Requirements for Occupational Safety Major in Boar Beer Company - Example

due: Final project Table of contents Purpose…………………………………………………………………………………3 Applicability……………………………………………………………………………..3 Summary………………………………………………………………………………..4 Definitions and acronyms………………………………………………………….5 Backgrounds…………………………………………………………………………5 Personnel qualifications/responsibilities………………………………………….7 Procedure…………………………………………………………………..10 Criteria, checklists, or other standards……………………………………………..13 Records management………………………………………………………………14 Quality control and quality assurance…………………………………………………15 References…………………………………………………………………………………….16 Purpose The aim of a job hazard analysis (JHA) is to observe the employee and record the process of a task from beginning till the end. This involves the identification, control, and elimination of probable hazards in a task. This is evident from OSHA (2002) publication number 3071. JHA is essential in the elimination and prevention of hazards in the workplace. The scope of this project includes beer production and some beer distribution and or delivery services. This paper will analyze the tasks or projects that a forklift operator performs in a production industry. Applicability This project paper is applicable in work places to be applied by employees and employers as it contains data that will help in recognition of workplace hazards. The guidelines followed are recommended by OSHA and is applicable across the beer production industry, and has been agreed with the main trade associations. JHA is applicable in training new employees in the steps that they are to undertake in performing their jobs safely. This paper explains in detail the standard operating procedures of a job hazard analysis that a forklift operator carries out and offers a framework to help anyone conduct an individual step- by-step analysis. This offers the necessary safe forklift operation for forklift operators and offers guidelines for those working near the trucks. In addition, a forklift operator task is linked with the highest probability of injury or illness. This job is also prone to the individual performing it into a disabling injury or illness, and or a severe accident. The recommendations herein are heavily borrowed from U.S. The Occupational Safety and Health Agency (OSHA). OSHA’s Hazard Communication Standard (HCS) requires the development and dissemination about the identities and hazards of the chemicals in the work place environment. In addition, the Material Safety Data Sheet for chemical products used in the brewing industry and was an essential component to this study. Summary Boar Beer Company is a medium sized beer production company which commenced operation two years ago. This beer production company manufactures small batches of homebrew. The company operates a fleet of thirty vehicles and has 62 employees. On March 30, 2014, a 35 year-old male forklift operator was injured by a falling keg batch during mechanical handling. The victim was a full-time employee at the beer manufacturing company. At exactly 12:18 p.m., the employee was using an 8,600 pound forklift to move kegs into a large shipment container positioned at the outdoor loading dock. The victim had just loaded the first keg batch into the loading container and on picking the second batch, after backing out of the finished products area; the forklift overturned. He was backed off the side of the loading dock, falling to the ground. He was thrown from the forklift and was crashed by the falling keg batch. Medical attention was immediately given to the employee. He was taken by an ambulance to the nearest medical facility where he was admitted with hip, back, and leg injuries. Luckily, the patient’s condition improved gradually. The patient is still under recovery. The company was deeply shocked by this incident as it was the first major incident and an investigation was suggested to prevent further incidents. I will assume the role of the supervisor and I will conduct the JHA according to OSHA standard operating procedures. Definitions and acronyms Forklift- A powered industrial truck used in factories and plants. Hazard- This is a condition or activity that is the potential for harm and if not dealt with can lead to injury, illness, or even death. HCS: Hazardous Communication Standard is an OSHA regulation issued under 29 CFR Part 1910.1200.  Job- An occupation or work done i.e. auto mechanic, welder, carpenter, punch press operator, and forklift operator. Job hazard analysis- This is a technique that the focal point is on the job task as a method of identifying hazards before they take place. Job step- Segment of the operation necessary to advance the task done. Preliminary job review- This is a discussion with the employees about the probable hazards in the workplace environment. OSHA: Occupational Safety and Health Administration, U.S. Department of Labor.  