Document DoQ9X7akVzKjpBg7eJK8D4VQ

;,-_'3Tt<0NG coire' C0w?ahi -loop. civisioh LA& CASTZi. FiijiKSILVANIA I. study of this plait ms conducted fron Larch 17 to April 7, 19AS by the Industrie! Health Section, Health aid Uelfare Division of the Metropolitan Life Insurance Company to determine the health hact-rds, if any, associated rita the manufacturing operations. Previous studies mere made in 1935> 193S aid 1943. The results of the current study led to the folioting recommendations: 1. AH exhaust systems should be kept properly repaired aid main tained. 2. Lead free pinnerus should be used rherevsr possible. If pig ments containing lend in any fora mist be used, the Ledical aid Safety Departments should be informed. 3. Inhaust ventilating systens at pigment or color scales should be re-designed to efficiently entrap and remove all dust pro duced by the operation. At Periodic samples of urine and/or blood should be collected from those employees tho handle or ere exposed to lead pig ments or litharge end should be analysed dor lead so determine possible absorption. In collecting the samples, necessary precautions should be taken to prevent contamination from the nanus or clothes of the employees and the samples should be z^s^zed by trained, experienced personnel* 5. Hating should be forbidden in locations there lead pigments are used. Znoloyees ;rho tori: in these areas should be cautioned to nasi, hands ana face thoroughly before eating. 6 . lioployees handling lead pigments should be instructed as to the need dor careful operating procedures to prevent dis persion of the duct into the atmosphere. -- k. ^ 7. Building ,t59-*'* - Litharge should be reighcd directly into the bucket to be used Tor chaining, rather then being dumped in to the charging bucket iron a tared neighing bucket. . The exinust system at the lidding table in the Sheet iletal Shop should be re-designed to remove the melding funes at their source. This may best be done by the use of a flex ible, easily adjustable exhaust duct, or by lateral exhaust if the nature end sine of the rork rill permit* 9. Lids should be provided for the charging chutes in the Asphalt Tile Building* These chutes should be kept covered except rhsn charging is taking place* 10. Positive exhaust ventilation should be applied to the lead melting not ana at the souring table in the Hackine Shop, Building* #30-3. 11. The present shot blasting equipment in Building #72 should be replaced rath modem equipment that rill provide a more efficient method of entrapping and collecting the duct. 12. The use of compressed air for floor cleaning should be dis continued, also dry steeping - especially in departments there lead bearing dusts are encountered. Vacuum cleaning methods should be ehpioyed. 13* Approved type dust respirators should be used by yard men, and car unloaders in the Sundries Department, then unloading bulk or bagged rar materials - especially then handling asbestos or siliceous materials. 14. The general ventilation in 3uiiding =7406 should be increased by the use of rail or ceiling ventilating fans, especially in the area of #3 Lacquer Machine, front end. 15* Operators at all hopper or mixer charging operations should be instructed to handle rith reasonable care all bags of rat material end, after emptying, the bags should be shaken rithin the effective range of the exhaust hoods. 4 separate exhaust ed hood should be provided to take care of the shaking and stacking of empty bags xhere required. 16. The inlay backing-in operation should be studied to devise a method of ventilation to prevent the vmuors of mineral spirits from accumulating at the rear of the machine close to the rail. - 3Housekeeping end Personal Peeilities Housekeeping is generally good throughout the various departments. Aisles ere '.veil defined end free of obstructions* Ample toilet, locker, cad tasking facilities are provided. A hospital supervised by a full tine physician sad nurses is naintair.ee. Restaurant facilities are also available to all employees. ?Jethods of Sampling and Ar^TTrsgg The samples rere collected and analysed by the nstkod used and devised by the United States Puhlic Health Service.^ The folio-ring tables saotr the dust, metal fume, and solvent vapor concen trations found at representative operations throughout the various departments, also chemical analyses of settled dust samples and of some of the cost ridely used rat: materials for lead., total and free silica. (1) United States Public Health Service, Public Health Bulletin Ho. 217, Determination end Control of Industrial Dust - J. J. Bloomfield end J. R. Dallavalle, 1935. KntfSTROUa CORK COUPAt! k rtOOR DIVISION UHCA3TCR. PBHNSVLVAKH Location Data Kill ton* of duot partlolosuraaa than 10 nitons In graataov.dlaxotor por-cu. ft* air oaoplod Typo of Duot Uatorlal Datorolnad Milli grams par cubie Kotor Parts par Million Remarks may Dopt.rf Building 34-D* 3/1/* tb floor* Charging j^4 Hoppar. 3*2 Wood flour Whiting Plgmanta Load 0.02 Exhaust. on hoppar. fide* 3**D. ?th floor. Cutting nd weighing boaf. 3*1 Wood flour Load 0-000 ildg* ?th floor. Cork rysr charging hopper. " 11.1 Cork idg. 3**0* 8tb floor. Boroan B A C Ulxora |4, $, A .f6* H 3*9 Wood flour. Whiting Plgmante. Load o-oi6 Idg. 3*-D. 8th floor. Botwoon * 3*1 food flour* t C Klxars |l, #2 and |3* Whiting Pigmanta Load 0.011 Idg. 34-D. 7th floor. Bor#n t*t> Canaan mlxora. " 2.4 Wood flour Whiting Pigments Exhaust at bolt transfar. Idg* 34-D. 7th floor, General lr, cantor of floor* * idg. 34-D. 6th floor- At trenoir of color nix fron bolt conrsyr to pano* idg. 3*-D, 6th floor, at color >ttlr. 2.6 3-7 2*3 Wood flour Whiting figments. Wood flour Whiting Pigments. Wood flour Hilling |71 rrmhM^ * Various colors dmpsd Into pan and fad by conrsyor to _____ Location Data U1U lorn* if dust particles laaa than 10 microns in greatest dlamster par cu* ft. air sampled. Type of Duet Material Deterralnod Milli gram* por cubic Ueter Parts par Million !Hg. 34-D.( 5th floor. Stan- 3/18/48 11 Shop* Buffing brorita plate* 2.2 tfotal Lend 0.007 Remarks Uan wears respirator* Hdg. 34-D*, 5th floor* Stencil * Shop. Soldering on stencil plate* Uotnl "log. 34-0., Pth floor* Slaving ** 5-0 Woo 1 -r\A tagging rood flour* Land 0*024 Potfr wan using electric soldering irons. Tespirator worn* tldg. 34-D., th floor. Loading * *ood flour into chute feeding sieve. VLdg. 34-0. 6th floor, between 3/19/49 *o disintegrators- 4.3 1.0 Wood Wood flour. Whiting Pigments Wood flour dumped from bags. 'ldg. 3*-D., 4lh floor* At iIx coat ecsles. H 1.4 Wood flour Whiting Pigments ildg. 34-D., 4th floor. At ceolvlng pane bolor dlaintagrator* 2.1 Wood flour Whiting Figmenta. Vntcrial d-opa from hopper into open pans* Idg* 34-D., 2nd floor, charging nlay machine hoppara iron pane* " Idg* 34-D., 2nd floor, Cork Room, egging cork* 1.0 Wood flour Whiting Pigments 1.3 Cork !fo exhaust. Idg. 34-D., lat floor, |3 Inlay able, at hand ecooplng* * 2.0 Wood flour Whiting Plguonto. Idg. 3-D. 1st floor, 1 Inlay " 1.4 food flour able. Whiting Pigments Location Lets Millions of duet particles less than 10 microns in greatest diemeter per cu. ft* air sampled* Type of Boat Material Determined 111 Mi graine Porte per cu. per Veter Million Hemarks Jldg. 3*-D* 6th floor, at ;o roll ecrateher. ildg. 3<-D.f 6th floor, '.enoral air* Udg. $-h - Bridge Beaming >t Stove if21* 3/26/18 n it Acrolein Acrolein Acrolein .01 Lose then .001 .002 <ldg. 3*"D** 2nd floor* Chargng platfdm for Bamtury Ulxor. 3/19/48 3*9 ldg. 34-D., 2nd floor, General Ir, Bambury batch weighing room * 4 1.4 ldg. 3,"D* let floor, at ambtiry dryer# N 2.4 ldg. 34-D., let floor, General irbsaide Cobtn Bnee prees. ft . 1.8 ldg. 33-E*# let floor. At rcopac Machine. itery Pept. Pldg* 31* Tth loor, near ^2 wJxer hopper. H j/ic/.o 5.4 Whiting Wood flour Figienta Clay Whiting Wood flour Pigments Cloy. Whiting Wood flour Plgmonto Clay. Whiting Wood flour Plgmonto Clay. Cork Ponceldohyde Trnce Whiting Wood flour Plgpionts Load O.OO? Mix air dried end dumped into certe. Exhaust on emerging hoppore Crnvea lorries winning et exhaust hoods. Location Data Millions of dust particles less than 10 aicrons in greatest dlameter per cu* ft* air sampled Type of Dust Ueterlal Determined Milli grams Parts per eu> par Meter Million Remarts dg. 31. 7th floor, at pig* nt welching. dr.* 31 3rd floor, at B * C *ors. 3/19/<6 M 30.1 2.1 dg* 31, 3rd floor. Between 3/l9/iB eotors and Finishing Ccllendere. dp. 31, 2nd floor, at Carman xor under B d C cn 3rd floor. ee 0.7 1.1 Pigments Lead Whiting Wood flour Pityeonts Lead Whiting Wood flour Plgmonte WMillng Wood flour Pigmenta 0.079 0.000 Exhaust at weighing in adequate* Exhaust orer mixer doers not operating. Charge dumped to floor and shovelled Into hopper*. Two Shooters sorting. Sly collector located here* Side of collector open. dp. 31* 6th floor, General r near PIC Mixers* dg. 31, 5th floor. General r at Gorman Mixers* dg. 31, 4th floor, General r, Pansoma Mlxor floor* II M 5-5 3*0 0.8 Whiting Wood flour Pigment a Lead Whiting food flour Pigments* Whiting Wood flour Plpoents 0.000 Mins mixers* Charge dumped to floor and shovelled Into carts. dg. 31, 2nd floor, at pan reciting. 3/20/48 idg. 31-C., 1st floor, at ills cf Rotary Machino* m da* 31-C., 1st floor, at olx >nt callender * 1.6 0*7 1.4 Whiting Wood flour Figments Whiting Wood flour Pigmento Whiting Wood flour Location Date Billions of dust partlolee less than 10 nlorono in greatest dlaooter per cu. ft. air sampled. Type of Dust Material Determined mill- grama Parte per cu. per Ueter Million Remarks 'ard Department. Bid*. #500. tacking^begs of asbestos for tormge. 3/30/48 52.6 Asbestos Pour men in area. 'ldg. 500* Unloading bagged Hleonltc from box oars. 4/1/48 22.2 Gileonite ard Dept* - Inside freight oar 3/20/40 hile unloading bagged whiting. 1notile Dept. - Bid*. #12. th floor* between two preseea. n ldg* #32 * 6th floor. Machine hop section. Oeneral air. m ldg. #32 - 5th floor. At Eh c tlng-ln* # ldg. #32 - 3rd floor. Be*een two eawe. m illender Dept. - Bldg. #44. th floor - At beef roll. # ldg. #44 - 6th floor. Between 11 A #12 Charging hoppers. ft ldg. #44 - 6th floor. Betwoen l ani #2 charging hopper*. n ldg. #44 - 5tb Hoor. Charging 3/22/48 #2 *d #3 77.0 1.3 1.8 1.3 1.5 1.6 2.0 2.7 4.0 Ihiting Miscellaneous Iron oxide and Motel Miscellaneous It Wood flour Lead 0.000 food flour Lead food flour 0.115 food flour fhitlng Pigment. Load 0.19? No respirators worn. Three grinders * on* operating. ldg. #44 - 5tb floor. Between >od flour screening and sorap m 3*7 food flour Location Dale Ullllone of duet pnrtiolae lean then 10 mlorone In grent''!t dlonetor par cu* ft. air aampled. Typo of Duet Material Determined vnu- grand Parts per cu* por lteter Hill ion Benarte Bldg. |44 - 5th floor* Charg 3/22/48 ing |ll Hopper over QIC Ulxer* 7*7 Wood flour Wilting Plpasnt. Lead 0.072 Bldg. |44 - 5th floor* At color veigh eoalee. Bldg. |44 - 4th floor* Betwoan B 4 C Ittxsrs |3 anA |4. Bldg. |44 - 4th floor. Between B A C Ulxsre |lO end |ll* n H ft 27*6 Pigment Lead 3*71 1*7 Wood flour WMtlng Wgraent Lord 0.032 1.6 Wood flour Whiting Pigment. Lead 0.000 Using colors 35 4 38 prii clpally. gxhauet above scale not efficient* Pour window fane* Bldg. |44 - 3rd floor. Oensral air near Canaan Ulxsre. 91dg. |44 - 3rd floor* Grinding bcof through Gorman olxere* Bldg. Sn - 2nd floor. At ra:elring pone for ground beef. Bldg. |14 - 2nd floor* Boolda atx grlndar* Bldg. |44 - let rioor. Cn jlntfona of |3 ctllender* *4 * ft m 3.2 Wood flour Whiting Ptgment 3.0 Wood flour 3*1 Wood flour 4.0 Whiting 1.1 Whiting Wood flour Pigments. Experimental procees* Operator throve whiting into grinder by hand. Bldg. |44 - lot floor. Spreading 'lx on rolls, Callender 1-A. " 2.1 Whiting Wood flour Pigments* Locat ionDate Ulllione of dust partiolee loos than 10 microns in groateat diamoter per cu ft. air sampled* Typo of Oust ork Mill - Rid*. 41-A - 4th loor. General air at gravity eparators and dreeaers. 3/22/48 ldg. 41-A - 5th floor. Decide otex ecreen. ldg. 41-A - 5tb floor. General if at eork dreeeere. ldg. 41-A - 6tb floor. General lr eeaple. m ldg. 41-A - 3rd floor. Cork *gglng. ldg. 41-A - 2nd Uerrenlnv. Cenral air at cork grinding. ldg. 41-A - 2nd Metianlne* Stone -seeing, using exhauat hose* m * tt i*r 15*0 3-2 3-5 5.4 13.8 9*4 Cork Cork Cork Cork Cork Cork Cranlte dg. 41-A - 2nd Metiaoloe. Stone * seeing without exhaust boeo. 15*0 Granite dg. 41-A - let floor. At irk breaker. dg. 41-A - let floor. Gen-nl air In Ball and Jewel o, near Rotex ecreen. linn Dept* - Bldg. 4J-f. let oor. Oenoml air near rolle* dg* 4?-S - 3rd floor. Siting * room at mixer loading. 3/?3/<fl M n ft 6.0 5*5 1*5 5-7 Cork Cork Slate Starch Slate Starch Material Determined Milli grams par cu* Meter Parte per Ulllion ___________ Remarks Cork mill hae Improved great ly alnco laot eurvey. Housekeeping excellent. Proceae alsoet completely enclosed *ith exhaust appli ed where necessary. Operator wears air lino reepirator. 31oto, r*larch, glue and Location U111Ion* of dust particles lass than 10 nitrons In greatest di ameter par ou* Typa of Duet Uatarid Determined miiigran* par ou* Motor. Part# par Ullllon Remark a dldlng #53 - Bag cleaning* 3/23/48 16*0 Wood flour Serpentina echnnlcal Oxidation Dept. ldg* At-C - Section 3 ppoeite oxldlsera #116 and #117* 1dc- 67-S - Soction 3* Oppooito xldltere #92 and #93* ldg* 67-2 - Soction 1 pposlte oxidltors ^36 and #37* ldg* 67-2 - Section 1 pposltc oxiditera #1.8 and #19* n n M 3*o 1.8 8*9 11*2 Wood flour. Wood flour Wood flour. Wood flour Bag turned Inal do out in ex haust duct* Little dust generated here. Host dust produced during handling prior to elatrlng. ldg* 67-B - let floor - Hilling If 1*9 Wood flour. pedal cooent for printers blanket ldg* - Bneeraent* At cooi ng pita undsr aaction #3 - bxl- Uer #110* M 1*5 Wood flour* ldc* 67"S - Basement - At #1 tonga pit*. It 14.8 O *O flour. ldg. (>7-K - Saetlon #1 - bealda 3/28/48 nit #29* ldg. A7-P - ffeaeoent - Under notion ?} pits. ft Acrolein Acrolein Lose than .001 Lose than .COl TVo oxldltere tapped during paneling. ldg.- A7-E * Section #3 * >rlde unite #99 and #101* tf Acrolein Lass Location Date Millions of dust partloles laia than 10 alorone in groat601 dl<* ameter par ou* ft* air sampled* Type of Dust Materiel Determined Ullllgratae Perte per eu* per Motor Million Mdg* A-59 - let floor* Gen 3/24/49 eral air before litharge weighing 6.2 Hleallanaoue Remarks B^dg* A-59 - let floor* Weigh ing litharge* Bldg* A-5? " let floor* General air after weighing* Bldg* A-59 ~ Emulsifying floor charging kettle with litharge* * * Litharge Lead 0*539 2.1 Miscellaneous Lead 0*007 Litharge Lend 0.000 Three 75 16 Vwckets weighed Exhaust over scales* Some spillage during hand scoop ing. Bldg* A-59 - EtauleiTying floor. General air aftor litharge mixing;* Bldg* 59 " General air* 3/26/48 Miscellaneous Lead 0.000 Acrolein Lees than *001 Bldg. 67-B - Charging roeln Into hopper for melting* 3/24/48 paint and Backing - Bldg* 6?-C let floor* Between mix ere working t ^41 palate* 3/23/48 Bldg* 67-B - 2nd rioor. Charg ing paint sit hopper (f8* 2*7 1-9 5*1 Rosin Figmenta Roeln Lead 19*5 0.009 Figments Lead 0.000 Ho exhauet* Titanium dioxide* cley,rlnc oxldo end blane fixe edded* Sxhnust at hopper* Bldg. 6?-B - 2nd floor. General H 2.4 Pigments Loed 0.024 elr, color paint hopper charging rooa* Bldg* 67-B - let floor. Beside m 1*1 Pigments Lead 0.003 ^9 paint mixer* ifl Mill charged during eacop ling period* Location Date Million* of duet partiolee lasa then 10 microns In greatest dlameter por cu* ft* sir sampled Type of Duet Materiel Determined Milli gram* Part* per cu* per Meter Million Bldg* 67-B - 2nd floor* Charg ing ifl* ,f2* #3 and #4 hoppers Tor backing nix* 3/23/48 21*5 Slate, Clay, Plgmonto* Bets ark* gxheuat at hopper*. >rpentar Shoo - Building #75 - 3/24/40 Denoral elr* 3*1 food Kxhaurt on most machines* Pip* Shoo* Conoral Air ft Sheet Uetal Shop - Bid*. #72. General sir* It Shoot Uetal Shop - Bldg. #2* voiding table while welding gel ran 1 ted material* At " 0*8 Uotal Lead Zinc 0*000 0*049 1*1 Uotal Lead Zinc 0.000 0.215 4.0 Iron oxide Lead 0.000 4 tine Zinc 1.215 fumoa* Sample collected while weld lng was being carried on* Battery Shop - Building 30-H Battery charging* t Sulfur ic acid .16 folding Shop * Bldg* 3*M* Bratlng steel pipe* m 3.6 Uotal Lead 0.000 fumes* Zinc 2.04 Ho exhaust* folding Shop - Bldg. 30-H* General 5*5 Uetal air in arc welding area* " fumee Lhchine Shop - Bldg* 30-H* Bottlw * 3*4 Plastic cep molding machine* Unchlno Shop - Bldg* 30-H* Oenersl " 2.6 Uetsl elr( tool grinding orea* Abreelre Unohlna Shop - Bldg* 30-H* At load metal melting and lead homer 3/U/48 cabling. 6*3 Lend fumee* Lend 079 Lend pot hooded end connect ed to a natural draft stack Location Date Millions of duot particles leee than 10 microns In greatoat diasoter per cu* ft* air sampled Typo of Duet Material Determined unit- grama Parte per cu* per Motor Million Heat Treating - Bldg. 30-A. 3/24/40 General air in heat treating area* 2.2 Miscellaneous Remark* Blacksmith Shop - Bldr* 30-A. General air* * Arphalt Til* Dept. - Ittda. 35-A - 3/25/48 5th floor - at mixer charging. 2*5 4.1 RldC* 35-A - 4th floor. At B C olxer* Bldg. 35-A -,4th floor* At scrap conveyor transfer* " 4.5 " 4.6 Bldg. 35-A - 4th floor. At German mixer. * 1*6 Cork Serpentine Aebeeto* Reelno Pigments Lead Serpentina Asbestos Rselne Pigments Serpentine Asbeetos Resins Pigments Serpentine Asbsetoe Resine Pigment* 0*000 Ho exhaual at charging chui Use pigmenis 4?