What You Need to Know About...

The Management Guidelines section includes the following sub-sections:

1. Assess What You Already Have a. Management Leadership and Employee Participation b. Plant Assessment c. Hazard Prevention and Control d. Safety and Hazard Training Assessment2. Management Leadership and Employee Participation a. Establishing a Safety Committee b. Assign Responsibilities3. Ergonomics & Musculoskeletal Disorders4. Emergency Preparedness & Response5. Recordkeeping6. Personal Protective Equipment7. Confined Spaces8. Powered Industrial Trucks9. Violence in the Workplace

The Employee Training section includes the following sub-sections:1. Ergonomics2. Lockout/Tagout3. Powered Industrial Trucks4. Confined Spaces5. Personal Protective Equipment6. Saw Safety7. Roller Presses, Vertical Presses and Finish Rollers8. Emergency Preparedness9. Workplace Violence10. Recordkeeping11. HAZCOM and MSDS12. Chain Saw Safety

The Certification section specifies the step-by-step processes nec-essary for Plant, Management and Individual certifications. This includes the details on the following items:

1. Designation and Certification of a Safety Coordinator2. Maintaining the database of in-house inspection checklists3. Obtaining a 3rd party inspection agency and passing the

inspection audit

The Checklists cover the following areas:1. Weekly Safety Checklist2. Emergency Preparedness & Response3. Employer Posting4. Fire/Emergency Alarm System5. Fire Protection6. First Aid7. Hand Tools & Equipment/Portable (Power Operated)

Tools & Equipment8. HAZCOM9. Hearing & Noise Levels10. Lockout/Tagout Procedures11. Machine Guarding12. Material Handling13. New Equipment

14. Personal Protective Equipment15. Portable Ladders16. Powered Industrial Trucks17. Recordkeeping

The Additional Materials include:1. Safety Meeting Minutes Form2. Policy Statement3. Employee Training Record4. Personal Protective Equipment Agreement Form5. Lockout/Tagout Work Permit6. Gas/LPG Forklift Daily Checklist7. Electric Forklift Daily Checklist8. Accident/Incident Report Form9. Assault Report Form10. Comment/Suggestions Form11. Hazard Communication Program/Request12. Substance Abuse Policy13. Confined Spaces Entry Permit14. HAZCOM Inventory 15. Safety Committee Meeting Topic Ideas16. Job Analysis17. New Employee Safety Checklist18. Proactive Achievement Log

SBCA Recordkeeping booklet: WTCA has created an easy-to-use booklet that gives a simple over-view of the recordkeeping rules. This booklet contains everything you need to complete the OSHA required forms.

The Safety Posters cover the following topics:1. Proper Lifting2. Forklift Safety3. Hand Tool Safety4. Roller Presses, Vertical Presses and Finishing Rollers5. Workplace Violence6. Saw Safety7. Working in Hot Conditions8. Lockout/Tagout

The SBCA Operation Safety Program also includes an Employee Handbook that covers the following topics:

1. Sexual Harassment in the Workplace2. Violence in the Workplace3. Ergonomics4. Bloodborne Pathogens5. Ergonomics6. Emergency Preparedness/Evacuation7. Lockout/Tagout8. Powered Industrial Trucks9. Roller, Vertical, Gantry Presses10. Saw Safety11. Hand Tools12. Personal Protective Equipment

SBCA OPERATION SAFETYBelow is a detailed list of topics covered

in the Operation Safety program.

SBCA OPERATION SAFETYStaff Contact: Molly Butz

Listed below are Frequently Asked Questions (FAQs) about SBCA’s Operation Safety program and certification process.

1. What IS Operation Safety?Operation Safety is a pro-gram that helps Component Manufacturers (CMs) monitor the safety and health issues present in their manufactur-ing facility. This program is a solid foundation for imple-menting a high quality safety program in a component manufacturing plant and is a tool that component manu-facturers can use to improve their own companies' programs.

2. Why was it developed?As with every program from SBCA, SBCA Operation Safety was cre-ated based on our members’ needs. In this case, members asked for a customizable, industry-specific safety program to assist com-ponent manufacturers in creating or improving their own existing in-house safety programs.

3. What is the goal of the Operation Safety program?Safety can seem like a daunting task, especially if you're starting from scratch. SBCA's Operation Safety provides step-by-step guidelines for imple-menting a well-rounded safety program, which in turn should help reduce the overall costs associ-ated with safety management in your facility. The financial savings range in expenses from workers’ compensation claims and higher insurance premi-ums to lost production time and poor customer relations. For companies that already have a safety program in place, Operation Safety can still be a very useful tool for providing fresh, industry-spe-cific material that companies can use to improve

existing programs and processes.

4. How much does the program cost to get started?For information regarding program, certification or ongoing costs, please contact SBCA or visit www.sbcatko.com and review the current pricing sheet in the Operation Safety section.

5. What comes with the program? The Operation Safety is pack-aged with a Safety Guidelines binder, a Safety Guidelines CD, eight safety posters, 20 employee safety handbooks and access to all of the SBCA Operation Safety resources on the SBCA Truss Knowledge Online (TKO) web site (www.wtcatko.com).

6. Is any of it available in Spanish?The safety posters, employee safety handbook and employee training modules on the CD are available in Spanish.