Background According to the OSH Act of 1970, worker safety is vial, this is evident from section 5 (a) (1); known as the General Duty Clause, that necessitates employers to “furnish to each of his employees employment and a place of employment which are free from recognized hazards that are causing or are likely to cause death or serious physical harm to his employees”. Accordingly, section 5(a) (2) requires employers to “comply with occupational safety and health standards promulgated under this Act.” Injuries and death occur at workplaces on a daily basis. The result of this calamity is due to work place hazards that could be easily rectified if identified on time. Thus, the identification and control of hazards is vital in the elimination and control of injuries and illness in the workplace. This means that safety and health in the workplace can add value to the company and life of employees in the organization. Workplace injuries, illness, and death can be death with by careful analysis of all workplace operations, establishment and implementation of proper job procedures, and proper safety training of all employees. The best way of doing this is by conducting a job hazard analysis. Forklifts are essential piece of equipment in factories and plants, but they can be dangerous if not well used. According to statistics, forklift operators in brewing industries suffer from fatal injuries from overturned forklifts while unloading beer kegs. From various studies, JHA has showed great workplace results by the reduction of employee injuries, illness, and death, safer and more effective work methods, reduced workers’ compensation costs, and more productivity. An effective JHA must be supported by the management. Management and supervision is conscientious for ensuring all work is safely planned; the Job Hazard Analysis will assist in determining firstly, what are the steps in the job; secondly, what are the potential hazards in the job; and finally, what are the protective measures for the safety of our worker(s) assigned to do the non-routine work. This project draws the attention to aspects of the brewing industry working environment that deserves special attention. The information in this paper is founded on analysis of injuries reported by employers and employees, safety investigations, and data from the industry. The most common situations that cause accidents across the industry will be analyzed along with the order of priority. This project will focus on the connection between the employee, task, tools/ machinery/ equipment and the work milieu. The first step that is done is the identification of uncontrolled hazards. Then steps are carried out to eliminate or reduce the hazard to an acceptable risk level. Personnel qualifications/responsibilities A forklift operator job is permanent, full time, which requires working days and sometimes even weekends. This means that the job of a forklift operator is very demanding Forklift operator duties are for operating a forklift to move, locate, relocate, stack, and count merchandise. A forklift operator uses a forklift, clamp truck, and any other power equipment performs the required task. The forklift operator is accountable for the safe and efficient operation of the vehicle and may also be required to perform Order Filler and Checker duties. In addition, overtime is also available sometimes. The task of a forklift operator is not limited to picking up a pallet and moving it to a specified location, other tasks are also carried out by this individual. They include replacing a propane cylinder, completing daily forklift safety checklist, stacking pallets, charging and changing a forklift battery, hand lading cartons on a pallet, shipping and receiving of all incoming and outgoing product, moving product using a lift truck, order picking, moving pallets of merchandise, cycle counting, maintaining cleanliness and organization for assigned areas, maintaining inventory, and unloading a trailer. Therefore, a forklift operator requires physical energy as he is required to lift and move heavy loads. The responsibilities of a forklift operator matter as this individual determines the probable accident/ incident. Some of the steps that a forklift operator does may have serious hazards, while other steps contain no hazard at all. These potential hazards include: entry into confined spaces from both toxic (carbon dioxide) and asphyxiant (nitrogen) atmospheres; falls into vessels which may contain hot liquids; falls of kegs and casks during mechanical handling; fork-lift trucks and reversing vehicles; electrical plant and access at heights. As a supervisor investigating this case from happening again, the question that keeps popping on my mind is “What can be done by the employees and company management to make the job safer?” The wok environment a forklift operator include hazards such as rough, sloped surfaces, uneven, unusual loads, narrow aisles, hazardous areas, blind spots, intersections, employees working close to the path of travel. The kind of injuries that a forklift operator is prone to include slips and trips, handling, falls from a height, being stuck by moving object, injury from hand tools, striking against objects, exposure to hazardous substances or hot objects, transport (fork lift truck