* 16, and 35 Charging nix for greoM*prc tile. Ho oxhauet. Running gro***-proof mix. pldg. 35-A - 4th floor# General * 2.0 Cotton air, sewing room* lint Bldg* 35-A - 3rd floor* Cbarglne " 3*2 Serpentine mixer boppera between beppeft ft Asbestos and Resin* Pi piient Kxhauot at hoppsr* during charging only. Lid* left open at all time*. Bldg. 35-A - 3rd floor# U * 1*6 Serpentine line roll below Genaan *i*fr* Aibetto* Rttln* tH * Location Drto Millions of dust particles lees than 10 microns In fleetest di ameter par cu. ft* adr asuxjledI. TjT of Dust Material Determined umigraae per cu. Meter Parta per Million Bide. 35-A - 3rd floor. Bo- V?5/<B tween charging hoppers #6 and ft* 11.? Serpentina Astostoa Resins Pigment. Bldg. 35-A - 3rd floor. At * rooelvtr bon under mottle grinder* 4*0 Serpentine Aabestoa Realns Pigment. Bldg. 3$-A - 3rd floor. At acrop ** receiving cart under ecrep grinder* 10.? Serpentine Asbestos Reelne Plgeent. Bldg. 3?~A - 3rd floor. General air, hopper charging room. " i.r Scrpontlne Aabestoa Resins Pigment. Bldg. 35-A - 2nd floor - At Baker-Porklns mixers ^1 end .^2* * Bldg. 35-A - 2nd floor. BakerPerkins Ulxere f6 arid ft* H plig. 35*A - 2nd floor. At heeter rolle. " Bldg. 35'* - 2nd floor, Rotroen line rnd hand punch preoo area. " 2.3 2.7 5*o 2.A Serpentine Aebeatoa Rcslne Figment* Serpentine Asbestos Roslno Pigment Serpentine Aabestoa Reolno Pigment Sorpontlne Asbostoe Remarks tocetIon Date Hi 11ions of duet partiolao laea than 10 microns in greatest dl~ emater per cu* ft* air aamplod* Type of Duet Haterlal Determined Mlllicroms Porta per cu* par Hater Ulllion Remarks Idg* 35~A - 2nd floor* In fection and packaging and of Ina* 3/25/48 idg* 3J-A - lat floor* Finleh- ig and packaging of Cobin Baso* ft 5*9 4.4 Serpentina Aobeetoe Beelna Pigment jiler Homo - Bid*. ^40 neral air on otokor floor* n 44.6 Coal Rollers otokar fired* Fluae cleaned during einpllng* '.rd DaptBldg* f?49* Cork 3/26/48 torag* Bldg* Stacking balaa of cork. 15*5 Cork trd Dept - Unloading cor of balod H 'rk * 14.1 Cork ird Dapt - Unloading Supcrflno 3/30/48 308irvood flour from box earn* Wood Two men In car pceelng bags to two man on trucks* ird Dept. Bldg|62-P, f4 abad* ortng bags of Suparflno flriod flour* rd Dept* - Uoloadlng bag* ebestoa 271* ft 149. Wood Aebaetoe Pour non in area* Two men in car, ora sen on truck* ft Order Dapt* - Bldg* Jl50* neml air enrple- 3/29/48 2*7 lfpcetlon 4 Trimming, Bldg*fl55* ongaldc *1 trioning and roll- > table* " epectlon 1 Trimming, Bld;j.fl55* twoen ift i 1 trimming table* 3/30/<8 trade-mark inking ornJ* 3*6 5*4 Ulacollaneoue UlecalloncouD HLecollanooue forking l/8M plain burlap backing. forking A6 burlep tacking. Location Unto Millions of dust particles loa than 10 microns In greatoet dlameter por cu. ft* air sampled. Type of Duet Material Determined Mini- grams Parts per cm * par Meter Ullllon Remarks Rug Triiming ft Inopectlon Bldg. 3/30/40 !>5I- _ ___________ Cansrel air sample* 5-4 Tube Winding Dept* - Bidft* #150. At cut-off raw. f* 40.4 T\ibe Winding Dspt. - Bldg* 0150. Between cut-off etma on tube winding machine* rt 37*0 Tube Winding Dept. - Bldg* ^1J0. M 15**9 Control air sample taken during machine cloaning poriod. Tube Winding Dept. - Bldg. 0150. Alongside elltter rolls. n 7*2 Crate Shop - Bldg. 0435' General air eample- M 6.8 Dio Cutting Dept* - Bide* 0159 General air eanple* 3*4 Lacquer Dept. - Bldg. 0406 - Botween 01 and 02 finishing lines at take-off end* N 4.1 L-equor Dept* - Bldg 0406 - Be H tween 01 and 02 coating machines * 3*6 Miscellaneous Paper Paper Peper Cork Wood Miscellaneous* Miscellaneous. tliecellenooue Exhaust applied but not effectively. Exhaust applied but not effectively. Duet on machine blown off with ccopresaod air. Floor also cleaned same way. Slitting Accopac. Making wooden etipping crates. ,01 Lino running burlap backing, 02 line felt back ing. Exhaust over lacquer dryer*. Adhesives Dept* - Pldg. 0405* Acoustical paste mixer* 3/31/40 5*3 Titanium dioxide, Chlcora clay, Color Lead Neg. Mixing 0F14O2 paeteExhaust applied. Location Date Millions of dust particles less than 10. nlcrona In greatest dlanoter per cu* ft.air sampled* Type of Dust Material Dotarmlnod Milli grams par cu* lister Porte per Million Remarks Adhesives Dept. - 2nd floor* Conant Mixing* 3/31/48 l8*5 Asbestos Brunswick clay* Exhaust applied* Mixing j?314 cement* Adhesives Dept. - 2nd floor* At Fuller Eaton Unit* Automatlo hopper oharging with bulk olay. Adhesives.Dept - Bldg* ^<05 - On box oar, unloading by air convey or bulk Brunswick olay. Adheelvest Dept - Bldg* f40J Wax mixing kottlo. W H m Adheslvss Dept* Bldg. |405 rilling 10 pound cans with soap powder crystals* Saturation Dopt. - Bldg* *)0t At roll-up end* Saturation Dept. - Bldg. ^90 At wet coating paint mlxere* Saturation Dept. - Bldg* Wt Dry or supply end* Saturation Dapt* - Bldg* (f?0* Coating paint nixing* At charg ing hoppers ll end f2 nixers* M * n H N 39*9 Brunswick clay. Exhaust applied* Mixing fs-12 Paste* 60*3 4.0 5*9 2*2 4*7 2.8 53*2 Brunewlok olay. Haw wax, Ammonia Oleic acid, Borax, Shell ac solution, Annoniua hydroxide. Triethanol amine* Sesqul- 0odium carbonate Sodium carbonate 29*7 relt paper. Faint Formalde hyde Felt pepar Chicora clay York white fl034 Red. Load 02*1 1*97 .24 Operators hand shovel and raks clay to air conveyor duot* Kxhsuat applied over kettloe* Hand filling operation* Exhaust epplled. Exhaust applied Empty bag shaking 1 handling outside rangs of sxhsuat duct axcun for moat of dual > - - . Location - 16 Date MilIlona of duet particles leea than 10 mlorone in greatest dlaoeter per cu. ft* air sampled* Type of Dust Material Determined MU11graoe Parte per eu* per Met sr Million Remarks Saturation Dept* - Bldg. 2nd floor. Near asphalt tank end hand duetlng area* Saturation Dept. - Bldg* ;f90 2nd floor. Hoar top of dry paper feetoone* 4/1/49 * 3*0 31*2 Soapstone 4 Asphalt Felt paper Exhaust applied oror asphalt tenk. Duet from dry paper per meates entire area. ralt Coating Mixing - Bldg* #92* Charging mixer hoppero* Print Coating Dept* - Bldg. #92* At control platform. Print Coating Uapt. - Bldg- f?2. let floor* Bell Mill Room. Dlgplay Dept* * Bldg. fl52, 2nd floor, Peteeen mood saw and ander. N H rl Trlnt Stove*! - Bldg* ^2} Boaalng out In ^5 etote* * 6.1 2.4 1.9 20.0 Chicora Ammonium clay, Fnl- hydroxide cheno Red, Emulsion oil, Caustic, Ammonium hy droxide, Tri ethanolamine. Paint Ammonium hydroxide Paint Mood Acroldln y.75 Chleorc clay fed from paper bagn. 74 Fire ball mills operating* co7 Unit dust collecting system Bag collector located adjacent to machines. Disc aander not exhausted. Engineering Dept - Cort shot blest shed. Bldg. ^72. 4/7/49 69.7 Ustel end Lead Mlocellencntic *79 Trucks from Inlay and Rotary Depte. cleaned by shot blasting. Those true have considerable dust adhering. 'ahalyseS of SETTLED DUST AMO PA',1 MATERIALS Arost V>rk 5 0 ponding r VgploLocation, Percent Total Silica 1 Inla;* Deportment* Building 3*-D, 9th floor. Trace 9 Rotary Departncnt, Building jf$lt 7th Tloor. 0-00 2 Inlay Deportment, Building iJ'jt-D, 5th floor, Stenoll Shop* 9 Rotary Depurtmont, Building Kilt 3rd floor, B and C Ulxere. Trace 2 Rotary Department, Building , 2nd floor, at Ceracn Ulxere. 3 Building if34-D, 2nd floor, at Banbury Ulxcr. 0.0 5.44 6 Callander Department, Building ^44, 5th floor, at Charging Hoppers. 4.35 9 Callender Department, Building f?44, 5th floor, at oolor weigh acalee. I Paint 4 Racking Department, Building fff>l~C, 20.94 ?nd floor. Charging hoppers ,fl #2, 3 and ft for backing* 0 Asphalt Tile Depertmont, Building //35~*i 5th floor, Uixcr Charging. 26.1 6 Asphalt Tile Deportment, Building #35-4, 3rd floor, botwson Charging ttoppore f6 and 1 27.23 Percent oe Silica 0.0 Percent oT Lecd 09 0.0 .12 .So 0.0 Hogat 1va 0.0 .04 Trace *31 Trcce 77 35.5 .0? Lean than 2 Lose than 2 .107 .08 ________ Renarks__ Settled duet* Settled duet. Settled duet* Settled duet. Settled dust. Settled dust. Settled dust* Red plr-ccnt #35 and #38* Ssttlod dust. Sett lad dust. Settled duet. -2ANAtVSgS OF SCTH-TP DUST AND RAT WTESHLS toponding sample Locatlqn l Mechanical Oxidation Dept. Bldg* ,59 let floor, near scales* ) Saturation Depertnont, let floor, Building .^90, *t coating p&int charging hcppere > Inlay Department, Building $34-0, 7th floor, between German mixers. > Inlay Department, 6th floor, Building between disintegrators* 1 Inlay Department, Building ^34~D, 2nd floor, Bambury Batch Weighing Room. ' notary Department, Building $31, 5th flcor. Genin Mixers* Linotile Department, Building floor, Near sews* 3rd Callender Department, Building jf44, 5th floor. lood flour screening. 1 Cork Mill, Building f4l-A, 2nd llsrienlns. Stcne Dressing. 1 Siring Department, Building ^49-E, 3rd floor. Mix room. 3 Rng Cleaning Department, Building jf$3* Percent Percert Percent Total Silica Free Silica of I.sed t.57 35*2 2*00 .016 0.0 Trace 41.04 0.0 Trace Tface *5-9 3.72 6.7 0.0 0.0 Trees 0.0 0.0 0.0 70.07 'f'raco Treco i Taint A Backing Building ,f67-B, 2nd floor. Charging paint mixer hoppers. 20.94 2.23 or* Remarks Settled duet* Settled duet. Settled duet* Settled duet* Sottled dust* Settled dust* Settled duet* Settled duet. Cutting and dust created by pneumatic chisel. Settlsd dust. Settled dust* Settled duet. -3- AHALYSFS OF SETTLED DUST km RAY MATERIAL 0 ponding Sample Location 31 Tube Winding Department' Building At Winding Machine. 42 Adhoelvea Department, Building |405* Acoustical Paata Wxer* <3 Adheslvee Department, Building $405* 2nd floor! Cement Ulxer* 6? Engineering Department, Building 12, Shot Blast Cleaning* 53 Saturation Department! Building if90, At coating point charging hoppora. 59 Tard Department, Building j?50tJ, Unload ing from box carai Begged Cilaonito* Slate flour Brunswick Clay Chicora Clay Percent Total Silica 1.47 Percent Free Silica 0.0 Psrcent of Lead 35-69 40.10 e.66 Lose then 1 Trace 35*20 0.0 2.80 Negative 8.9? 43*84 44.24 Trace 5 5 ) Building #69, White Paint Mixer. 16.07 1 Building f>3f Color faint Wlxere* 16.38 Arras tr- oik Remarks Settled dust. Settled duet. Settled duet* Settled dust. Settled duat. Bsw material. Bair material Raw material. Settled dust. Sottlid duct* Armat COHCEKTRAT.TCH OF SQT.V^MT VAP0F3 ion _ H'pt BldK\f2*t Colpr char go up operation. Dept. Ronavlng paint frrr ^6 machine. Dapt* W.dg*(?23 Front and j?6 no * Dept. Bldg.,f23 General elr. Solvent Potrcluuu Naphtha ft tt ft h ft m Parts por t/lllicn Jn Air 63 ~ Ifl? Max* 63 - 126 Remarks Pour iron in area. Wo exhaust ven tilation. 73-5 6) Dept * Bldg.23* 2nd floor. Paint Ing race* between mixere f3 /?4. Dept. Bldg*j?23, 2nd floor. Oenornl Point matching room. Mw H ft Dept. PIJe*?3 2nd floor* Faint r aim. Dopt. Bldg*(^23* Block woehing. Mng In toluol alcohol mixture* Dept * 01 de*.f?3. Block waehlng. '.>lng In naphtha after toluol wanh* Hm Toluol petroleum Nephtha Dipt. 01dg.f23t Point Thinning oppceltc <3 ato* Dept* ldg.23 n0 '!<* ot 91 Dept. Bldg* ,?23t lot floor- Paint room* ft ft n ft n ft 31-5 - 52.5 31.5 52.5 33.4 Win - IPO.2 -raj. 63 - 105 Exheuet ventilation eppjiod " one nan on this Job* Highest concentis4.ion attained dut ing drying by blowing off with ece prersed air. Sxhauot applied. 73-5 84. 105. (to exhaust applied. Low celling. t! on t Dopt. Bldg.013-A. Paint pan wash t Dept* BHg.,fl2-A Print pan wash General air* - Dept* Bldg*fl2-A* Paint preraix Ann st*"' ;ork cos.. ..stration cf splint >poks Solvent Parts par Ulllion In Air Remarks Petrolem Naphtha 63 - 1AT n if 94 Pxhauet ventilation applied* Operator vrorks much of the time rlth hie head in direct line rlth exhaust duct. Two men In this area* mH 21. One nan In thie area* icr Dept* Bldgf406, Front end $3 nackino guide* icr Dopt. Bldg. ^406, at lacquerrough on Hy machine. ar Dept. Plcfgf406, at taka-off 3 lr.cquor machine. filler Dept. Bldg.fTS* Canoral air. ruler Dopt. Bldg.f70, Near olxJ can filling* Backing-in, at operators* workieition* Oacklng-in - Roar and of ie naar rail- licktng-ln - On platform when ig in coating* Dopt. Bldg.fl2-A. Color Match Operator'- breathing lone during eaihing rlth V.U.P. Dipt. B14*.fl3-A. Color Match A* flr->r level during washing* Acetatee Acatatoa Acetates 273 - 336 147 - 109 10.5 Fumes dletirctly noticeable and irritating to nose and throat* Amoco f Amaco F 21. 42 - loy Mineral Spirits 42 - 63 Two man at this point* ttinorol Spirits 273 - 315 Mineral Splrlte 160 Petroleum Nophtlio 21 - 4? Uaod V.U.P. nllllicd for thie work.. Petroleum Naphtha 420 Ho excessive acrolein concentrations trere determined. Rotcry Department T.ith the exception of Semple #9, e.t pigment weighing, the dust coonncentra tions an this department were very Ion. At the pigment reighing operation. Building #31-7, a dust concentration or 30 million particles per cubic foot ms determined end a lead concentration of 0.079 milligram per cubic meter ms determined. This is about one half cf the allocable concentration. Luring this sampling period, the leadfree blue pigments rere being reigned almost entirely. employees hr-r:* lag lead pigments may be exposed to high lead concentrations from dust created curirg the reigning and dumping operations. Inhaust had been provided at-the color scale, but air velocities produced rere too lor to measure and little, if any, pro tection ras provided. Inhaust booths, originally baffled rich canvas curtains, had been pro vided at the charging hoppers. The canvas curtains have been removed and the resulting large face area has caused the air velocities into the booths to dron to a range of 50 to 75 lineal feet per minute, rhicb is too lor to control the dust. Car> Vi71 Samples #63 end #64, collected during stone dressing, shor that there is a narked reduction in dust concentration Then the exhaust hose is used. The operator at this operation mas adequately protected by an air line respirator. The balance of the dust concentrations found in the Cork 11 are comnaratively lor -- far belor those determined in previous surveys. Great improvement mas observed in the housekeeping and in the maintenance of exhaust systems in 6- this building. Sizing Department Dust concentrations in this department were low and the l'ree silica con tent of the dust res negligible. Mo potential health hazard was detected. Bar Cleaning This operation is dene in a separate building. The begs are attached to an exhaust duct which draws the beg inside out and into the exhaust duct. T.hat dust is dispersed into the atmsphere is produced by hand handling prior to cleaning. At the tine of sampling in this area, hags that had contained rood flour principal Zjfand a very few with serpentine, were being cleaned. The dust con centration found, considering the ccuparztively non-tonic nature of the dust, does not indicate any health hazard. However, when cleaning bags that had con tained core toxic substances, such as asbestos or highly siliceous naterial, a dust concentration in the sane range would indicate a potential health hazard. Lir.otile Deoartaent Dust concentrations were low and r.o potential hazard*was observed. Callender Denartnent The only potential hazard detected in this departnent was at the opera tions involving the handling of lead pipnents. A nixed sacple of colors #35 and #38 was analysed and found to contain 25-5 per cent lead. An air ample, #49, collected at the color weighing operation showed the presence of an average lead concentration of 3.71 nilligrars of lead per cubic refer. Sarnies =46 and -/.Z, - 7collected at the charging hoprsrs, showed 0*199 end 0*072 nil?,igran of lead por cubic meter, An exhaust hood, located about five and one-half feet above the scales, was ineffective an controlling the dust produced in scooping, weighing and handling of the pigments. In order to be effective, the exnaust hood should create an air velocity of at least 150 lineal feet per minute past the location of dust generation and away iron the breathing acne of the operator. This hood had a face velocity of 100 to 125 feet per minute, but ms located so far above the floor that the air velocity nt the pigment drums and scales ms under 25 feet per minute* The charging hoppers were provided with exhaust creeping an air velocity of 150 to 250 lineal feet per aimite into the hopper. This is adequate to control dust produced during charging. The atmospheric lead deter mined in the vicinity of the hoppers ms probably caused by careless hanclins of containers and by dust created during pigment weighing* The batch weighing end charging operations vary from day to dey, depending on the type material being made. The lead intube of the various workers rill also vary, depending on the batch formula and the individual working habits. At operations of this type, air sampling does not always give reliable in dication or tne degree of exposure. Routine urine and blood analyses should be performed on those operators who handle the lead pigments to determine the de gree of lead absorption. it the tine of this survey, the Accofloor mining was not in operation. 