Document GzGBGgzYrdn7Z1DmDDwBn1oyV

OCT 15 '91 09=32 H-C INDULS'TlKRIILESS i>Ak / /. // c?,/rVp // // " P.2 SAFETY AUDIT FROM EVALUATION TEAM INTERVIEWS SAFETY PROGRAM EVALUATION The numerical values to be insert-ed below are the weighted ratings calculated from the attached evaluation -sheets- The total of these ratings becomes the overall rating for the plant or location. I. Commitment II. Organization and Administration III. Communication IV. Accident/Near Miss Investigation v. Hazard & Engineering Controls VI. Industrial Hygiene & Medical Surviellance vii. Work Practice Controls Training Motivation Total = Overall plant rating Accident-Injury Experience 13^0^) OCT 15 '91 09=33 H-C INDUSTPIES P. 1 962356 0050 OCT 1? '91 09:33 H-C INDUSTRIES P.3 /. COMMITMENT A. Location Safety & IH Policy Rating Good Has signed, posted local policy. Meets corporate requirements. Recommendations Needs formalized process for policy development. Needs each level of management to formally review the policy with their employees. Needs to have a planned schedule for review of policy. 962356 0051 r OCT 15 '91 09:34 H-C INDUSTRIES P.4 /. COMMITMENT - B. Top Management Visibility and Involvement Rating Good Location's management is involved in safety committee. Location's management takes a hands-on approach. Recommendations Ragsdale needs to better define and communicate the role of the executive safety committee and the Ragsdale location committee. Minutes of ESC should be communicated to all line managers to serve as model and provide direction. 962356 0052 OCT 15 '91 09=35 H-C INDUSTRIES P.5 /. COMMITMENT - C. Safety as an Equal Priority Rating Good T.H.E. much better housekeeping. Most people believe that safety is a priority . Safety is discussed at all staff meetings. Money is being spent. Recommendations JSA's/ESA's need to be current, prominent. Housekeeping needs improvement. Storage in office hallways. Paint/can track area; Shipping and Receiving Outdoor Need re-evaluation of maintenance resources. Equipment sales/demonstrations need to be improved. 962356 0053 OCT 15 '91 09=36 H-C INDUSTRIES P.6 /. COMMITMENT - D. Clearly defined Safety & IH Responsibilities Rating Fair ; ; Safety responsibilities are written. Burden of responsibility is still management. Recommendations All department supervisors need to have the same level of understanding and commitment to safety as the best. Safety must be viewed as an integral part of performance. 962356 0054 OCT 15 '91 09=37 H-C INDUSTRIES //. ORGANIZATION AND ADMINISTRATION A. Executive Safety and Health Committee Rating - Fair Line management under represented (loop). Recommendations T.H.E. to join Ragsdale's committee. Include general foreman, supervisors, etc. OCT 15 '91 09:37 H-C INDUSTRIES P.B II. ORGANIZATION AND ADMINISTRATION B.Joint Safety and Health Committee Rating - Poor Ragsdale does not conduct consistent committees with, an agenda. T.H.E. involves a supervisor, 3-hourly employees and R. Krumberger. Recommendations Ragsdale to reconstruct previous joint S&H committee. T.H.E. to develop an agenda (hourly to assist). 962356 0056 OCT 15 'Hi 09:38 H-C INDUSTRIES P.9 //. ORGANIZATION AND ADMINISTRATION C. Department and Other Safety Subcommittees and Task Forces, etc. Rating Fair Cut Busters and QIP activities to address safety, but this is a minimum coverage. Recommendations The majority of departments {or work groups) should have consistent (monthly) committee meetings. Organizational status via executive safety committee/joint safety committee. 962356 0057 OCT 91 09:39 H-C INDUSTRIES P. 10 II. ORGANIZATION AND ADMINISTRATION D. Adequately Trained and Supported Safety & IH Staff Rating - Fair Primary deficiency is lack of time. Recommendations Accelerate supplementary assistance (R. Krumberger to prioritize). 962356 0058 OCT 1? '91 09:40 H-C INDUSTRIES P. 11 III. COMMUNICATIONS - A. Atmosphere for Employee Involvement Rating Fair Few department teams exist. Does have a safety suggestion system. Recommendations Need to establish a joint safety IH committee. Need to clearly annunciate authority and responsibilities. Need to publicize committee actions. 