Document 6BBgr1DOEeJdK56pxbOOjGqmo

An INA Corportion Comotty 1341 W Mockingbird Lane - Suite 903 E Dallas TX 75247 214 631 4919 PLAINTIFF'S 'v EXHIBIT JMMC-10 3 July 24, 1984 Mr. Terry Lohman, Plant Manager _ J'.M. MANUFACTURING COMPANY, INC. " "A/G Pipe Corporation '........... Hwyj_ 75 North . - ___________ ~ Denison, TX 75020 Re: E51180.... . _ ......... .................. *' Main Issue Loss Control Survey :Dear.Mr. Lohman: _- HDTTJuly 13, 1984, vis"iTea^o'Or^TatiTiTy^U~rriet 'WtttTWT^c'hard-Arant - *:and.Jnez Scott, Employee .Relations.Manager and.Employ.eeJlel.ations...5iiper- visor. During that, visit, I evaluated your accident experience ;by; com- "`ptet'ing a 'causaT~ahaTysi's ot occupational injuries thathav^occurred -_dn: 1-984. -Together,-we--rev-iewe-d-j&e-management;-Toss-control.programs- .. . '.designed to. reduce the injuries at your plant.1 We also toured the plant * `during which time I "Had' the pi ea'sure of-meeting with some supervisory" r-personnel -who were'-very"recept4ve-and--cooperative- t-othe-oontr-ol-l-i-ng-of .losses. . ............... --Attached is the' evaluation-data-,--les-s-oen-tr-el-recommendations-and-the accident analysis which we discuss_ed_.__ Although you have many good loss ""control programs, i'm confident that these recommendations will Tielp you ^to:meet your goal- for--reducing-oceupational-Tnjuries.------- ----------- - If"you have any questions, or if we can be of greater service, please call me at (214) 631-4919.------------ CO)----------- ------------------- ... Sincerely, f-' --------- --------------------____ Charles R. Nelson, PE, CSP, CPCU ..... --Senior Workers' Compensation Specialist ' '' CRN/vr Attachment cc: E. Edward WAng, Ph.D. Environmental Control Manager J.M. Manufacturing 1051 Sperry Road Stockton, CA 95206 Beth Ingleston Alexander & Alexander 1185 Avenue of Americas .. New York, New York 10036 JUL2 619B4 D 004840 ESIS ACCIDENT/CLAIMS ANALYSIS (BY DEPARTMENTS) ClMm! | J.M* MANUFACTURING CO.. INC. lOCMtOh 4J DENISON. TEXAS * **OOUCI WORKERS COMP A*Air3t* hakjd CC mC CAUSE or description op claim Op U4 rA) Failure to eonoensate for ohvslcal en- 1 v1rnrmnt. Cauoht between Dl DC -StOD and end of Mnh. hand: raised ud. hit head on teniDeratnre hhv' uslnn oiler*. cut flnoer On -# FORMING LINING a a Z Ci. >H 2oc s o.| c ' ii * : PVC cr - IP zX u. 1 1 _JL 2LJL 4 : -; - - PERCENT OF TOTAL | CLAIMS i TOTAL number of cases LOST WORK. |OAYCASES 11 c T0TAI- w, t V<>-i vi D u vs>>O.) SHE tHwo-C> hO ;l1l Z, \ -t t )1 .3 wTre trF*w struct dunnaop nn nrnund with Prn-H < **---wind VTew up _ fnnt i 0 rh/prPYp'nJ-inn* . ulliag -lev-elll ng hnarri-. 28 i. '1 14 20.0 3- 3 65 <2.8 71.4 harh; sliding large otp*. hack: removing 18` perna-Tnr rlnn. arm. shoulder. '- _____ Fat lure to use tool crnoprlv; 'Hand grinder, cut tnee: cutting wye with shoe - ~ . - " 2- Vntfp, finger; aligning motor and-tranS- ; - * mfrrtnn with pipe, finger___________________ 3? CpTTlirp t.n handle equlpmentf material* l ? pmpe-Ty. Thumb rrinhpd between mandrel s: ` -: ': 1 T .. hard ranrhfnr rotating cnpppr pipe: using hofst.`"soruno up", strlklno Ud. ** . Failure to use safetv device: Testlno i -.1 20,6 '3 ' 20.0 3 2 10 28.6 11.0 : 6.7 .1 - pipe. "blew up", lip. tlslno defective eauioment: Pullino on l T5 6.7` 1. 1 15 14.3 16.5 handle fmaterlals on forklift) handle came loose, bach strain._________________________ Total 23 73 7T 3 1 /i 1 1 74 1 1 T 1 15 7 q1 CP-K2&< Fid n U.S A D 004841 WSli JAME: J.M.'MANUFACTURING CO., INC. LOSS CONTROL PROGRAM REPORT LOCATION: Denison, Texas I. Analysis A causal analysis has been completed using the 1984 OSHA log, and supporting data, for occupational injuries, through June, 1984.' (See attached analysis).- The 15 recordables on the log have been categorized into 6 areas. There is-really'not a statistically significant trend developing within any of the injuries varies considerably. As a category, however. Failure to Com pensate-for the Physical Environment has the highest frequency of accidents; 4 or 26.7 percent of all recordables. .It also accounfecTfor 1 or 14.3 percent of-; loss'time cases and l.day or 1. percent of all days' disabl i'ng. As the-', analysis; shows, persons injured in: this'category were striking against a'fixed object or being struck by something. * The~cfaT:eq'ory having the next higest frequency (along with using tools and handling equipment) is Overexertion; -This category accounts for 20 percent of.all claims. It.is also responsible for. 42.8.percent, or:3,:of;all dis abling injuries and 71.4 percent of days disabling. The three claims in .thjs category all resulted in lost time. ' Looking: at; the claims-;by department; ..Forming- and :-E'& -R-had-the" highest frequengyj .each with; 3 -cases.