1 - 9of baching arterial, shoved a concentration of 21.5 million particles per cubic foot of air. It vras noticed that cost of the dust here vas produced by the handling of bags outside of the range of the exhaust system. Because of the short duration of this operation and the lor free silica content of the dust, no health hazard is indicated here. No high lead pigments rere being used at the tine of the survey and air borne lead concentrations are negligible. Exhaust has been provided at the charging hoppers rhici should control dust produced during dumping, provided care is exercised in handling the bags rnd material. Maintenance Shoos Of the samples tahsn at representative operations in the Maintenance Shops, only sample =147 and sample #162, shoo any significant concentrations. Semple #147 shots a lead- concentration of .079 nilligran per cubic meter of air - approximately one-half of the maxirao allor&ble concentration. The lead, melting pot is enclosed in a hood connected to a natural 'draft stach. Ho control neasures are applied at the point of pouring, at rhich point probably most of this lead concentration is dispersed. Sample #162, tahsn at the shot blast operator's position and at his breathing level, shots a high dust concentration. This dust contains a consider able amount of lead. The concentration of lead found exceeds the naximua "allow able linat by five times. The present respiratory protection provided Trill not adequately protect against lead dust. The entire shot blast equipment and type of building housing this operation is antiquated. Under present methods of operation, complete control of the duct is not feasible. Boxes used in the Tni -r end Hotciy Departments ire brought ir.to this S" ot blast roon, coated with an accumulation of dusts. After plnciiv; the box in proper position for denning, the operator stands outside the actual blest rccr in front of glass panelled doors, directing the strean of steel shot propelled by air against the boa. The building doors directly behind the operator are also closed during blasting. This confines the operator in an area approximately 50 square feet. Some of the heavy dust concentration created in the blast room itself seeps through, the doors of the blast roon into the working area. la the blast roon, a propeller fan on one side blows the dust tocards an exhaust duct on the opposite side. This exhausts the dust to a point about one and one-half feet above the roof level on the outside of the building. Ko attempt is made to collect this dust. Comparatively low concentrations of nine, and no concentrations of lead, were determined at the galvanised sheet metal -celling operation in the Sheet 'etal Shop. In exhaust hood had been provided about four feet above the welding table. The hood was too far above the work to be efficient in removing the welding fumes and its principal effect, if any, would be to draw the fumes across the faces of the welders. In order to protect men welding on galvanised materiel from exposure to zinc fuaes and to lead, which is frequently present as sn im purity, local exhaust ventilation should be used. This would remove the fumes at the place of origin. If the nature and size of the v;orl: permits, this may be done efficiently by the use of lateral slot exhaust. If the work varies greatly in sice or shape, an exhaust duct of flexible, easily Adjustable, tubing is usually preferred. In the Electrical Shop, cordon tetrachloride was occasionally used for cleaning motors. As the work was dcr.e in on exhausted booth, r.o health hc.rc.rd was indicated* Several potentially hazardous operations were not in progress during the survey and no evaluation could be cade. These included degreasing in Building "30-, netallining in Building #30-1, end cleaning with carbon tetrachloride in the leter and. Instrument Section, Building #2* Asuralt Tile Derartnent High dust concentrations --ere found at only two locations in the Asphalt Tile Department while grease-proof tile was being run. These were an the hopper loading operation, 3rd floor, and at the scrap receiving location under the scrap grinder. At both locations, the periods of-high dust concentration were intermittent and of short duration. Znhaust ventilation was provided at each charging hopper and ras used only during actual charging. TThen the charging of one hopper was completed, a damper in the exhaust duct was dosed and the work proceeded to another hopper. The exhaust provided was adequate to control the dust produced during charging. However, it was customary to leave the lids to the charging chutes open at all times. As soon as the exhaust had been turned off, the dust and gases produced by the miners mere blown out of the chute and contaminated the immediate area. * An irritating gas or vapor is produced during the miming of the ingredient, for the grease-proof tile. It mas not .-possible to identify the versa, although the odor was strongly suggestive of the petroleum distillates. It is probable - 12 that the vapor was produced by the heating of the various oils added to the rdc:. The irritating condition res noticed principally during unloading of the B i ^ hirer on the 1th floor, and at the hopper charging area on the 3rd floor, k nor. yy cooler fan is located at the 3 hopper on the 4th floor. The vapcrc cn the 3rd floor con be controlled by keeping the loading chutes dosed. Yard Deuartnent Exceedingly high dust concentrations were found at rood flour, asbestos end writing car unloading operations. Staples >7132 and '"135, taken while un loading and stocking bags of Super-fine fir rood flour, and Saaspla -737, taken shale unloading whiting, show concentrations e;:ceeding 50 aillion dust partides per cubic foot of air - a standard nor being suggested for non--toxic and nan- siliceous dusts. Bio respirators are worn by the ren rhile unloading. Staples 7=134 and #135 shoe very high dust concentrations for asbestos, exceeding the maxinuK allowable' 1 in; t of 5 aillion partides per cubic foot of air. Although the exposure to the asbestos dust is not constant, it is, however, 'recuent enough to warrant dust control aeasures either by exhaust control equip ment or by the use of personal- respiratory protective devices. The sane crews of Ben are used daily for unloading various raw naterials. This nears that their sxposure to high dust concentrations of one hind or another is cuite frequent. Cut Order Department, Building. =150 - Inspection and Trinninr guildinp. 4155. Crate Shoe lent.. Buildinr 443^. lio excessive or toxic concentrations of dust or solvent vapors, were ound in these departnents. Tube 'Vindinr Department. fr^dir.r fl?8 Sanple #133, taken r:hile cleaning up, is the only staple to chov; a duct - 15 Print Department, Building ;?23 Shoe Filler Department. Building #78 The concentrations of solvent vapors found at the breathing level of sen in these departments are low and do cot indicate any* health hasard. Inlay Backlrr-In The concentration of mineral spirits found around the Inlay Baching-In machine, although below the toxic limits, is nevertheless irritating. The heaviest concentration was found at the rear end of the baclzing-in machine. Due to the irritating effect of these fumes, the need for core general ventilation on this floor is advisable. -4German end British factory inspectors, after careful study, could find no con stitutional disturbance traceable to butyl or cxyl acetates, although one fatal case in 1930 was claimed following the use of a mixed solvent containing amyl acetate. ^ The threshold limits adopted by the Governmental Hygienists are as follows: Amyl acetate Butyl acetate Ethyl acetate Methyl acetate P.-rts flfr Sillicn 200 200 400 200 Sulfuric icid This acid has a local caustic action on the skin and mucous menbranes of the eyes, throat, and upper respiratory tract. Except for accidents with con centrated acid, this is not usually a serious hazard in industry. Exposure to dilute sulphuric acid mist cr spray may cause irritation of the upper respirator} tract and eyes and nay discolor the front teeth of those exposed. Toluol Toluol has an anesthetic effect and the symptoms of poisoning are: head ache, dizziness, anemia, amocular tremor, scarlet lips, spots of extravasated blood on skin, possibly cough. Animal experiments reported in the literature in dicate that toluol is more irritant than benzol and'With lower concentrations ha; a somewhat stronger narcotic action, but its effect on the blood picture the blood-forming organs is considerably less severe and of a different type. The diminishing solubility on ascent in the series could, on the other hand, tend to 2, Industrial Toxicology, Alice Hamilton and F.utherford T. Johnstone, Oxford liedicai Publications - 1945. severe feimsf depending upon the strength of the solution, length of ccr.tc.ct, end individual skin sensitivity. Amonia gas, readily given off by aqueous solutions of aaror.iu, may cause severe irritation of the skin, eyes and respiratory mucosa. The threshold limit for annonia adopted by the Governmental Industrial Hygienists is 100 parts per pillion. Kerosene The .toxicity of kerosene is similar to other aliphatic kydrocarocas - naoktha, gasoline and benzene. Isrosene being less volatile than cue others could be .less active. The most pronounced effect of these lydrocarbcns is on the nervous system, for instance "naphtha" jags and possibly some chronic effects. Horrever, these substances nay e::srt some irritant action cn the respi atory tract. The Governmental Industrial Hygienists have adopted a threshold limit for gasoline of $00 parts per million. Triethar.olgLgine The literature on .triethanolanjpg is chiefly concerned rith its chemistr and uses; only a few studies concerning its piysiological action are available 2nd these are on experimental animals. Victor E. Zindsvatter of the University of Pennsylvania reported in the Journal of Industrial Hygiene and Toxicology, June 1940, that the pathology of the liver, kidney, spleen, adrenal, heart, lun optic and peripheral nerves of the animals exposed to varying concentrations over a-period of several months. indicated only slight reversible effects on lit and kidney, and that restitution to normal readily took place as demonstrated by animals rith normal livers - and necrly normal kidneys after maximum exposure jUUSTSQHG COiiX COMPACT LAKClSTAR, PA. TIDOR UIVISXQH At the request of Dr* Sullivan, Plant Physician, a survey was tuudo of its Backlog In repartees t of the Floor Division by the Industrial Health Section, Health cod Selfsre Division, Metropolitan Life Insurance Company on June 9, 1950# to determine whether any industrial health hanard as sociated with tie iiau gensrated in tne stoves in this department. Manufacturing Operations Felt ^ *"v4 used in taa aanui^cture of Quaker Tfili Covering van satura ted with a prise coat containing linseed oil, ioain, talloU and setiillic driers. Tie prime coat is applied to the felt cn a machine and the operation is known as S.I Baturating. After saturation the felt mas fed into f27 Stove mere it tt&s festooned to dry, Drying ua hastened by heat supplied by steam coils. The stove is open at opposite ends and the steas turned off during the charging of the stove, Two men work opposite etch other on near the top of the stove. They regulate the length and spacing cf the fertccn*, are in tne oven until it is filled - a period cf -bout 60 to 9u minutes. Heavy acid fumes are giTen off from the treated felt which cause the eyes to srart and sometime* cause violent coughing. Air Saar, ling An air iunple tun taacn in fill Itcve eftir it van 2/3 fLUou with treatad felt in order tuut the funos uculu have a cmw'.cu tu luilu u,. tu *J._- -t'm mm coneaiitrutlon. The Tuneo ten ^r.tr**,-, wu in *.i>..oiuto a_coiiwS. by <j' two DuOui--r tuL*ji coluj-jcL^d in 7 ..^ kMont.>. trhin :..._ ...-- .Tj. in tn ice leth to ninisixe evaporate, cr. o- t:.- ^.vz-lusl juvU. t... soapa-a.,; ..-sriod. Suction, supaliou. by *u e*;>ctric*iiy arivsn ;.uap, urtT t,._ air so: tnrou^li the Absorption train* The aaiapl? %4u analysed Tor aiaanyaos and Cii.cuii.tia to aaro-cin, ta=. aost toxic or any oi* the aldahyMO possibly prea-sut in tar t/ta-wa/aere. Cheaical Eesults A concentration oi acrolein oi 25.^ parts per uilliau o* iir res found in tue stnoxphare of ^27 Stove during tii laut l--iro oi ten: stove loading* CoDciutdcns Acrolein is an irritent ana in even lo* ccnc^tratiuns effects tnv uop. respiratory tract. On inhalation of high concentrations, it Cc.ue,, a. too lungs. It causes intense irritation cf the e. --t> us- ncje iu or; U- SaC. exposure. Acrolein couaoniy occurs than fats oil. ; tic. to teepertturss it is ta. principal irrit-nt ir. n._ cxr-.u>t j__tree co_puttier engtaas. uenderson uns i.t^ura (hoaicus i-cira.s-u 1- * Corp., lo* Io:u, l?ip# lege st-t-. :--t ons ,-art ;.er ail_im of w.M . in air is in* ecieteiy cu=t=rctahie, t-ut p.i parts cause intense irrit * i * ai, s-i t.*a . --o a.rt^ pvcr ^ia-ion as --.a t; .. i .* ^ Tae c-ixinun ailo.uhit con.-diitr-tio:: cf -crcxw.r. an__r _a acc.-.t.:o t. .v i.i'r lucrican Csufaruneo o. Govcrnn^uU.! hy^.-nast. i_ parts ;>wr clllian. Th: concentration reuse ir. this tu..t is toe sij; tor wen ii sr-srt jsrioJ o: ex osuro Recoauendsti one co4iCijnirbliwn xii et^ovu^ iji iho in Department gh"1llrt be reduced tv s > r-if:i^ concentration of C.p parts per ailiion cl' acrolein ourxcg tvs tino aorxaen ers exposed by* (u) Exhaust ncthods for raaovd ef t_uo fanes; i'rou tli* stoves. (b) Dilution of tue fuaes in the stovea by sup:JLied air. 1. Exposure of the vorszes car. be controlled by: (a) Hie of cnrtriof'e type rea-irudrs using activui;v ciiirccal as x absorbent* (b) Dae of lot sup-lieu respiretors. T<0risen resect the Tearing cf respirators because they are hot end interfere unth br-.aatM.Tyg, Too eyes css be protected using gow;ies or a respirator face piece did contained goggles. The lens of such eye protection tend to fog end interfere T.itb vision, Ac sir supplied caxiinition goggle face piece overcomes this difficulty because 1he lees are prevented iron fogging and are core pleasant tc tear due to toe coding action of toe supplied air. J * T n. Feted, Director Industrial Kygio.ii laboratory >nd field service A HSF03T OF SOKTiy j> ini/-->yA Foreword A Suggested Organization for Preventing Accldente Safety Organisation and Functions of Executives Organization............................................................ Inactions.................................................................... General Superintendent................ ................ Safety Engineer............... -............................. .. Foreaen................................................................ . A Proposed Svetea for Recording end Using Accident Data Directional Control.................................................................... Foreasn'a Report of Esployee Accident................ Fora "A"................................................................................ Table 1, Actual Causes of Aceident......................... Table 2, Manner of Injury........................................... Table J, Code for Mature of Injuries..................... Record of Personal Injuries........................................ Fora "S"...................................... ......................................... Sketch of Filing Cabinet.................................................. Special Rote Regarding Minor Injuries........................... Statement of Accident Experience............. ........................ Fora "C"........................................................................................ Table k, Allowance for Fatalities end Disabilities. Statenent of Disability and Medical Release............... Fora "D" (Front)........................................................................ Forr "D" (Back).......................................................................... Suggestions far Stimulating Eaulovee Interest in Safe Practicee Preventive Activities............................................................................... Plant Safety Committee.............. .................................. .. Structure......................................................................................... Changes in Membership............................................................... Meetings................. ......................................................................... Order of Business......................................................................... Duties........................................................ ..................................... . Minute............................................................................................... Sub-Coaaitteee................................................................................ Safety Coapetitione.......................................................................... Drafting the Rules.................. ................................................. . Departaental and Plant Record.................................. ............ . Awards................................................................................................................ Safety Advertising............................................................................ . Suggestion Boxes................................................................................ . Sefety Rules......................................................................................... . Discipline...................................................................................... Penelties........................................................................................... Physical Conditions of Properties.............................................. Metropolitan Cooperation Pace 1 T_ 2 2 4 15 14 17 19 2D 21 25 25 23 29 50 52 54 5 45 45 -5 44 44 45 45 47 49 50 50 52 55 56 1 53 59 oD cl 61 J DIGEST 0? KECOyMSHDATTOKS Safety Organization end Functions of ^Executives 1. The existing plant management comprising the general superintendent and his assistants, the safety engineer, and foremen is recommended as the safety organization for the plant. (See page 1) 2. It Is recosmended that the general superintendent continue to display a personal interest in preventive methods, hut indicate in a sere definite manner to subordinates his determination to stop accidents. (See page 3) 3- As an advisor to the general superintendent in developing tie acci dent prevention policies of the plant, it is recommended that the work of the safety engineer - a. be advisory rather than functional; (See pace h) b. follow certain basic duties. (See page 6) 1. It is recosmended that preventive work be co-ordinated with oper ations by - a. impressing foremen with their accident responsi bilities and emphasizing the four fundamentals of good supervision; (See page 9) b. developing a working plan by vhieh foremen can en list the interest and support of employees in preventing accidents. (See page 11) Directional Control 5. It is recommended that the accident recording methods of the plant be standardized, airrolified, and changed to provide an efficient system with two primary objectives: a. to maintain a complete history of your accident experience; b. to aid in the effective direction of preventive work. (See page lU) 6. For recording and utilizing accident data, four Bimple .forms are proposed: (See page 14) a. Foreman's Report of Accident (FROFZRIY CGMrLZTTZDO b. Personal Injury Record of Snployee c. Departmental (plant - company) Accident Statement d. Treatment Record and Medical Release (a) 7. It io recomended that all accidents regardless of severity be reported by foresen immediately and directly to the safety engin eer. (See page 18 end special note on page 29) 8. It is recommended that all accident records excepting those purely of .a medical nature, be maintained in the safety department. (See page 24) 9. Begardiese of how trivial an injury may appear, it is strongly recocaended that employees report imediately to the nodical department vhen injured while at work. (See page $6) Preventive Activities 10. Unless a nixed camittee would conflict with ccnpany policy, service by workmen on the plant safety camittee is reearaended. (See page 43) 11. Periodic changes recommended. (See page 44) members of the safety committee are 12. Bather holding periodic meetings, it is recemended that short, infernal, end animated meetings be held only as often as inter esting material can he presented for discussion. (See page 44) 13- A definite order of business is recommended for meetings of the safety committee. (See page 45) 14. It is recommended that duties other than the correction of physical hazards of the property be included for the safety ccmittee. (See page 46) 15. It is recommended that the various functions of the safety ccmittee be conducted on a sub-committee basis. (See page 49) 16. Sane form of organized safety competition applicable for the departments of the plant as veil as all plants of the company, is re commended. (See pans 52, also cement cr. page 53) 17. A variety of safety advertising material ettractlvely main tained, frequently changed, end located at strategic places in the plant other than entrances and emits, is recommended. (See page 56) 18. Operating natters in addition to preventing accidents and waste are recemended in conjunction with the suggestion system. (See pace 57) 0>) Ii 1 Functions Jron diseuBBiers viph plant executives and a study of past accident occurrences, it Is believed that the accident responsibilities and preventive functions of the general superintendent, his supervisory staff, the safety engineer, the foremen could be more clearly defined and better understood. Accordingly, in the fallowing part of this section, their roles in the general safety plan ere discussed together vlth the more important preventive duties related to each. general Superintendent - Because of the pressure of other business, .there apparently is a tendency on the part of the general superintendent (and his immediate assistants) to delegate their responsibility for preventing accidents to the safety engineer, Mr. Zeen. When safety and production natters seen to conflict and secondary consideration is, given to accident prevention as an operating problem, production as veil es the safety program both suffer. Since the prevention cf accidents is not confined alone to personal injuries but also includes damaged equipment, spoiled material, production delays, vaste, etc., the application of preventive principles to plant production problems very often remedies the ccmditicn involved. But of equal importance, whatever attitude tahen by the general superintendent towards safety, this is reflected advertising medium. Recommendation ^2 - Ae accidents occur "because of faulty vcrldns methods or failure of management to rectify a hazardous condition, the attention of the general, siqperintendent should he directed to the importance of safe working , j practices by employees, not only as a means of avoiding personal injuries hut also to facilitate operating efficiency. It is recommended, therefore, that the general superintendent continue to display his personal interest in safety, hut indicate in a more definite manner to subordinates his determination to stop accidents. "When the working force fully understands that he will r.ct tolerate an unfavorable Bafety record, supervisors end employees usually give more serious consideration to the matter of accident prevention. Bulletins and letters over his signature and similar media may he used, hut these are j not generally as effective as a brief hut pertinent interviev end "foliov-up" either vith individuals or groups whenever this is possible. As the success or failure of your safety program is, therefore, dependent in major part on the general superintendent, his leadership is important; end his role In pre ventive verb may he summarized as follows: a. Continue to give active cooperation end support to the company's accident prevention work. b. Consider the prevention of accidents as definitely related to production and a function of the operating organization. ,c. Impress upon the entire operating force that "accidents" not only mean personal injuries, hut likewise involve damaged or spoiled stock, toolB, and equipment resulting from inefficient working methods. d. Make safety a pert of every man's Jot. -3- e. "Where occasion demands, send for a workman or a fore man and discuss vith him personally the accidents he has incurred or the record of hie unit. f. Be conversant vith the accident experience of all units of the plant, maintaining a knowledge of the accident situation from periodic analyses of records prepared fcy the safety engineer. g. Preside personally (as functional head) as chairman of all safety meetings of foremen and safety committee meetings. h. The general superintendent may assign details of the preventive program to the safety engineer who should serve as an assistant in accident prevention matters hut not as a substitute. Safety Bnrineer - imperience has shown that successful safety work re quires the continuous conduct of well-directed activities rather than spas modic effort. Similar to other large industrial units, a safety engineer has "been appointed to supervise activities concerning accidents and their prevention. While department heads do attempt to follow the recommendations of the safety engineer, cne if the deficiencies of the present preventive set-up is the manner in which such recommendations ere transmitted to the supervisory staff. For example, rather than emanating directly from Mr. Heen to departmental heads (sometimes vith the endorsement of the general super intendent), safety suggestions and other material on the prevention of acci dents should he prepared for and forwarded over the signature of Mr. Blaiedell or Mr. Jfarshail. T-is mt cnly will add importance to the matter in question hut, if ororerlv fclloved-uo hy the general superintendent, also will serve to: 1. Femove the burden of accident prevention from the safety engineer alone. -k- the chief duty of the safety engineer ie to design and supervise the details of the safety program, presenting methods of co-ordinating preventive activ ities vith operations for the approval of aid transmittal by the general super intendent. The actual execution of the preventive measures ere functions of fcremer., vhich ere discussed later. Incidentally, it is believed that the foregoing suggestion lihevise vill aid cutrustically in correcting a scmewhet obscure condition effecting both the efficiency of your safety verb end general operating costs. Tor exempie, there is no way at present to determine vhether or not the required effort is - 5- b. Maintaining propor records and forme depicting the plant's accident experience. c. Preparing experience and other statements periodically for the guidance of the general superintendent, supervisory staff, and foremen in conducting the preventive work. d. Issuing reports to foremen and interested executives cover ing pertinent facts regarding accidents and accident circum stances of their units, such as: causes, types, incidence, costs, accident-repeaters, etc. e. Visiting operations as frequently as possible and raking a record of inspections covering particularly unsafe methods and working practices as veil as physical hazards of equip ment and property. f. Conferring vith executives and foremen, calling attention to hazards, 'unsafe conditions, or faulty working practices and assisting in co-ordinating safe methods vith operations or processes. A list of these itens should be maintained for the information of the general superintendent end checked off as corrections are made. g. Obtaining special preventive information or material from outside sources for the use of executives and foremen. h. Convincing workmen that the management is sincere in its efforts to stop accidents. i. Interviewing nev men on the Job whenever possible, empha sizing the velue of safe practices end assisting in the subsequent placement and training of nev employees. J. Assisting ir. the preparation of safety rules for those operations in vhicb specific hazards are involved. k. Promptly eclmovledging end recording all suggestions by vor}=en, maintaining a record of recc=endations end final disposition. l. Securing proper poster material, warning signs, etc., and supervising the preparation of attractive safety dis plays at strategic locations. n. Serving ae secretary (not as chairman) of ell safety com mittee meetings, keeping minutes of the transactions. -7- n. Arranging for safety comnitteo meetings, providing material and helping the general superintendent vho serves as chairman, to make the meetings interesting. . Conducting such other activities which the general superintendent believes are necessary for substituting more active safety effort in place of passive accep tance by the operating force. Foremen - These comments are not intended to be critical of foremen, as the preventive situation is not uncommon in industry vhere management has not had an opportunity to appraise occupational safety practices as a means of facilitating production. In Justice to the foremen, it also must be added that the majority interviewed seemed anxious to co-operate with accident prevention, activities of the company. Still, they seem mostly of the opinion that pro duction is paramount over all other natters of an operating nature. However commendable, this attitude is not altogether consistent with present practices in industry because production, although gained in a given time, will hardly pay dividends when added expense resulting frca accidents or operating mis takes is involved in attaining it. Generally, good production depends upon two important factors; namely, quality end low unit cost, and one without the other is indicative of faulty supervision which bo often views am accident as e phase of employment and unavoidable to a certain extent, `rfhile the accident experience of the floor division plant has not been unfavorable, it is believed that a better safety record can be obtained when foremen appreciate their safety responsibilities end fully "understand that accidents whether or not personal injuriee occur, ere largely the result cf someone foiling to do the right thing in the right way at the right time - in other words, faulty working methods. A proper nttitu&o reflecting an active interest in good operating hatits by employees, therefore, is very important on the part of foremen. Moreover, workmen conotantly scrutinize their foremen and observe | how closely the latter conform with the company's accident prevention program, i and in this way the attitudes of executives and supervisors are interpreted to the working force. Kecommendation - As education is essential in promoting good working habits among workmen, it follovs that the teaching of proper practices is one of the most important duties of foremen. To provide measures by vhich they can develop a safer and more competent working force, it is recommended that the following four functions of supervision be emphasized: a. Placement - In placing s newly hired employee as veil as those 1 transferred from other departments, a knowledge by the supervisor of the emplohee's experience should be gained. This can be done by the supervisor examining personally the qualifications and ability of the employee. Vork should be selected for which the y-n is best suited,-both mentally and physically. A careful explanation to the 'man of the accident prevention policy of the Company, the operations and methods peculiar to the Job, and "the nature of the equipment and materials with vhich to work, is highly important. b. Training - danger points of each operation should be pointed out, end the precautionary measures together with the reasons for them, made clear. Any special departmental hazards such as acci dent, health, or fire, should be brought to the - attention of the employee end the prentices of the unit or section to overcome them should be described. The training of workmen includes an under standing of the established safety regulations, first aid rules, the use of departmental fire protection equipment, and such other measures to insure good working habits. c. Supervision - >7hile work is in progrees, foramen should be super vising operations. Casual and spasmodic inspections permit the development of circumstances leading to accidents. Foremen who confine themselves largely to their desks or offices eases the - 9- statue of clerks, ary3 other arrangements should he followed for the completion of routine paper vork and minor production details. Proper supervision also provides for a systematic program of instruction regarding safe and efficient practices for all employees. For example, the Impressions gained hy a new employee beginning vork for the first time are likely to be lasting ones, and he pro bably is influenced more by vhst he sees than by what he is told. Consequently, his later conduct vill be governed largely by the actions of the men vith whoa he is to vork. It is very essential, therefore, that the verting methods of older employees also be checked periodically, not only to eliminate faulty habits vhich they right acquire but to introduce new employees to safe sur roundings and to Impress them vlth the value attached to good working practices. Periodic studies of all Jobs aid foremen to insure accurate scheduling end to assure the proper use of equip ment end materials. Chance -taking, unnecessary haste, hazardous "short-cuts" and other unsafe practices likewise can. be brought to light and corrected. Good supervision also includes orderly housekeeping, early repairs and conditioning of equipment, the operating condition of equipment should not be neglected until breakdowns occur, but should be checked frequently by foremen. At the came tine, the use of safeguards can be determined as well as necessary protective apparel and equipment. d. Education - To aid the safety educational program, informal dis cussions by foremen with their men either individually or in groups, are extremely helpful. 