962356 0059 OCT 15 '91 09=40 H-C INDUSTRIES III. COMMUNICATIONS B. Use of Bulletin Boards Rating - Fair Does use bulletin boards. Recommendations Sectionalize boards. Have procedure for update notification. Use more safety grams. OCT 15 '91 09M1 H-C INDUSTRIES P. 13 HI. COMMUNICATIONS C. Distribution of "Off-the-Job" Literature Rating Fair Uses monthly safety magazine for OTJ safety information. Occasionally uses newsletters for OTJ. Recommendations Develop program to specifically addendum "OTJ" safety. Set up OTJ safety committee/team. Track OTJ safety status. 962356 0061 OCT 15 '91 09:42 H-C INDUSTRIES P. 14 III. COMMUNICATIONS- D. In-plant Safety Newsletter Rating Fair They do have one. Recommendations Publish in advance and promote article submission. Invite suggestions for topics in addition to article. Promote increased home use. Get T.H.E. into newsletter. 962356 0062 OCT 15 '91 09=43 H-C INDUSTRIES P. 15 III. COMMUNICATIONS - E Feedback loop for IH Sampling Rating * Fair Posting of area sampling results. Recommendations Need to step up training programs as they relate to IH, i.e. haz comm (material specific), hearing conservation, respiratory protection. I 962356 0063 OCT 15 '91 09=43 H-C INDUSTRIES P. 16 III. COMMUNICATIONS - F. Safety Suggestion System Rating - Good Recommendations Increase the number of locations. Simplify the process. Define the approval,implementation process, speed up implementation. 962356 0064 OCT 15 '91 09=44 H-C INDUSTRIES P. 17 IV. ACCIDENT/NEAR-MISS INVESTIGATION AND REPORTING A. Alcoa/OSHA/MSHA Reporting practices Rating Fair Backup documentation scattered. Inconsistent filing methods. Not a clear understanding about recording hearing loss. Supervisors, as a group, not clear on record keeping requirements. Recommendations Obtain updated Triple I Forms with Type 6 specifier and vertical/crane designation. Develop consistent policy for determining injury classification (supervisors - personnel director, etc.). Incorporate training efforts at T.H.E. to remain consistent and to help employees' understand importance of injury reporting. 962356 0065 OCT 15 '91 09=45 H-C INDUSTRIES P. 18 IV. ACCIDENT/NEAR-MISS INVESTIGATION AND REPORTING B. Reporting Practices for First Aid and Jnjury-Free Events. Rating - Fair First aid injuries not consistently reported. No in-depth analysis of first aid and near misses (injury-free event). Management not consistently involved in accident investigations. Recommendations Continue efforts to train employees in CORE principles to emphasize importance of reporting injuries. Pursue analysis of first aid and near-miss incidents to become more pro-active in injury/illness prevention. Management should consistently be involved in serious injury accident investigations. First-line supervisors should be involved in all accident/incident investigations. 962356 0066 OCT 15 '91 09=45 H-C INDUSTRIES P. 19 IV. ACCIDENT/NEAR-MISS INVESTIGATION AND REPORTING C. Quality of Investigations and Analysis Rating - Fair Not all supervisors have received CORE training in accident investigations. Not all managers consistently participate in accident investigations in respective departments. Recommendations * Develop an accident investigation policy. For example: All serious injuries will be investigated by plant manager, manager of area, general forman, line supervisors, safety director and involved employee. * Develop policy for injury classification. 962356 0067 OCT 15 '91 09:46 H-C INDUSTRIES P.20 IV. ACCIDENT/NEAR-MISS INVESTIGATION AND REPORTING D. Follow-up on Identified Corrective Actions, Rating Fair No verification of follow-up by supervisor (T.H.E.) or other responsible parties (Ragsdale). No pro-active program for follow-up system. Recommendations Supervisor should have formal system of follow-up on corrective action(s) taken (T.H.E.). Documentation from responsible parties on follow up should be maintained. 