- Each-.of.the cases in' the-'Forming-department involved:lost time, accounting for 21.days;: How.'stgnificahi this"comment : = is .depends .-on .the number, of .persons within a department, hours worked, physical environment and the tasks being performed. Reviewing the loss record for the past 18 months reveals a very favorable relationship with the norms used by the BLS. That comparison is as follows: Organization (All Cases) . LWDCR v: LWDR ij: y* .LC Denison 1-83/6-84 10.3 4.8 48.6 1983 9.7 in 42.0 1984 (Y-T-D) 8.6 4.0 52.2 Goals: 1984 7.5 3.5 48.0 BLS (SIC 3272) 19.7 8.9 152.1 The goals we established for the remainder of 1984 would appear very re alistic and readily achievable based on the information obtained during my visit. 1A99 Ptd. In U.S.A. D 004842 l33i -IAME: '_____________ O.M. 'MANUFACTURING CO., INC. LOSS CONTROL PROGRAM REPORT LOCATION: Denison, Texas II. Management Controls Management Involvement Management is fully committed to controlling losses at this facility. As in all industries, acceptance of loss .control measures by middle management and supervisory personnel varies greatly. There were no instances where it was not clear to any level of management that the goals and objectives of this,pi ant are to control losses and reduce ' injuries toil's personnel. ' Safety Committee A safety committee was formed and disbanded years ago. A recommendation ' is submitted addressing this subject. . * ' Supervisory Accountatyfilly........................ '. . .. Every supervisor with hourly employees has production and safety goals. ^--Eacfi "is documented and formal i zed; -.-.Appropriate action is taken by.- management should such goals: not'be .met.- Facility Inspections .~ ~ : ' . - Some'supervisors go beyond the required monthly formalized inspection report and document their inspections daily:': While it is required to be performed each month, only'about 50 percent of.the supervisors are doingso. A recommendation is submitted on this. $ Lock-Out Procedures ' -- A formal tag-out-pull the fuse-procedure'is used. Generally, no lock outs are performed. A recommendation is offered on lock-out procedures. Accident Investigation Procedures are highly formalized. Supervisors must complete a separate report and submit it to the employee relations department within 24 hours after having knowledge of the accident. Failure to do so prompts a call from the ER department requesting its submission. Orientation New employees are given a formalized slide presentation on "Working Around Asbestos". Foreperson has group, or one-on-one, discussions with his/her subordinates concerning safety and other aspects of their jobs. This is done weekly and documented for a period of 90 days. D 004843 nwnniww____ __________ JAME: . J.H. MANUFACTURING CO., INC. LOSS CONTROL PROGRAM REPORT LOCATION: Denison, Texas First-Aid The day shift has a full time nurse. Every supervisor is trained in first-aid. There are CPR instructors on-staff. .Other personnel are CPR trained. . Personal Protective Equipment . ..; : : . All PPE is provided to the workers except shoes. Arrangements are made to have a van from a shoe supplier routinely visit the premises. Personnel are allowed to purchase such products .through-payroll deductions. -^Safety shoes are.not mandatory but shoes of substantial construction are required. Safety Meetings ' ' . . * .' Monthly meetings are held -' between the foreperson and.crews;. The topics . of discussion .and the .names iof^thqs.e in attendance are documented. III. :Summary . . . -- The above analysis and review..of^substantive mana'gement-controls-has' been completed for the-purpose :of. identifying-the;"Ma*in'Issues" j 'Attention * to these main issues and the--attached 'rec6mmendati*ohs^win."further'a'dvance your loss.control efforts,. . -- .; ; JA99 