2bs advantages of such meetings are many. In the first place, they add the personal touch to the preventive program so necessary in eliminating the business aepectB of safety from the minds of workmen. Second, they offer opportunities for announcements, a review of progress, a discussion of practicable ways to avoid accidents and to eliminate accident causes, and to develop better methods for conducting the oper ations of the unit. 2hird, information is obtained from employees regarding the intimate knowledge they have of actual operating conditions which the management perhaps can obtain in no other way. Fourth, meetings create a feeling of partnership among men with the management in the matter of preventing personal injuries and production interruptions. In addition to the above considerations, it must be remembered that certain employees are incapable of assimilating knowledge as a group. Fre quently, a workman is prone to accident because of faulty habits, improper - 10 - attitude, temperament, a physical ailment, or hone worries; and in many of these cases, mass instruction la of little consequence. Such employees must be treated individually by the foreman in order that the nan aay fully understand the importance of safety to himself and to others, and so that proper working .methods will become fined habits. A sympathetic attitude on the part of the foreman together with a sincere attempt by both the foreman and plant management to remedy the condition, very often removes the chief cause, of an accident. Generally, these efforts provide definite returns not only in better wording methods by the employee concerned, but in in creased efficiency and morale on the part of the operating force as a vhole. On the basis, therefore, that the safety of their men is as much a responsibility of foremen as operations and production of their departments, the following steps also may prove helpful in developing a working plan by which foremen can enlist greater support among employees in preventing acci dents : First, vin the confidence and support of employees by - a. Proper personal example and attitude. b. An active interest in accident prevention matters. c. Correcting physical hazards and unsafe conditions. Second, emphasize methods of preventing accidents by a. Instructing employees in all details of their Jobs. c. Shoving how to do the Job properly and safely. c. Cheching methods for operating mistehee and errors. d_ rollov-up periodically to insure safe practices. Itird, develop cooperation of employees by - a. Conducting short, informal, departmental meetings. b. caving something interesting to talk about. c. Having employees do most of the talking. - 11 - d. Discussing accident causes and their elimination. e. Ending the meeting while interest is still high. Fourth, utilise hey men to assist in departmental safety activities, delegating to them certain responsibilities euch as: a. The erection, maintenance end use of safeguards, h. The detection and correction of physical hazards of . buildings, grounds, and property. c. The maintenance of good housekeeping conditions. d. The repair of tools and equipment. e. The proper handling and movement of materials. f. She safe storage of supplies and stock. Fifth, try for a departmental safety record by a. Encouraging departmental spirit. b. Seeping employees advised of standings. c. Watching especially the habits of new men. d. Giving a little praise occasionally. Sixth, be a friend as well as a supervisor by a. Shoving employees by their first names. b. Aiding vhen possible with their personal problems. c. Considering suggestions and investigating complaints. d. Being fair and impartial. e. Talking privately to en employee vher. discipline is warranted. 12 - rn\ P50?0S33 SYST34 FOB KSCOHPUTG jaas uSHvo ACCHEirr iata For= "P" (front) M it- Fom "D" (beck) DiaSCTIOIIAL CONTROL Accurate and definite information la eesential in malcing a com plete study of any problem. For example, if production costs ere higher than they should be or certain machines or employees ere not operating efficiently, an analysis of available records covering the situation aids in correcting the faults responsible for the condition. 33ie maintenance pna use of facts concerning the operations of a company, therefore, ere indispensable to proper management. For the intelli gent direction of preventive effort, the compilation AND USE of accident data ere equally important in preventing accidents, especially since your Company is a self-insurer. The method followed by the floor division plant for recording accident experience is not believed adequate to provide effective control of accidents. Accidents ere recorded as they occur and seme attempt is made to analyze them occasionally, but the procedure followed and the in formation obtained (largely medical which is of little value for preventive purposes) would seem to furnish a small emount of wording data of practical value. As a matter cf fact, one of the main difficulties is the apparent laclt of understanding regarding the type cf information required as a means of directing safety activities. Another difficulty seems to lie in the use of rather indefinite records uncoordinated with your safety program. More over, the time necessary to complete seme cf the records is hardly Justified in view of the limited material they offer. It is believed, therefore, that - 13 - the accident recording method of the plant not only con "be standardized as well as simplified somewhat, but changed to provide an efficient system. Such a system would have two primary objectives: a. To maintain a complete history of your accident experience, and b. To aid in the effective direction of preventive worfc. Beocanendatlop - Tar recording and utilizing accident data, four simple forms are suggested for consideration, namely: a. Teresian's Beport of Accident b. Personal Injury Becord of Employee c. Departmental (Plant-Company) Accident Statement d. Treatment Becord and Doctor's Release naturally, these forms may be modified later as experience dictates. It is obvioualy impossible now to determine their ultimate scope or design, but they ere offered as a basis for a proposed recording plan which Incorpor ates, modifies, and in some Instances tends to eliminate certain accident forms now being used, together with most of the accident statements presently made. Foreman's Re-sort of Employee Accident - A foreman's retort of an accident to am employee, PROPERLY CgfPLLTlU, is considered the source of all accident information and hence, the foundation upon vhich en accurate hnnvledge of your accident experience depends. Although a form of this hind, #2646, is in use, many of the questions ere not considered altogether proper to include in a foreman's report of accident. For example, the last tvo questions of section 1 of this report, the lost den cf the second section, er.d - 14 - The general purpose of a foreran's report of an accident is pri marily to indicate an accident occurrence. Although it ie customary to in clude the more pertinent circumstances, it would seem questionable whether or not the many entries in your present Foreman's Report of Accident are con ducive to completeness "by foremen In entering Information. In reviewing past reports of accidents, it vas noted in many Instances that very brief des criptions vere given in the present form and that a number of entries vere omitted altogether. To encourage completeness in the preparation of accident reports by foremen and to insure the receipt of information necessary for analysis and study, a brief report (Form A) is proposed on page 17 covering entries vhlch are considered essential end which foremen can be expected end required to answer. Wien properly completed by foremen, this form together with the plant personnel records and the information resulting from an inves tigation, should provide the material necessary for reporting an accident to the State Industrial Commission. Essential data also would be provided for the Safety Engineer in analysing the accident. Occasionally no one will be present with an employee when he is injured, or possibly hie foreman will be absent or some distance away from the scene of fin accident. As injured employees often are able to report important details, a brief statement from them should be obtained immediately, if possible, following an accident. It may be desirable, too, for the injured enroloyee to initial his statement on the Foreman's Report of Accident if he is able to do bo, - particularly that type of man who, given time to ttinh, nay later distort the facts. - 16 - (For-a After the iter "Describe Fully How Accident Occurred" in the pro posed report, it is very important for foreman to give a complete and detailed statement depicting vhst the employee was doing and Just how the accident occurred. The importance of including all the facts and answering all ques tions fully might veil be called to the attention of foremen. Perhaps a meeting of foremen may be desirable for this purpose, indicating hov the lack of sufficient information in their reports vill handicap the preventive vorfc of the plant and necessitate time for inquiries on the part of the Safety Engineer and others in order to obtain all the circumstances. In Justice to the employees and to avoid later embarrassment to the Company, an accident should be reported impartially end truthfully. Attempts to obscure the actual circumstances may Jeopardise the position of the Company, especially in the more serious cases, since the facts usually are disclosed following an inves tigation. As one egr.< of training foremen to provide the data covered, incomplete reports should be returned to them for completion with appropriate notations by the general superintendent. It is strongly recommended that all accidents, regardless of severity, be reported by foremen immediately and Form A forwarded directly to the Safety Engineer. As the medical department in practice deals more with the curative rather than the preventive field, it is the function of the safety department to record and maintain the history of your accident exper ience. After determining the actual cause or causes as veil as the nature of injury, these cam be entered in code (See pages 19, 20, end 21) in longhend by the Safety Engineer to facilitate future reviews of the records. i - 18 - TABLE I ACTUAL CAUSES OF ACCIDENT Supervisory and Snrplo?ee Instruction 1. none 2. incomplete 3. erroneous Supervision 4. faulty 5. lack of proper inspection Ability of Employee 6. inexperience 7. unskilled Concentration 8. absent-minded 9* attention distracted Working Practices 10. chance taking 11. abort cuts 12. haste 13. inproper method 14. unsuitable tools 13* failed to use proper protective devices Discipline 16. not enforced 17. disobedience 18. interference by others 19. fooling or horse-play Mental 20. ignorant 21. poor Judgment 22. temper 23. excitable 2k.' asleep or intoxicated Physical 25. defective 26. fatigue 27. unsuited for claee of vork Equipment and Material Property Conditions 28. unguarded 29. ineffectively guarded 30. lack of proper protective devicee or materials 31. insufficient ventilation 32. poor illumination Housekeeping Conditions 33. Improper piling or storage 34. congestion 35. refuse material 36. lack of sanitation Equipment 37. defective material or tools 38. defects in machinery, equipment, or building Planning 39. improper layout of operations hO. improper layout of equipment or materials 41. unsafe processes Working Apparel 42. no goggles 43. lack of proper protection for hands, feet, heed, etc. 44. unsuitable clothing - long or torn aleeves, flaring trouser legs, etc. - 19 - ?j&i2 a MAIJIfEH Of IK-JURY a. Eandiing Material h* InnAllng Tools c. Falls - heights d. Falls - levels e. Falls - steps t. Bums - heated materials g. Bums - Chemical h* Bums - other i. Falling Material J. Striding Objects h. Band Trucks 1. Motor Trucks a. Flying Objects n. . Machinery o. Electricity p. Gas q. Stepped, on. Objects r. Miscellaneous - 20 - 'ABLE 3 COLE FOR NATURE OF INJURIES A. Amputations D. Bruises and contusions C. Cuts and lacerations D. Dislocations F. Fractures E. Hot substances and burns X. Irritations J. Objects - foreign IC. Silled L. Electrical injuries II. Infections O. Overcone - heat or cold P. Punctures or Olivers R. Ruptures and hernias S. Sprains end strains X. Asphxiations Z. Poisonings K. Miscellaneous PART OR MI-EEES AFFECTED 1. head 2. eyes p. nose 4. ears 5- nech 6. shoulder 7. chest 8. abdcnen 9* bach 10. spine 11. ribs 12. ems 15. hands 14. fingers and thumbs 15* body - internal 16. buttochs 17. hips 18. legs 19. feet 20. toes IXGZZl e, cede fer trohen right am: 12,r 21 - I 1 Appropriate opacee for these entries together vith that for caeo file numbers, have been indicated at the top of the proposed fora. Use of the code tables on pages 19, 20, and 21 vould shov imme diately upon inspection the true causes as veil as the injuries sustained by an employee for any particular accident. Although the tvo codes suggested nay seen eonevhat involved at first, their continued use viil lend facility in identifying causes and injuries. Beviaions, of course, nay be nade from tine to tine to corfera vith the progress of the vorh, and core specific causes nay be found as studies of the circumstances surrounding accidents are nade. When the accident repents are coded in the spaces provided at the top, the accident cases nay "ce cohered according to the number of accidents ex perienced by an. employee. For convenience in filing and for reference pur poses, it vill probably be found desirable to number the cases consecutively regardless of year, attaching all papers relating to a particular accident, and placing in a filing envelope vith other cases of accident involving the employee. A cross-reference also can be established between the case files relative to each consecutively numbered accident, end the personal injury record card (See page 2p) vhich should be filed alphabetically. Objections nay be nade by sene foreaen to the reports because of the tine required to couplete the fora. Such objections usually are based upon advanced opinion rather than actual fact, and their attention may be called to the presumption that the prevention of accidents vill eliminate the necessity for malting reports of this hind. Moreover, the method of obtaining full information for completing the fora properly is btrie tip e supervisory 22 - function, and not one which should bo delegated to the plant nuroo nor the Safety Engineer* Eovever, medical treatment ehould not be delayed In order to complete the fern, end for serious injuries and in cases of emergency, the employee should ro or be tajeen to the plant hospital iroaedictely. After noting the information needed for hie records, the Safety Engineer should refer Joremam1 s Reports of Accidenta received during the day to the general superintendent - together vlth any suggested memoranda (vien advisable) over the signature of the general superintendent for the attention end further action by the foremen concerned. In this way, the report will serve to educate foremen in their safety responsibilities, and the importance of printing accidents will be emphasised when they realize that the general superintendent will read every line of it. Later, these accident repcrus should be initialed by the general superintendent and re turned to the Safe-- Engineer and filed in the manner suggested. Reccrd of personal Injuries - Wot only do the accident forms used by the floor division plant vary somewhat from, those of the other units, but the-utility of several forms is believed doubtful from the standpoints of preventive information covered as veil as the amount of clerical time involved in their preparation. Moreover, the rather evfcverd procedure followed in developing useful accident data is further complicated by the different plant set-ups for maintaining eccident records. Ecese conditions are mentioned since they tend to illustrate the present impracticability of obtaining and utilizing accident facts readily by your Safety Engineers, end the need fer a standard accident recording system for all plants. - 23 - In addition, the nature of the information supplied by the medical departments is largely medical aa stated "before, and deals mostly vith the results rather than preventive featurea relating to accidentB. Again, mention ie made of the fact that no cricicisa of the medical departments is intended "because they hare very capably administered treatmenta to employees for various disabilities, and doubtless they have cooperated to the best of their abilities in the tash of reporting accidents, maintaining records, and develop ing experience statements. On the other hand. It must be remembered that the medical units are more curative than preventive agencies, and also that accident data are of no value except as matters of record when buried in file. Jor the above reasons, it is recommended that all accident records, excepting those purely of a medical mature, be maintained in the safety de partment gad utilised by the Safety Engineer to determine corrective neesure6 and to guide his preventive program. A proper running account is one of the essential needs for tabulating information efficiently concerning the daily occurrence of accidents. Such an account is important as a vorhing record for the Safety Engineer and to facilitate his preparation of periodic statements of accident causes, locations, rates, trends, etc., as veil as studies of departmental end plant accident experience. As discussed with Mr. Marshall, a single method for recording em ployee accidents and one which is adapted for periodic reviews in connection with the safety activities of the plant, is suggested by using a pwwi 1 index about 5 x , fem ,,2", Personal Injury Record, vhich appears on page 25. This card incorporates the information in the present accident Journals 3T0RM B (FBONT) &.jeJocyf?z. /cyuoB'r eeca&o >*>*& rcY^CYTL . <r* r <r* T p/aca n___________ ________ Mik *?rc y /trT* 1V ________________ c^oc/c SYS. OC CO/O&7~/OCT_____________ T __. fl.. * /O CaiUI *r/y ffaife Co ft* Oocfer* ffos/*f " tt. / J _L------------------ C o* rj (* JSafa 1 | ToTaf 1 ' jii* -- i --i-- it it ii ii |i [l t1 ti it 1| 1 1 1 1!!------------------------------------------------------------------------------------L11----------------------------------------------------------' _JL 1I 1x i( 1 1 iir I^ i( 1i i i FOKM (BACK) *>V* wcw> cr* crt | ) ^/c* I ffcc'f j 1 1 Oaf* **r~ Oay* Cajf 6n[ /tiff C*<fm\Co<j* \ 1 1 Ooefos* Abjo*t Co | Kf* 1 7\jCot'o Cowo C *d'/ | Tota/ |A ___________________L__j- i r 1I \ ! 