962356 0068 OCT 15 '91 09=47 H-C INDUSTRIES P.21 IV. ACCIDENT/NEAR-MISS INVESTIGATION AND REPORTING E Statistical Analysis of Accident/Injury/Exposure Data Rating Poor CADA reports not distributed to respective departments. Recommendations Distribute CADA reports to all supervisors to assist in understanding accident/injury problems of each department. 962356 0069 OCT 15 '91 09M7 H-C INDUSTRIES P.22 V. HAZARD & ENGINEERING CONTROLS - A. Compliance w/ Regulation Rating - Fair Some attempts at compliance. Some problems exist. Recommendations Accelerate CORE training. Bring additional resources in, specifically policy development/deployment and Hazard abatement. 962356 0070 OCT 15 '91 09:48 H-C INDUSTRIES P. V. HAZARD & ENGINEERING CONTROLS - B. Planned Inspection Programs Rating - Poor Recommendations Need to develop formal/plant-wide inspection programs. Need overlapping inspection Need periodic analysis of results. Need established STD's of performance. Need pre-operator inspection programs. OCT 15 '91 09MB H-C INDUSTRIES P.24 V. HAZARD & ENGINEERING CONTROLS - C. Housekeeping Rating Fair T.H.E. much better than Ragsdale Recommendations Need formal housekeeping policy. Assigned responsibilities. Measurable STD's Need records. 962356 0072 OCT 15 '91 09=49 H-C INDUSTRIES V. HAZARDOUS & ENGINEERING CONTROLS D. Lockout/Tagout Rating - Fair Program is written Training has begun. Recommendation Need to bring training down to the "affected employee" level. Contractors need to be trained and certified. OCT 15 '91 09=50 H-C INDUSTRIES P.26 V. HAZARDOUS & ENGINEERING CONTROLS - F. Fall Prevention Program Rating Poor No formal survey documented for evaluating potential fall hazards. Not all employees trained in fall prevention/protection. No guardrails in place on top of office area at T.H.E. to prevent fall. Recommendations Perform and document a formal survey of fall hazards. Train all employees on requirements of fall prevention / protection program. Install guardrails on top of office area at T.H.E. or eliminate storage. 962356 0074 OCT 15 '91 09=50 H-C INDUSTRIES P.27 V. HAZARDOUS & ENGINEERING CONTROLS - G. Mobile Equipment Safety Practices Rating Poor No written training program on crane operation. No medical examinations for vehicle operators. No pre-shift inspections for cranes or other industrial vehicles. Recommendations Develop a training program for crane operators. Develop inspection checklists for cranes and vehicles. Review and incorporate medical protocols into mobile equipment operator training program. 962356 0075 OCT 15 '91 09=51 H-C INDUSTRIES P.28 V. HAZARDOUS & ENGINEERING CONTROLS - H. Project Safety and Review Procedures Rating - Poor Does not exist. - Recommendations Need to develop the process. Document ail meetings. Resolve problems. Retain records. 962356 0076 OCT 15 '91 09=52 H-C INDUSTRIES P.29 V. HAZARDOUS & ENGINEERING CONTROLS I. Compliance with Alcoa Engineering Standards Rate - Poor Engineering department does not incorporate engineering standards into design considerations and operating practices. Safety and health engineering standards not communicated beyond safety personnel and engineering manager. No format program in place to ensure contractor compliance with STDs. Recommendations Engineers and supervisors should be trained on importance of complying with requirement of STDs. Engineering should regularly involve safety department in product design/revision decisions to ensure compliance. Develop program to ensure contractor compliance. 962356 0077 OCT 15 '91 09:52 H-C INDUSTRIES P.30 V. HAZARDOUS & ENGINEERING CONTROLS - K. Welding, Burning and Hot Work Procedures Rating - Poor Program not adopted. Recommendations Need to adopt program. Train employees. Monitor program. Train contractors. Review requirements for ventilation and IH monitoring of affected employees. 