7. Who should be the Safety Coordinator?Your Safety Coordinator will oversee all of the elements of the SBCA Operation Safety implementation process through train-ing, scheduling and delegation. The Safety Coordinator should be someone that can dedicate a reasonable amount of time to the safety program. Some companies choose to hire someone specifically for safety, but it is also perfectly acceptable to combine these responsibilities with another position in your facility, whether it's your general manager, production supervisor or someone else.

8. How long does it take to get the program implemented?The amount of time that it takes you to complete this process will depend on the circumstances in your individual facility. If you're starting from scratch, it could take as long as a year; if you've got an existing plan in place that you would like to freshen up, it could take as little as three months. SBCA has a document showing a timeline, which is only a suggestion as you will choose the path that makes the most sense for you.

9. What does "Certification" mean?“Certification” in Operation Safety simply means SBCA confirms that the Component Manufacturer understands and is using the program correctly. Certification also indicates that the manufac-turer is attaining a minimum level of safety.

10. What are the benefits of a company being certified?Those companies choosing to be certified will enjoy the following benefits:

• Safetyaccountabilityatyour plant, including a systematic plan for improving safety.

• Expectedcostsavingsdueto a decrease in accidents and injuries.

• Potentialdiscountsininsurance costs.

• AmarketingbenefitofusingtheSBCAOperationSafetylogo.- Your plant's name will be printed in SBC Magazine as one

of the companies in our industry that has an industry pro-gram commitment to safety.

- On a quarterly basis, SBCA will provide an updated list

to our approved insurance brokers and all insurance company members so that they know of your company's commitment to safety.

- You can apply the Operation Safety logo to any of your corporate literature where your commitment to safety may differentiate your company in the markets you serve.

11. What steps do I need to take to get certified?The following outline represents the steps necessary for Operation Safety certification:

• MembershipinSBCA• Purchaseasubscriptiontothe

Operation Safety Program, including the Safety Guidelines Binder and CDs and online access.

• Designateamanagementemployeetobe your primary safety coordinator.

• Thedesignatedsafetycoordinatorwillbecomefamiliarwiththe entire safety program. This includes reviewing all the online resources to get an overview of the courses and proce-dures that are integral to the program.

• Thedesignatedsafetycoordinatormustbecomecertifiedineach individual subject by passing a proctored exam with an 85% or higher.

• Performaplantassessmentandcompletethefacilitycheck-list.

• Designateaproperrecordkeepingandpaperfilinglocation.Keep required records correct and current.

• DesignateaproperMaterialSafetyDataSheet(MSDS)loca-tion. Keep current and correct records of hazardous chemicals.

• Designateanareafortheproperpostingofanemergencyresponse plan (ERP).

• Designateanareaforafirstaidkit.• Haveproperpostingofconfinedspaces.• Providenecessarypersonalprotectiveequipment(PPE)for

specific hazards.• WorkwithSBCAstafftosetupathirdpartysafetyinspection

agency to perform annual reviews. Note, this agency must itself be certified by SBCA. The component manufacturing plant must pass a scheduled third party inspection before it can be certified. If the third party agency charges for this inspection service, the cost of these inspections will be borne by the component manufacturing plant. After the plant is certified, the plant must set up an annual third party review to be performed randomly during each year. (In the first year, the plant would be inspected twice - once as a scheduled inspection, and a random inspection would follow at some point in that same year.)

• WorkwithSBCAstafftoachievesafety certification.

• Performweeklyandquarterlychecklists, safety audits, proactive achievement logs, safety meet-ing minutes, and new equipment logs. These must be performed and entered into the database quarterly. Before attaining certifi-cation, the plant must send data

to SBCA staff to show evidence they are completed and up to date.

• Oncebecomingcertified,theplant will continue send data to SBCA staff on a quarterly basis. For more information, view the “Requirements for Maintaining Certification” (page 4).

• SignCertificationAgreementandreturn to SBCA.

• Thefinalstepincertificationisthat once you are certified, your company makes the commit-ment to remain certified. It is very important that companies be sure they can maintain the requirements of certification before completing their certification process.

12. Will I be OSHA compliant by using this program?Each component manufacturing facility is different, and although the Operation Safety program is a solid foundation for your safety program, it would be impossible for SBCA to tailor a program that is individu-alized enough for each plant. In creating Operation Safety, SBCA's goal was to assist component manufacturers in meeting the goal of OSHA compliance, but please note that being OSHA compliant and abiding by all required OSHA regulations is the responsibility of each individual component manufacturer.

13. What is 3rd Party Inspection and why do I need it?In order for the SBCA Operation Safety program to have value, it is necessary to ensure the program is being used properly by com-ponent manufacturers. SBCA determined that the most effective means of accomplishing this is to require two third party inspec-tions the first year (one scheduled inspection and one random inspection), and one inspection to be performed randomly during each year following certification.

14. Who can provide 3rd party safety inspections?Your third party inspection can come from one of several sources, such as:

• Yourinsuranceagency'sriskmanage-ment or safety specialist

• ACertifiedSafetyProfessional• YourlocalstateOSHArepresentativeor

state government safety official. • YoucanalsocontactSBCAforassistance

in finding and setting up a third party inspection agency.

15. I've made a decision to participate in Operation Safety! What do I do now?

Visit www.wtcatko.com and order the program online, or call 608.274.4849 and order today!

If you have any other questions that were not addressed above, please let us know. Contact Molly Butz at mbutz@qualtim.com or 608/310-6741.

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