11 i i ________________________ f i- ______________________________ i -- 1 | 1 i l ! I _J 111 i I 1 i i t i t i 1-------------------------------- -- i i i i i hospital, and similar charges. would "be indicated in colimn 13; and the com bined compensation and medical costa for each accident experienced by an employee would be entered in column Ik. Column 15 night show two entries, the number of weeks for which compensation already had been paid and the number of weeks remaining. Until the total compensation awards and total medieel expenses ha?e bees determined for each case, it ie suggested that entries for colons 1Z, 15,. It, end 15 be made in pencil es remittances ere cade, indicating the total amounts paid out for each item to date. When the case is closed, final entries can be made is ink. Vhen filed alphabetically, (see sketch on page 23) current and pre vious indexes are very helpful. The current index refers to the current month under which all personal injury cards of employees experiencing acci dents during that month, are placed. The previous Index refers to those men incurring accidents previously, Ir. case of separation from the company for any cause, the card for the- employee can be placed alphabetically in e "deed" index file. This will provide a check on former employees considered undesir able for re-employment by reason of their working methods, incorrigible ecoident tendencies cr other causes. Many advantages are possible in the use cf Perm ,t2"; fer example, the accident experience cr details regarding a particular accident involving a certain employee can be determined by a glance at his individual card. Special analyses incident to lost time, causes, locations, etc., are facili tated by arranging the cards "solitaire" fashion according to desired groups. Other advantages in the use cf Pom "3" are: 27 - 1 Sketch No. / 1. A permanent running account of employee accidents "by deportment can "be developed. 2. Accident-prone studies of employees, tabulations according to causes, units, costs, or any other desired statement can easily be made. 5. Considerable clerical vork, non-essential entries, and repeated items vould largely be eliminated. k. A check can be made on the re-employment of workmen vith undesirable accident tendencies. 5. Ike plan systematizes, and ie simple to maintain and operate. 6. It provides a cross-index to the suggested numerical file of accident cases. Special lets - It is understood that by an agreement vith the linolevci Workers Inter., the occurrence of minor injuries Is disregarded for recording proposes. Ike reasons advanced for this policy ere appreciated, since sene concern on the part of the union apparently exists over the like lihood that an sznlcyee' s position might be Jeopardized if he unfortunately experiences a number cf minor accidents. By the sane token, the management feels that a tendency night develop among employees to neglect nedical treat ment of minor injuries if these are recorded and included in the accident ex perience of the plant. Eovever, the mala issue seems to relete to the filing of records cf minor accidents in the personal folders of employees. frankly, it is believed that too much emphasis has been placed on the evils vhich nay result. In the first place, a representative organization such as the Armstrong Cork Company can hardly be expected to utilize minor accident data to the detriment of the employee concerned, but rather to use such information in disclosing hidden vork hazards or operating difficulties for the benefit end safety of the employee. Moreover, the present practice of employees in reporting immediately for treatment of every Injury is simply a matter of training and discipline vhich seems to be very veil instilled. In the opinion cf cur engineer, the matter is one vhich ought to be easily adjusted to the satisfaction of the union as veil as the management and, at the sane time, promote the effectiveness of your accident prevention activi ties vhich, after all, ere to the advantage of both. As the : the success cf yc accidents be: :rting of minor cases of eccident is very essential for afety program, it is proposed, therefore, that all minor - 29 - 1. Reported promptly "by foremen. 2. Investigated and recorded toy the Bofety engineer in plant experience statements. 3. emitted as records in the personnel fol ders of employees as in the past. There are several pertinent reasons for this proposal; but im portantly, it vi11 provide: 1. A complete history of your accident experi ence vhich is not covered at present. 2. Information regarding accident circumstances vhich may not be detected until a serious accident occurs. 3. Greater protection to employees from hazards that ere complicated or obscure. frequently, the difference toetveen a minor accident or a very serious one is only a matter of a second or tvo, or "plain luck." To illus trate this end also a striking example of the need for reporting minor acci dents involves an incident vhich occurred in a department vhere a large roll of linoleum vas toeing pushed on a dolly truck toy tvo men. Because of the vorn and uneven condition of the cement floor, extra effort vas necessary to move the roll to a "touch" vhere the roll vas picked up toy a traveling electric hand-operated crane. On this occasion, the tvo men pushing the truck vith its roll of linoleum lost control and the heavy steel spindle projecting from the roll vas pointed tovards the crane-man's helper vho vas adjusting a sling to enother roll on the "buck." A vanning cry from the men pushing the truck caused the crane-man's helper,- vhose back vas turned, to glance behind him just in time to Jimp upwards and allow the spindle .to pass between his legs. Aside from a very minor bruise, no injury resulted and no time vas lost ex cept for a fev minutes at the plant hospital; tout a potential serious injury if not a permanent disability vas possible. Under ordinary circumstances and according to your present practice, the safety engineer vould have no know ledge of the event nor the need for corrective meaeures. It also is inter esting to note that the damage to the roll of linoleum as veil as to the equip ment apparently vas considered rarely as an incidental phase of production. It is suggested that a meeting toe arranged vith union representa tives for a discussion of this proposal and an understanding to the end that minor accidents toe reported for investigation, study, and recording by the safety engineer. Statement of Accident Experience To present the accident experience of the various `units of the plant to the management as veil as to interested supervisors and executives. - 30 - It usually Is desirable to prepare monthly statements of accidents. Although statements entitled "Injuries by Types'* and "Illness by Types" are prepared at present, It seems doubtful if the information and the manner of its pres entation Is of special interest or utility to those receiving the Gtatenent aside from a routine medical record. In our opinion, such a statement should provide a complete record of the accident status of each department for the period covered, combining data vhieb a department head should bov in order to taice whatever preventive measures are necessary. lorn "C" on page 32, offers a sirgple means of presenting the monthly or yearly experiences of the departments, end contains essential information which can be interpreted readily by the executives concerned. With proper emphasis on the part of the manage ment, it also should serve to stimulate more interest in accident prevention methods on the part cf the supervisory force. Most of the material for Fora "C" (column 1, 2, 3, h, 5, 8, 9, 1C, 11, and 12) can be obtained directly from the personal injury records, Form '73". In column 1, the names of employees vho experienced accidents for any given period may be included under the names of their respective depart ments. The combined experience of each unit would precede that of individual employees and appear in the columns in line with the name of the department. Data covering injured employees would be indicated similarly tr. line with their names, excepting no rates would be involved in column 7. Such e statement should prove particularly helpful to foremen. For the information of the Plant Superintendents end other executives, the combined experience of each plant probably would be of considerable interest as e means of comparison. Omitting 31 - ^rxtr^cfcarisr^hcc/DBcrr izx&e/:<rcj */>< *nA>. fg the nemos of employees involved, such a statement covering the accident ex perience of all plants of the company could, he developed quarterly, or for any other period, Bimply hy substituting the naaeB of the plants in colirnm 1 and entering the respective plant totals in the columns after each plant. Column J has been included in case it is desirable to differentiate minor injuries from those involving loss of time less than seven days. lata for column 6 can he secured ft'cm the payrolls, vhile the rates Tinder column 7 mu3t, of course, he computed. Frequency rates are based on lost-tine accidents only, and ere used rather generally in. industry as a means of comparing the accident experience of various units and to measure the results obtained from safety vorh. When com puting frequency rates under column 7/ the definition commonly accepted in industrial safety practice defines a lost-time accident as one erising out of and during the course of employment, resulting in loss of tine other then that day or shift during vhich the accident occurred. Accordingly, the method ord inarily used for determining the frequency rates of an organization or a unit is to multiply the number of lost-tine accidents for a given period by `one million end divide the product by the men-houre vorhed. Occasionally, it may be desirable to have indications cf accident severity and rates should be computed in accordance vith past procedure cf the company. Eovever, for fatalities, and total or partial disabilities, Table on page 31* is suggested for computing severity rates. In such cases, the allowance indicated should be used instead of actual days lost, and attention particularly is invited to the note following the table for determining - 33 - TABLE U ALLOWANCE FOR FATALITIES AND PERMANENT, TOTAL OB PARTIAL DISABILITIES Nature of Injury Degree of Disability in of Permanent Total Disability Allowance in Pars Lost () Fatality Permanent Total Disability 100 100 6000 6000 Peminent Partial Disability of: Aim at cr above elbow Aim below elbow Hand Thumb Any one finger Two Fingers seme hand Three Fingers sene band Four Fingers sane band Thumb and one finger sene band Thumb end tvo fingers-same hand Thumb and three fingers sene hand Thurfr and four fingers Bane hand Leg at or above knee Leg below knee Foot Great toe or any two or mare .toes foot One toe other than great toe One eye Iobs of eight Both eyes loss of sight One ear loss of hearing Both ears loss of hearing 75 60 50 10 5 12h 20 30 20 25 33-1/3 1*0 75 50 ho 5 30 100 10 50 1*500 3600 3003 600 500 750 1200 1B00 1200 1500 2000 2b00 1*500 5000 2h00 300 ? 1800 6000 600 3000 (Prepared by the Ccsittee ca Statistics and Compensation Insurance Costs of the International Association of Industrial Accident 3oards and Commissions.) {#) In cases of injury involving impairment of function, but not amputations of members, percentages of the allowance in days lost ere used conferming with the degrees of disability determined by the authority adjudicating compensation claims. For example, if the adjudicating authority determines that a case involving the impairment of an arm warrants 160 weeks compensa tion - in a State which allows 2h0 weeks compensation fer the entire less of an arm - then 160/21*0 or two-thirds of the allowance in days lost is used; that is, two-thirds of 1*533 cr JS000 days. - 31* - severity rctee for accidents of this kind. A thorough knowledge of the cause of accidents is very important as a guide to determine vbat remedial measures are required. In addition to reporting such information to the management and also for the particular guid ance of the Safety Engineer, the department heads should be edvised period ically concerning the causes of accidents occurring in their units in order to supply them with pertinent material by which action may he taken to eliminate such causes* Column 8 of Foma "C" is designed to provide this in formation. If master copies of Tables 1 end 2 on pages 19 end 20 ere given to interested executives end department heeds, practice in the use of these tables should lend facility in recognizing the causes of an accident by code. For example, actual causes of accidents, on page 19, Table 1, have beer, numbered serially from 1 to 14. Provision likewise has beer, made to show the manner of injury or secondary causes which are indicated by the small letters *e.n to "rn on Table 2, page 20. Thus, an accident coded!2-e, would show haste or foolish hurry as the actual cause and a fall on steps as the manner of injury. In case the fall was due to a slippery substance carelessly spilled and left on the steps, the accident might properly be ceded as 35~e. After entering the proper code in column 8 of Form "0", three or four words regarding the accident nay follow. Although the code of accident causes is indicated primarily for the use of the Safety Sagineer, he may briefly describe accident - causes on Form "C", column 8, by the use of such words as: "Fall-foolish haste" or "fall-level-refuse material.1' - 35 - One of the benefits in the use of Fom MC" ia that it shove the deportments experiencing the highest incidence of accidents and vhere initial efforts can be applied moot advantageously, permitting consideration of the other units in their order of Importance. Vhen required, practically any type of diagram, chart, or graph can be developed frcsa it to depict special acci dent features or interesting phases of the safety program. As time goes on, these accident statements vill probably be found of increasing value as records and for the furtherance of the preventive vork. Statement of Disability and Medical Release When an illness or injury occurs to an employee as a result of his work, a statement is especially desirable concerning the immediate status of the employee and the disposition of his case to insure profit receipt of in formation necessary for the proper maintenance of both accident and medical records. However, in addition to having a check on medical treatments re ceived and days lost by employees, it also is important to have certain in formation covering the exact nature of injuries or illness, possible loss of tine, end other data in order that proper safety measures and operating arrangements car* be effected at once. For these purposes. Form "D" shown on pages 38 and 39 suggests a method whereby cases of accidental injury or illness incurred while at work are handled to the advantage of the employee, the physician or nurse, and the company. A plain card about 6" by 6" detachable at the middle, can be used. The plan utilises both sides of the card, two sections of the form appearing on the front and two sections at the back. The rreeent practice of an employee reporting immediately to the medical department vhen injured is strongly recommended. - 36 - 2n cases of minor injury when on employee is able to reoume work and no redressing or subsequent visits are necessary: A, The nurse should - 1. Conplete sections 1, 2, end 2. Strike out "Safety Director" nnd "home-hospital" on section 1. 3. Indicate the nature of either accident or illness on section 3 and strike out "has been absent since." 4. Indicate either injured or taken ill on section 4, and strike out "and absent since." 5. Strike out "work of a nature lighter than his regular duties." 6. Send the entire fora to the employee's foreman. 3. The foreman should - 1. Rote any additional information he requires to complete his foreman's Report of Accident. 2. Inter time, date eaployee again began work as veil as his remarks, if any, on section ?. 5. forward the upper part of fora "D", sections-1 and 3 (together with his report of the accident) to the Safety Engineer. z 1. Return the lower part of the fora, sections ^ end 1 to the aedical department. C. The Safety Engineer should - 1. liote all information required to conplete his reoords. 2. Investigate the accident and/or arrange for its investigation by e sub-committee appointed for this p purpose from the safety conaittee. 