accidents), and machinery complications. The qualification of a forklift operator includes: Authorized trainee and or possess a certificate of competency Must have completed a course of training and regarded as competent Application with a clamp. Forklift driving and merchandising Proven ability to work with minimum supervision First aid training and previous work experience with an ISO certified company are considered an asset. Strong organizational skills Strong effective communication skills Preferred education level is vocational school, high School Diploma, partial college, and or grammar school. Minimum five years recent experience in a similar role External and current forklift certification High degree of initiative and innovation Ability to follow health and safety rules A forklift operator must meet satisfactory completion of a forklift training program as per the required knowledge, experience and skills. Benefits of a forklift operator include dental, vision, medical, group, life, and pension benefits. In addition, a forklift operator must have valid experience and certificate. A forklift operator reports to a warehouse supervisor and the forklift operator supervises no one. A fork lift operator must possess the following competencies; job knowledge, flexibility, inventory management, meeting expectations and production standards, customer and market knowledge, sense of urgency, safety, accountability, job knowledge, use of job related equipment, continuous learning, process improvement, accuracy, thinking independently, teamwork, process knowledge, inventory management, and comply with OSHA standards. Procedure Each of the tasks done by a forklift operator has to be analyzed for hazards. Each step of the JHA have to be observed and analyzed and the sources of the injury identified; this is necessary in comprehending the job. According to OSHA 2000 publication number 3071, a JHA analyzes all aspects of a task, describing all qualifications and tasks in a specific job. For a safe work procedure, personal protective equipment must be worn. They include; foot protection, hearing protection, sunscreen, and protective clothing. The forklift operator gets assistance from one or more staff members in respective areas. The forklift operator works at the raw materials, warehouse, and end products areas. Each forklift operator in this company is designated a specific area which comprises of a specific route. Procedures for forklift operation include: The operator wears the appropriate safety work gear. This includes safety shoes, had hat, and a hi-visibility jacket. Next, the operator does a routine check to check the equipment for any faults i.e. brakes, steering, warning devices, mast, controls, and tyres. Any noted damages must be notified and the forklift should not be used till it is repaired. If no damage, the team is dispatched to the designated areas. The operator seats correctly in the forklift and fastens the seat belt. The equipment’s controls are confirmed to be in reach and the seat position and mirrors are adjusted as per the operator’s desire. The operator then drives the forklift as per the designated route. The operator arrives at the area of duty and with the help of the staff in the area; he checks the loads carefully for stability and damage before moving them. He then checks for any overhead objects before lifting the load, and he stacks the load to the allocated area. The operator does this continually till the task is over and the shift ends. After use the forklift is parked in a designated area. The operator fully lowers the forks to the floor and applies the park brake. Next, the operator turns the forklift “off” and removes the key. Before the driver leaves the allocated area for the day, he signs a maintenance log sheet to certify that the truck is in good condition for next day use. The procedure for completing a job hazard analysis involves the following steps: 1. Breakdown of task done- This involves the task identified for analysis by the supervisor, which in this case is forklift operation in a brewery. I being the supervisor must oversee the breakdown of jobs into steps, as listed above. This is done with the assistance from other staff members. Each task done comprises of a series of steps from the beginning to the end. The basic steps have to be recorded. 2. Identification of the potential hazards- This procedure must be in reference to the JHA form. This involves the identification of probable hazards at each identified step. This is better done with the observation of the job done and knowledge of accident/ incidence cases. Questions that are to be asked include: Can any body part get caught in or between objects?; Do tools, machines or equipment present any hazards?; Can the worker make harmful contact with objects?; Can the worker slip, trip or fall?; Can the worker suffer strain from lifting, pushing or pulling?; Is the worker exposed to extreme heat or cold?; Is excessive noise or vibration a problem?; Is there a danger from falling objects?; Is lighting a problem?; Can weather conditions affect safety?; Is harmful radiation a possibility?; Can contact be made with hot, toxic or caustic substances?; Are there dusts, fumes, mists or vapors in the air? The findings of the JHA should be communicated to all workers and recommendations implemented with immediate effect. These findings are essential in determining if the staff works according to OSHA guidelines. 