –  But concentrated among people at or near retirement age.

Figure 2-3 Causes of accidents (ages 25 to 44 years, typical year).

Note that for persons from 25 to 44 years of age, the leading cause is accidents. Accidents are a serious detriment to productivity, quality & competitiveness in today’s workplace.

Accidents are one cause of death & injury that companies can most easily control.




TIME LOST BECAUSE OF WORK INJURIES

•  An important effect of accidents on industry is the amount of lost time due to work injuries. –  About 35 million hours are lost in a typical year.

•  Additional time is lost for medical checkups after the injured employee returns to work. –  Accidents in previous years often continue to cause

lost time in the current year.




WORK INJURIES BY TYPE OF ACCIDENT

•  Work injuries can be classified by the type of accident from which they resulted. –  Overexertion –  Impact accidents –  Falls –  Compression –  Exposure to radiation/caustics –  Bodily reaction (to chemicals) –  Rubbing or abrasions –  Exposure to extreme temperatures –  Motor vehicle accidents




WORK INJURIES BY TYPE OF ACCIDENT

•  Overexertion, the result of working beyond physical limits, is the leading cause, at 31% of work injuries.

•  Impact Accidents are the 2nd most common •  The next most prominent cause of work injuries is

falls.




DEATHS IN WORK ACCIDENTS

•  Deaths on the job have decreased markedly. –  But still occur, with

causes that vary.

Figure 2-4 Work deaths by cause for a typical year.




DEATH RATES BY INDUSTRY

•  Variety of agencies & organizations collect & rank data on death rates within industrial categories.

•  Highest to lowest: –  Mining/quarrying - including oil & gas drilling/extraction. –  Agriculture - including farming, forestry, and fishing. –  Construction –  Transportation/public utilities. –  Federal, state, and local government –  Manufacturing. –  Services - including finance, insurance & real estate. –  Trade - both wholesale and retail.

•  Death rates are computed based of the number of deaths per 100,000 workers in a given year. –  Rankings sometimes change slightly from year to year.




PARTS OF THE BODY INJURED ON THE JOB

•  To develop/maintain an effective safety & health program, it is also necessary to know the parts of the body most frequently injured. –  Injuries to the back occurred most frequently. –  Followed by thumb & finger injuries and leg injuries.

•  Frequent injury rankings show that a fundamental component of a safety & health program should be instruction on how to lift without hurting the back.




CHEMICAL BURN INJURIES

•  The greatest incidence of chemical burns, about one-third, occurs in manufacturing, with the rest in services, trade, and construction. –  Acids & alkalis; soaps, detergents, cleaning compounds. –  Solvents and degreasers. –  Calcium hydroxide (used in cement & plaster). –  Potassium hydroxide (drain cleaners, etc.). –  Sulfuric acid (battery acid).

•  Many occur, in spite of personal protective equipment, safety instruction, and available treatment facilities.




CHEMICAL BURN INJURIES

•  Strategies recommended for safety & health professionals, for preventing chemical burn injuries: –  Familiarize yourself, workers & supervisors with the

chemicals to be used and their inherent dangers. –  Secure the proper personal protection equipment. –  Provide instruction on proper use of equipment.

•  Supervisors confirm equipment is used properly every time. –  Replace personal protection equipment when it begins

to show wear.




HEAT BURN INJURIES

•  Almost 40% of heat burn injuries occur in manufacturing every year. –  Most frequent causes are flame (also smoke inhalation),

molten metal, petroleum asphalts, steam & water.

•  Employees should be familiar with hazards, know the appropriate safety precautions, and have & use the proper personal protection equipment.

•  Safety professionals should monitor to ensure that safety rules are being followed, personal protection equipment is being used correctly, and that it is in good condition.




REPETITIVE STRAIN/SOFT TISSUE INJURIES

•  Repetitive strain injury (RSI) are typically associated with soft tissues of hands, arms, neck & shoulders.

•  Carpal tunnel syndrome (CTS) is the most widely known, but there are several other RSIs also. –  CTS is typically caused by repeated and cumulative stress

on the median nerve. –  Symptoms of CTS include numbness, a tingling sensation,

and pain in the fingers, hand, and/ or wrist. –  Evidence suggests a higher incidence of CTS among

women than men. –  Overall incidence rate for CTS is increasing at a rate

of more than 15% per year.




ESTIMATING THE COST OF ACCIDENTS

•  Successful, safety & health professionals must show that accidents are more expensive than prevention. –  They must be able to estimate the cost of accidents.

The procedure for estimating costs set forth in this section was developed by

Professor Rollin H. Simonds of Michigan State College working in conjunction

with the Statistics Division of the NSC.




Cost-Estimation Method

•  To have value, a cost estimate must relate directly to the specific company in question. –  Applying broad industry cost factors will not suffice.

•  To arrive at company-specific figures, divide costs associated with an accident into insured & uninsured costs. – Determining insured costs of accidents is

a matter of examining accounting records.





•  To calculate uninsured costs, divide accidents into the following four classes: –  Class 1 accidents - lost workdays, permanent partial

disabilities, and temporary total disabilities. –  Class 2 accidents - treatment by a physician outside

the company’s facility. –  Class 3 accidents- locally provided first aid, property

damage less than $100, or loss of less than eight hours of work time.

–  Class 4 accidents - injuries so minor they require no physician attention, property damage of $100 or less, or eight or fewer work hours lost.





•  Average uninsured costs for each class of accident can be determined from records of accidents in a specified period. –  For each accident in each class, record every cost

not covered by insurance. Compute total of these costs by class

of accident & divide by the total number of accidents in that class to

determine an average uninsured cost for each class, specific to the particular

company.





•  Shown is an example of how to determine average cost of a selected sample of Class 1 accidents.

There were four Class 1 accidents in the pilot test. The accidents cost the company $554.23 in uninsured costs, or an average of $138.56 per accident. With this information, accurate cost estimates of an accident can be figured, and accurate predictions made.




Other Cost-Estimation Methods

•  Costs associated with workplace accidents, injuries, & incidents fall into broad categories such as: – Lost work hours – Medical costs – Property damage – Fire losses –  Insurance premiums and administration –  Indirect costs




Other Cost-Estimation Methods

•  Compile total number lost hours for the period and multiply times the applicable loaded labor rate. –  The employee’s hourly rate plus benefits.




Accident costs are like an iceberg, in that the larger part of the actual cost is hidden beneath the surface.

•  Slowdown in production near the site •  Need to replace the injured worker

–  Costs associated with the learning curve •  Accident investigation team time

Estimating Hidden Costs




Estimating Hidden Costs




GLOBAL IMPACT OF ACCIDENTS AND INJURIES

•  Rapid development & pressure of global competition are resulting in increased workplace fatalities in China and the Pacific Rim countries. –  Many developing countries becoming industrialized

lack a safety and health infrastructure. •  Occupational safety & health must be seen as a

strategy for sustaining economic growth & social development in emerging countries.

•  The ILO reports record-keeping & reporting systems in developing countries are deteriorating instead of improving. –  Only a fraction of the real toll is being reported.




GLOBAL IMPACT OF ACCIDENTS AND INJURIES

•  Occupational injuries in developing countries are more prevalent in such high-risk industries as mining, construction, and agriculture. –  Men tend to die as the result of accidents, lung diseases,

& work-related cancers such as caused by asbestos. –  Women suffer more from musculoskeletal disorders,

communicable diseases, and psychosocial problems. –  Younger workers are more likely to suffer nonfatal injuries.

•  Older workers are more likely to suffer fatal injuries. –  More than half of retirements are taken early to collect

pensions based on work-related disabilities rather than normal retirement.




END

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