3. fasten sections 1 and 3 to any papers relative to this particular accident and place them in the employee's accident folder. If the employee 1b permitted to resume work but is instructed by the medical departusnt to return cm subsequent days for re-dressings or other treetsent, the sene procedure is followed excepting that the nurse retains the lower portion of fora *'D", sections 2 and U. The fact that the man nay con tinue work, but is to return at prescribed times to the medical department or to an outside doctor will be indicated to the foreman as veil ae the Safety Engineer in the renarks of section 1. When the employee no longer is required - 37 - to report to the medical department, the foreman is advised of the employee's release fi'om further treatment "by sections 2 and 4. After initialing section 4, the foreman should return this pert of the form immediately to the medical department. In-the event an employee is unable to resume work, Dr. Stair is available to render necessary treatment and visit the plant at certain hours during the day. Eovever, in Dr. Stehr'e absence, a few obvious changes are indicated in the use of Form "D" vben the nurse considers a case serious. If the disability is such that the employee may lose time other than that dey or shift during which the accident or illness occurred: A. The nurse should 1. Enter the foreman's name, department, employee's end clock number, the hour and date of first treatment on section 1, leaving the other entries of this section for completion by the doctor. 2. Indicate on section 3 whether an accident or ill ness end the date it occurred. 3. While convenient, enter on section 1 such items as employee's name and cloclc number, and the date when the injury (or illness) actually occurred, and the first day of absence by the employee. 4. Send aection 1 irmediately to the Safety Engineer when it is completed by the doctor. 5. Forward section 4 to the foreman concerned when the employee is released for work by the doctor. B. The doctor should 1. Indicate on section 1 his diagnosis, probable length of disability, disposition of the employee, end any remarks he considers pertinent. (Note: In the ab sence of the doctor, it may be desirable to send Form "D" in an envelope to the doctor, either with the employee or the person who nay accompany him.) 2. Beturn section 1 to the plant nurse with the employee, the person who accompanied him, by Mil, or personally. { Iiote: If no more than one visit to the doctor is necessary, the doctor, after entering the treatment given on section 2 and properly completing aection 4, also should return these eectlon3 with sections 1 and 3). - 4o - 3. Retain section 2 in serious cases ouch as those re quiring subsequent viaits or hospital care, netting current entries In the treatment record during the convalescence of the employee. h. Release the employee vhen he is able to resume vorh, completing section 4 and returning it to the plant nurse. (Note: If subsequent visits to the doctor later are warranted after the release of the employee for vorJc, the plant nurse should eend section 2 to the doctor for additional entries in the treatment record.) C. She Safety Engineer should * 1. Irmediately investigate the accident upon receipt of section 1 fsrom the plant nurse. 2. Discuss the circumstances with the foreman end obtain his accident report from him. 3. Leave section 1 with the foreman. 1. Arrange for a thorough investigation by the subccizcittee of the safety coranittee. 5. Tile section 3 vhen received from the foreman with ether papers relating to the case in the employee's accident folder. D. The foreman should 1. Retain section 1. 2. Obtain all the facts regarding the accident and complete his accident report if he has not already done so. 3- Return section 3 properly completed to the Safety Engineer vhen section 4 is received from the medical department. t. Initial section h and return it to the plant nurse. It probably vculd prove helpful if the medical department also maintained e small index cabinet for filing the lover part of Rom "D". If the cards were filed alphabetically according to department and the closed cases separated from those pending, an arrangement consistent with that sug- I gestea for filing Form '3n Personal Injury Record, by the safety department, would be provided. The code preposed for section 2 covering the record of treatments is merely an example sf items vhich could be used by the doctors and r.trees for - hi - "their convenience while treating employoea. Naturally, these items ae veil as the procedure suggested can he revised to stilt conditions as experience dic tates; hut in the use of a record such as Fora T", several advantages ere believed possible. It serves to: 1. Maintain a constant check on the status of employees incurring occupational accidents or illnesses. 2. Give necessary information for the guidance of the safety deportment in recording accidents and pre paring statements of accident experience. 5. Provide a system for determining actual days lost from accidents. 1. Prevent employees and other persons receiving un authorised treatment in the name of the company. 5. Prevent return to vork before an employee is physically able to do so. but permit the under taking of lifter duties vhen desirable. 6. Overcome malingering on the part of employees. 7. impress foremen end supervisors vith their accident responsibilities.- 8. Furnish a brief factual record of a disability vhich information may prove extremely helpful before a compensation boerd or court of lav. Incidentally, Form **D" is not prepared as an inclusive medical record of e disability, but rather as a medium to coordinate information essen tial tc both the medical and safety departments. Although the form vould elim inate a certain amount of clerical vork now performed by the plant nurse, no conflict is intended vith vhatever additional records Dr. Stahr or others con sider important for maintaining necessary medical information. On the other hand, dependence largely cn medical records has been one of the weaknesses of your present safety program, and the continued use of such records alone as e basis for directing preventive activities is strongly opposed. PHrvsrrrivs actjvitiis To emphasize and oustain the subject of safety in the minds of the working force, safety educational work generally follows the coordination of effort "by the management, foremen, and safety engineer to eliminate accidents. As a mean, therefore, of arousing greater interest in preventing accidents among supervisors, hut particularly workmen, certain activities are suggested in this section as aids in the development of your safety program. Plant Safety Committee There are few ways more effective to interest an individual in a special subject than by giving that individual something definite to do regard ing the matter. Such is the basis for the formation of safety committees, and. when correctly organized and efficiently directed, they have proven to he a very effective means for increasing general interest and decreasing accidents. Usually, the purpose of such a committee is to assist in co-ordinating the pre ventive verb end in developing -e proper safety attitude on the pert of all employees. P.eccmcenAaticn #6 - Structure Although a plant safety committee has "been formed, it is composed largely of supervisors and foremen with little direct representation from the working force. Of course, it is advisable to give representation to each phase of a plant's operations as now provided in order that any question of operating practice relating to a certain department nay he answered by the member con cerned. rer certain reasons, it may be the better plan to limit service on the committee to supervisors and foremen; but if a mixed committee would not con flict with company policy, service also by employees is recommended. It should - 1,3 - lie remembered that supervisors and foremen aa a croup do not usually cxperlerico accidente vhich, in the majority of cases, involve employees. If possible, therefore, some employees might veil em" included, as members of your safety committee; but the size of the committee should be limited for practical pur poses in order'that it vill not be too unwieldy. The general superintendent as functional head of the plant, should serve permanently as chairman of the committee. This duty should by no means be delegated to the safety engineer. Service as chairman is one of the best means for the general superintendent to indicate the attitude of management and official interest in the plant*s preventive verb. The safety engineer should serve as secretary of the remittee, act as an advisor or consultant to the members on matters of safety, and assist the chairman in conducting the meetings end making them interesting. Be commendation *7 (Chances in Membership') - A change of membership quarterly or every four months,* is recommended as a means of uniform develop ment and continuity of effort embracing *n crafts and departments of the plant. It also is recommended that only a fev members be changed at one time. This vould provide for the service of experienced members and facilitate the train ing of nev members. Among vorhmen, the election of members by fellow employees of a unit attracts considerable interest. Elections may be conducted as an item of a safety meeting by a foremen with his men. Becccnendation 8 fMeetings) - It is recommended that meetings be short, informal, animated, and held only as often as interesting material can he presented or brought up for discussion. Periodic meetings frequently - kk - `become routine in nature and often result in aimless discussions and waste of time. However, at first, following the initial re-organitation of the com mittee, meetings at frequent intervals may be advisable. Official surroundings are often undesirable for plant safety committee meetings which should be held where all will feel at ease end free from restraint. Domination of the meet ings by officials or executives is to be avoided for best results, and every encouragement given vorimsan to enter the discussions. It should be remembered that vorkaea have an intimate knowledge of actual operating conditions, and it is this knowledge which the management Bhould endeavor to procure. The following order of business which can be modified to suit future developments, will probably be found helpful in conducting meetings of your safety cccsnittee: 1. Call meeting to order. 2. Boll call, listing names of members present and absent. 5. Beading minutes of previous.meeting. h. Unfinished business (reccsmaandations referred from last meeting, etc.) 5* Eeports of Inspection committees (discussing each recommendation). . a. Iftmber of reccsaendations made. b. Humber of recommendations carried out. c. Huhb-r of recommendations now being worked on. d. IIember of recommendations upon which no action has been taken e. Beeemendations passed to general safety permittee for action 6. Beading of special inspection committee reports. 7. What departments have new employees? Check and discuss methods of instruction, improper methods of performing duties, etc, 8. Accident reports read and discussed, Including methods to prevent recurrences of such accidents. 9. Hew business. 10. General discussions, safety talks, and first aid training. 11. Date set for next meeting and adjournment, The form offered cn page ^7 likewise may be found helpful in main taining a record of the minutes of meetings. The "Statement of Other Matters - 1*5 - Coring Before the Meeting", may he as Ions ao required, supplemented, perhaps, by an additional sheet recording the general discussions and other Business. It voulc he desirable to Brief and circulate the minutes of the meetings, after they have Been prepared, to those vho attended the meeting. Becsmr.endation - duties Ilost failures in safety cesmittee work are largely due to faulty direction. The management is usually at fault and organit.es committees uncon vinced of their advantages or vhat as organisation of this hind really can accomplish. The causes of a ecmzittee's ineffectiveness are frequently trace able tc the lack of: 1. leadership and training 2. A definite job 3* Encouragement and support of the management At first, the natural tendency of a ccemittee is to correct obvious conditions of safeguarding instead of concentrating on unsafe practices and careless vorking habits. Although mechanical safeguarding is important to in dicate that the management is doing its part in the safety proven, the atten tion of the committee should be gradually directed to the detection of danger ous practices vhich are generally complicated or obscure. In this vay, the constructive stage of the committee ` s vork embracing the fundamental safety defects of the operating organization is reached. An important item of safety committee vork is the assigxzsent to It of all of these duties for vhich its organization is adapted. For example, questions pertaining to "working methods and sefe operating practices ere soma of the matters vhich the committee may veil consider and offer recommendations. - 46 - In addition, the committee nay "bo assigned the task of correlating preventive activities with the operations of the plant, acting as a policy-setting body in deciding issues vhere present practices and safety appear to conflict, con' sidering operating changes, reviewing accident records of the various depart ments, and indicating its official interest to the various units. Other functions of a plant safety committee consist of: 1. Assisting foremen in training and instructing new men, and offering recommendations concerning the transfer or retire ment of old employees. a. Preparing safety rules. 3. fee use of questionnaires to develop interest and to determine the location cf hazards. k. Preparing safety publicity material and maintaining bulletin boards. 5. Planning and conducting accident contests and arranging celebrations for successful "no-accident" records. 6. Considering friendly competitions with companies engaged in similar limes rf-business. 7. Studying employee suggestions end maintaining suggestion bones. S. Arranging for suitable ewards or prizes for winners of safety contests and for the best employee suggestions. 9. Planning safety rallies and "no-accident" drives. 10. Finding suitable work for injured men not able to assume their regular duties. 11. Periodic inspections of property. 12. Inspecting special equipment such as cranes, elevators, chains, goggles, clothing and protective wearing apparel. 15. Investigating all accidents and near accidents, determining the true causes and contributing conditions, rising responsibility and suggesting preventive measures to obviate recurrence, and t recomnending disciplinary action when advisable, (Note - In this connection, the committee may sit as e court of inquiry before whoa the injured employee and witnesses are brought for examination.) Reccu-.er.dation --*10 - Sub-Committees Very lihely, all of the activities cannot be covered practically by this organization as a body. For this reason, some of the activities might be assigned to one, two, or more members on a sub-ecnmittee basis. The various activities cam be rotated periodically to Insure proper training in the dif ferent elements of the safety vorh. Safety cmnittees are not usually vested with executive authority. It is, therefore, advisable to have all proposed actions submitted first to the supervisor or foreman concerned, in recommended rather than mandatory form. Crdinarily.. the general superintendent should not be appealed to except when combined Judgment clearly indicates the desirability of the change and when all measures to convert the dissenting supervisor have failed. As the safety program progresses, many other activities will present themselves. Such subjects as fire prevention, sanitation, health hazards, waste eliminaticn, new methods, etc., ere sene of the special problems which a co^ittee may consider and for which recommendations may be offered. Reports from the plant safety committee offer excellent opportunities for the manage ment to reflect official Interest. They can be made the bases for visits to the group when members may be congratulated officially for a fine safety record end so encouraged to maintain the work in the most productive channels. It is suggested that committees be allowed to perform their duties during verhing hours, or to arrange for the necessary over-time. In most - U9 - companies vhlch have organized vorianen'e safety committees, the former plan Is preferred. Safety Competitions Friendly competition In the form of accident prevention contests has "been found an excellent means of stimulating employee interest in safety activities. After an practical physical Improvements have been made, such as the safeguarding of machinery and the development of better operating methods and working conditions, a problem frequently remains of preventing accidents caused by the unsafe habits of employees. As the spirit of competition is reflected to a large extent in the daily work and play of nearly all individ uals, this spirit generally can be directed adventegeously in encouraging a concentrated effort by employees to prevent accidents. For example, at Beaver Falls, Mr. Corbett has made use of the "white elephant" stunt by which the department having the worst accident experience is "awarded" the white elephant trophy for a certain period or* until another unit "wins" the award by its unfavorable record. Simple competitions such as these do have particular value after the novelty of launching a safety program has dulled. Feccmendatlcn ^11 - Plgoninc a Contest Some fora of organized safety competition applicable for the depart ments of a plant as well as the plants of the company, is recommended. In planning such a contest, the following items should be considered: Drafting the Fules - In any game or sport where the selection of the winner restB upon a score, it is important that the contestants understand and believe in the rules and scoring methods. In planning safety contests, it is - 50 - customary to have definite rules prepared