3. Preventive measures- This stage determines methods of eliminating the hazards identified. There are several ways on eliminating hazards. They include choosing a different process, modifying an existing process, substituting with less hazardous substance, improving environment (ventilation and lighting), and modifying or changing equipment or tools. There are instances where the hazard cannot be eliminated; therefore, it must be contained. This involves prevention by using enclosures, machine guards, worker booths or similar devices. Additionally, minimizing exposure has to be done to reduce the number of times the hazard is encountered. Sequentially, the work procedure must be revised. This involves modifying steps that are hazardous, changing the sequence of steps or adding additional steps (such as locking out energy sources). 4. Communication of Job Hazard Analysis to Workers- When the Job Hazard Analysis is completed, the results must be communicated to all workers who are, or who will be, performing the job. The job hazard analysis must be discussed by the employees performing the job to ensure that all the basic steps have been noted, are in the correct order, have suitable controls and be documented and signed by the worker and supervisor. Supervisors will ensure that workers are following the appropriate control procedures. Criteria, checklists, or other standards I observed forklift operator procedure and came up with a checklist focused on operator standards and maintenance; mainly on the machine pats i.e. overhead guard, hydraulic cylinders, mast assembly, lift chains and rollers etc. I carefully outlined the tasks and probable accidents/ incidents. Commencing a JHA in the company must comply with Occupational Safety and Health Administration standards. These federal standards are mandatory, and they must be included in the JHA. A safety checklist includes the most common situations that cause injuries, as well as a list of preventative measures. The standards that breweries employees ought to comply with include 29 CFR Part 1910.178(l) Occupational Safety and Health for General Industry. Pre-operational and operational safety checks have to be conducted. Pre-operational safety checks include the following which must be done by the forklift operator:  Locating and ensuring familiarity with all machine operations and controls.  Checking brakes, lights and horn before use.  Ensuring reversing beeper and warning lights are operational.  Ensuring seat belt/safety restraint is in good condition.  Knowing the capacity of the forklift before using it.  Checking gas-powered vehicles for gas leaks in fuel lines.  Ensuring the lifting forks are in sound condition and centered either side of the mast.  Checking tyre pressures. Operational safety checks done by the operator include:  Watching out for pedestrians.  Ensuring the lifting tines are secure into the pallet and the load is stable before lifting or driving off.  Being careful of ceiling clearance or overhead obstructions when raising the mast.  Always remembering that the safe working load of a forklift reduces as the mast is tilted forward.  Always putting the heavy end of the load against the load backrest.  Avoid harsh braking, especially when carrying a load. An essential task in the criteria for forklift operation includes refueling, ending operations as per SOP, and cleaning up the machine. This entails parking the forklift on an even ground, and lowering the forks to the ground. Also, the gear selector must be shifted to park position and the parking brake applied. The ignition must be turned off and keys removed. Records management Daily inspection lists are relevant in managing the forklift devices. Keeping of records is relevant in ensuing proper documentation of the forklift, and accidents/ incidents that occurred. Records of the forklift operator training must also kept. Quality control and quality assurance According to the OSHA powered industrial truck standard, employees must develop a particular training program to the type of truck to be driven and the working conditions encountered. This means that the employees must also evaluate the fork lift operator’s performance in the workplace and certified that each operator has received the training required. Title 29 Code of Federal Regulations Part 1910.178 under The Occupational Safety and Health Administration (OSHA) outlines the training requirements for powered industrial truck operating training. When each step of the JHA is carefully observed and analyzed, the sources of the injury can be identified. References "Occupational Safety and Health Administration - Home." Occupational Safety and Health Administration - Home. N.p., n.d. Web. 28 Apr. 2014. . Read More