Ptd. In U.S.A. D 004844 iMnpi LOSS CONTROL PROGRAM SUGGESTIONS AME: * J.M. MANUFACTURING CO INC. LOCATION: Denison, Texas ' 84-1 Personnel maintaining and servicing equipment are using tags and pulling fuses to inform others that the equipment is being worked on. No locks are used. It is recommended that a formal lock-out procedure be established and rigorously enforced to eliminate any possibility of personnel being "caught" by machines inadvertently turned on during servicing. The procedure must be more than the mere pulling of a fuse, turning off a switch or breaker. Material concerning lock-out procedures has been sent to Richard to serve as a guide should such a program be implemented. 84-2 The analysis indicated a high frequency and severity of accidents due to overexertion. None of the three claims in this category reflects the unavailability of material handling-equipment. It is recommended that personnel again be apprised of the necessity of using that equipment or obtaining the assistance of another employee when handling heavy or awkward loads. And supervisors should imme diately correct every improper or unsafe practice of which they're aware. 84-3 There is no formal safety committee functioning at the present time. It is recommended that a committee be established to further de velop safety awareness on the part of facility employees, review accident trends, and provide input and direction to the plant's , loss prevention program. Persons on the committee should be ro tated, as should the chairperson, to allow for as many workers to serve within a realistic time frame. Information concerning com mittees has been mailed prior to your receipt of this report. 84-4 Our discussions revealed a formalized, and documented, procedure "for monthiy~mspecf]ons. Only about 50 percent of the supervisory personnel are conforming to this requirement. It is recommended "that the procedure be reaffirmed to all supervisory personnel and closely monitored to assure that inspections and reports are done in a timely fashion. It is also recommended that unscheduled visits be made periodically to various departments to follow up on the reports to determine whether they're being completed as a mere for mality. 84-5 No in-depth, routine and frequent analysis is being done of accidents. It is recommended that accidents be evaluated periodically using the guidelines mailed to Richard earlier. Supporting any ^galysis should be a review of the costs associated with claims wheViNthat information is available. . .A97 Ptd. in U.S.A. D 004845 ukhlliM NAME: J.M. MANUFACTURING CO.. INC. Denison. Texas LOCATION: SUGGESTIONS 84-6 Persons were observed working on a platform on the upper level of the end of the 13' pipe machine. There were no handrails at the edge of the platform similar to adjacent areas at the upper level. We observed the operations, discussed it with Tommy, and reviewed my recommendation concerning the installation of perimeter protection. Moveable handrails would allow for the once-a-week inspeciton of the crane when the lifting devices are placed on the platform. In the meantime, persons frequenting that area would be protected form falls by the handrails. 84-7 Very few crane hooks were observed with safety latches despite the hooks being designed to accomodate the latches. It is recommended that such devices be installed to minimize the possiblity of a load being disengaged during lift, lowering or moving of the equipment. Hooks without the eyelets at the throat have latches with special collars that can be fixed to the hook. Any equipment supplier should be able to secure these devices for you. 84-8 There were a number of instances throughout the plant where the electrical power cord to pedestal fans presented a tripping hazard. In some cases the cords were defective. It is recommended that the fans be relocated wherever- possible so that the cord will not increase the potential for slips and falls. Most preferable, however, would be the installation of outlet boxes (when applicable) to allow the unit to be plugged in where the cord would not be placed in an area frequented by personnel. And other conditions can be corrected by raising the cord off the ground where that measure is appropriate. 1A98 Ptd. In U.S.A. D 004846