by a responsible group, ouch as the plant safety committee, and, if necessary, the reasonableness of those rules explained to voriccen. It is also considered highly important that company or plant officials and executives he in sympathy vith the rules and plans for the contest, nd their enthusiasm aroused in order to secure their cooperation. After a p??n has been developed, it usually ie discussed at a meeting of exec utives and foremen. Short informal meetings of foremen vith their men, and bulletins describing the contest, serve to place the matter before employees. Participating' units - It is the practice of a number of companies to eliminate units of a non-operating nature, such as the general office, sales department, etc., from the ccmpetitive plan. In planning your contest, it is suggested that only the operating units be included. What Constitutes An Accident - Most companies with successful safety programs require that all accidents, no matter hov trivial, be reported for investigation, enalysis, er-d proper treatment. However, when minor accidents are included in determining departmental standings In safety contests, it 8onetinsb happens that these accidents are not reported by some units, thereby .Jeopardizing the fairness of the system. On the other hand, if minor acci dents are not included in the rating plan, greeter attention often is given then by foremen and supervisors to obviate possible infections or other con sequences resulting in lost time. For these reasons, it is reccumendad that your contest he based on lost time accidents only, as defined on Page 33 Contest Period - The period of a contest ordinarily followed by a number of industrial organizations is one month. In many esses, however, these - 51 - monthly contests are incidental to periods lasting from three, sis, or twelve months* A period or either sir months or a year seems best suited for your requirements; as a unit having an unfavorable experience during any one month will not be eliminated necessarily from the contest, but may be determined the winner by operating safely during the remainder of the period. Departmental end Plant Accident Record Sheet -- A plan .for presenting the safety performances of the operating departments of a plant together with those of the other plants of the company, is shown below. This plan utilises frequency rates and, although the departmental contest of a plant can be based on monthly or other suitable periods, the plants compete for the lowest fre quency rate for six or yearly periods according to the ccsul&tive hours worked and number of lost-time accidents. ARMSTRONG CORK COMPART Safety Contest Standing. Fulton Plant. February 1942. (Kote - Specimen, not actual figures) Department Lost-Time Accidents lian-Eonrs Frequency Bates Standing This Mo. This Tear This o.This Tr. This Mo. This Yr To Date A B C D Others Totals Feb. 1941 Feb. 1940 - . Beaver Falls Pittsburgh Pensacola Others Company -- 0 1 1 2 4 6 --7 0 1 2 7 0 2 1 3 6 11 . .. 13 2 3 5 10 35000 87484 34200 67660 72500 175891 67799 145750 224344 750190 725420 265763 282356 301745 461940 1782250 15B3426 554784 684941 723862 1074208 2425527 0 11.4 28.2 29.5 17.8. 7.98 9.61 0 3.5 6.7 6.5 0 11.4 14.7 20.6 -1 2 3 4 13.0 6.17 e,2P o.6 4.4 6.9 1 2 3 4.1 feriodlc monthly statements such sb the above can be recdily pre pared by the Safety Engineer of each plant, excepting the lover portion having to do with the experiences of the other plants of the Company. This latter part could be assembled at Lancaster with the understanding that plant state ments must be ^received in Lancaster by a certain time. Reports then could be forwarded to all plants covering the experiences of each unit of the company. After receipt by the plant safety engineer, these additional data could be added to his plant statement, copies of which could be sent to the general superintendent end certain executives of the unit as well as to the foremen. (Ccmsr.t - Pr~ discussions with general superintendents and ethers, there is seme veriance of opinion as to an equit able basis for conducting an inter-plant contest icr the best safety record in the company. A consensus reveals that the comparative hazards of the several units ought to be considered. If desired, a plan of this hind or any other suitable for the operating peculiarities of the company as a whole, cen be developed. Eovever, before attempting to present a tentative method for consideration, it is suggested that our engineer further discuss the mat ter with executives in Lancaster. In this way, it is believed a worhable plan can be developed and most of the *bugs" eliminated before the contest is placed into oper ation. The foregoing type of contest based on accident frequency, is similar to the present plan conducted. The safety contest standing record, illustrated on the pre vious page, is submitted only to provohe thought and can be changed, modified, or entirely eliminated as require ments dictate.) An accident score based similar to the one at Beaver Rails would serve to acquaint eaployees with the standings of the various departments of a plant and the performance of the plant in relation to other units of the Company. The lay-cut of such a hoard right be eB follows: diplomacy and the attention of the unit diverted, to the remaining period of the competition. This personal interest also has been known to manifest itself by a tendency of the men to return to work as soon as possible. Awards - Suitable but Inexpensive awards seem to lend considerable Interest in contests. The following are some of the forms of awards which might be used in connection with your competitive plan. 1. Watch-fobs, lapel-buttons, pens or pencils for members of a winning department. 2. A pair of theatre tickets. 3. "Sunday dinner" baskets, containing the material required by an average family. h. A day or two off on the stagger plan, with pay; or double time if working. 5. A new hat. 6. Cash pri2es or bonuses. The safety profit-sharing plan is one method cf distributing cast prises among employees cf those units whose records merit recognition. The plan is usually based on tie reduction of accident expenditures for a year be low the previous year's experience, thereby a percentage of the savings accrued are allotted for distribution. All accident costs of a unit, such as production losses, damage to equipment, spoilage of material, etc., are usually considered in apportion ing the percentage of savings allotted to an individual or unit. 7. A banner cr trophy to be competed for periodically. A unit winning the -reply a number of consecutive tines should be allowed to retain it permanently, and individual awards, such as vatch*fobs, lapel-buttons, gold pencils or other suitable awards made to members. 8. A trip to the Ketional Safety Congress for a foreman or super visor whose unit has the best safety record for a year. In this case, it would be desirable to give individual pri2es to the vcrimer, cf the unit. * ,, Reccrmendatior. ^12 - Scfetv Advertising - Bulletin boards are stationed at the entrance to the plant. For best results, however, the value of any advertisement depends largely on the number of mental impressions pro duced, and for this reason it is recommended that a variety of material, preferable of local interest, be used. Rather than relying entirely on printed posters and bulletins which have been prepared by outside agencies, it is believed that mere appeal can be had in the use of home-made bulletins, photographs, newspaper clippings, neesages from company officials, accounts of accidents, statements of prize-winning suggestions, exhibits, etc. Such material of local interest is considered an excellent supplement to the use of news Berri.ce, posters and special bulletins which can be subscribed for from commercial ecencies. I'any organizations have found that bulletin boards located at the entrance of a plant do mot receive much attention from employees hurrying to and frem verb. For this reason, safety displays generally ere pieced at more strategic places on the property, such aa near drinking fountains, in lunch rooms, rest roems end places where employees naturally congregate, or even in working places. Is brief, best results are usually obtained through a clean and attractive bulletin board, properly located, frequently charred and offer ing a definite message. A few safety signs were found on the properties where specific hazards were found, cr at points where the employees were exposed to danger. In addition to a definite message, a safety sign should have gcod visibility, be made cf substantial material, and have a cleanly eppearence. Periodic - 56 - replacement of signs tecring similar messages "but in different wording makes for continual effectiveness and refreshes the minds of employees concerning a particular danger or condition involved. Recowendetior. ^33 - Suggestion Boxes - Many companies have found that suggestion systems hare proved a valuable means towards reducing pro duction costa, improving operating practices and promoting safety. Accord ingly, the present suggestion system may well he continued. In order to overcome timidijfcft on the part of employees, or the fear of criticism from supervisors, prompt actaiowledgment to an employee submitting a suggestion is highly essential. Moreover, regardless of the nature of the suggestion or how trivial it may seem, careful consideration ie important; and, if the suggestion is believed impractical, the natter should be explained carefully to the employee and an acknovledrpaent made thanking him. for his in terest. A form letter prepared for the signature of the general superintendent is suggested for this purpose: If the suggestion submitted is considered worthy of adoption, a similar letter may be sent with the thanks of the man agement -- encouraging the employee to offer additional Ideas concerning conditions cr practices which he has observed. Unless this is done, workmen will soon lose interest in your suggestion system end fev, if er.y, results will be obtained from it. In same companies, it is customary to give inexpensive evards cr prices to employees for suggestions which merit adoption. This arrangement would probably create additional interest on the part of your employees and result in an increased use of suggestion boxes. The posting of employees names, together with the nature of the suggestions adopted, also eerves to - 57 - stinulcto the cooperation of vorlcncn. Sone of the matters vlilch o suggestion system may consider are: 1. Bov earn the ccmpapy save sonething that nov is a loss or vaste? 2. What economies can be suggested In the use of time, machinery stocks, supplies, etc.? 5. Hov vould you rahe a better tool? 1. Hcv car. 2 41ob or fixture be improved? 5. Hov can har.d or machine operations be elininated by changes in tools or patterns? 6. Hcv car. vori be handled to do it better, faster, and vith greater ear. euy? 7. Bov car. material be used vhieh is nov being scrapped? 8. Bov car. arrenreneut of machinery, tools, or supplies be improved? 9. Bov car. the appearance of our products be improved? 10. Bov can the handling of naterial or finished product be improved? 11. Vhat nev features can be suggested to increase the 'usefulness of cur urcducts? 12. Hcv can. vori be dcr-e vith greater efficiency and safety? 13. Hcv can ventilation, sanitation, and all other matters vhieh prenote the heeBth, safety, and comfort of the employees be in ureved? 1^. Bov -an nethods of filing and handling information be improved? 15. Hcv can unnecessary reports and duplications of reports be eliminated? 16. Where can machinery be used to better advantage? a, ccner.daticr. =1U - Safety Pules - In many industrial organizations vhere employees are constantly exposed to hazards, it is customary to establish renerau sarety 1nr the conduct of the operating force vhile at - 53 - vorK. Such a code of ruleo iE recommended for your orgunicatlon, primarily for self-instruction and guidance of employees and secondarily, as a means of discipline. Speciel rules concerning process or departmental safety are believed of greater importance than those intended to cover ccssnon, veil reco'piized hazards. For example, a rule such as: "Goggles must be vorn if your vork endangere your eyes, " is considered poorly defined. A much better vay to prescribe the veering of goggles is to specify those operations vhere they are to be vorn. Only ir. this vay is individual responsibility properly interpreted in the rules - avoiding varus, unenforceable regulations or rules of question able utility. Simple language srd brevity, without sacrificing; clarity and pur pose, ere very essential if the rules ere to be studied and understood. Il lustrations are very helpful in impressing e vortann vith the danger of his Job end the practices he is 'expected to follow vhile at vork. In the formu lation of rules, it is advisable to firav upon the experience of the foreman and supervisors end to discuss with them the various proposals contemplated. This will create greater interest in the rules among this group and tends to better enforcement than if they had been originated by the management and thrust upon then. a. Si scinline - A nev employee, unfamiliar vith his Job or surround ings, usually is unimpressed by rules until he learns they will be enforced. Without enforcement, rules are valueless and veaken the structure designed to maintain safe vorimansiip. To obtain best results from a code of safety rules, - 59 - they should he impartially but rigidly enforced*. Kcrohness is unnecessary, end discipline is not recommended until ell the facts are known* Value to the company, position or Job held# and length of service may he given consideretion in determining the nature of a penalty, hut such factors should not apply in the ratter of enforcement. h. Penalties - For some men, dismissal is the severest form of discipline, accept for ^corrigible cases and those men who through their hahUs constitute a constant hazard to their fellow workmen, a lighter form of punishment is desirable. However, instances occur when dismissal is fully warranted. It is the most striking form of penalty and consequently has the greatest effect on the operating force as a body, particularly if the individ ual concerned he prominently known or holds an important position in the company. The utter disregard by a department of a safety rule may be remedied effectively by the dismissal of a foreman or supervisor responsible for the enforcement. Suspension is a form of discipline resorted to by some organizations for the infraction of an established rule or regulation. For certain classes of employees, it is unsuitable as it frequently causes hardships on dependents. Temporary demotion is another disciplinary measure for violations of -regula tions, which is occasionally accompanied with a decrease in pay rate. The latter case, in nearly all instances, produces resentment. A verbal reprimand under impressive conditions, given after an ex planation -has been asked, usually serves as a sufficient penalty- for the first violation. However, such actions should be given privately, end ridicule avoided to eliminate reactions prejudicial to the morale of the offender. * 6o - Physical Conditions of the Properties Aa mentioned previously, safeguarding together with pood housekeep ing is an important phase of safety work. Hot only do the guarding of mach inery nnd the maintenance of good order prevent certain accidents, hut they indicate to employees that the company is sincere in ita efforts to prevent injuries physical suffering. A number of items of safeguarding and house keeping vere discussed vitb Hr. Keen and vlth certain foremen during vie its to the departments. It is believed, however, that this part of your safety program can he undertaken constructively by your plant safety committee. In placing safeguards correcting unsafe conditions of the plant, the mere important eases might he considered first. This plan provides for a progres sive grid gradual Improvement rather than attempting to correct all items at once. It is reeor^ended that individual goggles he issued by the company to employees requiring then, -irr their work. In this way, suitable goggles can be obtained for the types of work conducted by your company. The majority of companies which provide employees with goggles issue these without charge and replace them when unserviceable through fair wear and tear. If lost or care lessly broken, they ere replaced at the expense of the employee. >ZTROPOLITAH COOFZZA7IOZ The safety service of the Metropolitan Life Insurance Company has been glad to make this stuiy in the interest of preventing accidents among your employees. The kind assistance of Messrs. Blaiscell, Marshall, and Keen aided our engineer materially in the survey, end this opportunity is teken to - 61 - expresB our appreciation of the many courtesies extended. The recccsncndatione offered in this report may be considered as features to assist you in your accident prevention problems; and those vhich, in the opinion of our engineer, can be used advantageously to create greater interest in pafety eranr your employees. If there are any items in the re port not sufficiently clear, or if -other problems arise in connection vith your safety progrtu, ve s'r.al* be pleased to have you consult us further or have one of our engineers return to discuss the natter fully.