962356 0078 OCT 15 '91 09:53 H-C INDUSTRIES P.31 V. HAZARDOUS & ENGINEERING CONTROLS - L. Pre-Selection and Use Rating Poor Proper equipment not provided (prescription glasses not ANSI approved) (No pre required/supplied for handling corrosives). Equipment not adequate for specific hazards (side shields not required for working around machinery - T.H.E.). No written, formal policy on use of shaded glasses. Jewelry policy not consistent between plants. Recommendations Require and enforce use of ANSI approved eye protection. * Require use of side shields at both plants. Develop written policy on use of shaded lenses. * Enforce consistent policies in both plants. 962356 0079 OCT 15 '91 09=53 H-C INDUSTRIES P.32 y._HAZARDOUS & ENGINEERING CONTROLS - M. Emergency Procedures, Equipment and Response Rating Fair Drills not conducted on regular basis. Emergency lighting not provided. Fire brigade (emergency brigade) not formally trained. Fire extinguishers not inspected monthly. Exit lights not in continuous operation. Not all fire extinguishers are mounted and identified (red bldg, column). Recommendations Regularly schedule emergency drills. Provide emergency lighting Train all emergency response personnel. Inspect extinguishers monthly and document. Fix exit lighting. Mount and identify extinguishers consistently. 962356 0080 OCT 15 '91 09:54 H-C INDUSTRIES P.33 V. HAZARDOUS & ENGINEERING CONTROLS - N. Product Safety Bating Fair 4 Claims last 2 years. Accountability poorly defined. No centralized records. Labeling deficiencies Warnings in literature (noise) Training Recommendations Assign accountability (Team). Improve record keeping. Establish design review. Engineering modifications. Machine labels. Upgrade product literature. 962356 0081 OCT 15 '91 09=55 H-C INDUSTRIES P.34 V. HAZARDOUS & ENGINEERING CONTROLS - O. Toxic Substances Control Act Rating - Poor Accountability assigned. TSCA P.O. Note not used. Japan printing inks - "Section 5 Violation" TSCA Poster 8(c), 8(e) TSCA Training Recommendations . Implement P.O. Notes (procurement). Train employees, supervisors, medical. Implement reporting process. Modify posters. 962356 0082 * OCT 15 '91 09:55 H-C INDUSTRIES P.35 VI. INDUSTRIAL HYGIENE & MEDICAL SURVEILLANCE A. Medical Protocols used for Critical Jobs Ratings Poor Pre-employment physical Pre-employment respirator clearance Baseline audiometric testing Drug program Not aware of Alcoa protocols Recommendations Implement Alcoa medical protocols for job classifications and chemical/physical exposures Annual audiometric testing Ongoing medical clearance for respirator users Review ADA act 962356 0083 OCT 15 '91 09=56 H-C INDUSTRIES P.36 VI. INDUSTRIAL HYGIENE & MEDICAL SURVEILLANCE B. Access to Adequate IH Equipment Ratinn - Fair CGI, detector tubes, pump available No calibration program R. Krumberger's equipment Too reliant on EHL Recommendations Purchase own equipment Develop calibration practices Train people to sample l 962356 0084 OCT 15 '91 09 = 56 H-C INDUSTRIES P.37 VI. INDUSTRIAL HYGIENE & MEDICAL SURVEILLANCE C. Established Hazard Communication Program Ratings Poor (Ragsdale) Fair (T.H.E.) No department inventories Lacking MSDS No in-house labeling No specialized training Generic training has been done Recommendations Complete written program Implement HAZ Min Develop Department Inventories Conduct specialized training Improve purchasing controls MSDS/labels waste products SARA reporting 962356 0085 OCT 15 '91 09:57 H-C INDUSTRIES P.38 VI. INDUSTRIAL HYGIENE & MEDICAL SURVEILLANCE D. Exposure Assessments Rating - Fair MSDS/chemical exposures not assessed Baseline IH sampling <50% Noise surveys conducted Paint, welding, grinding IH sampling feedback occurs Recommendations Link chemicals with sampling needs Develop baselines/periodic for job classifications Ozone,NOX - Lead - Pentacies - Solvents - Methylene Chloride Glycol Ethers Need stel sampling Explain IH results Prioritize engineering controls Cobalt Oil Mist 962356 0086 OCT 15 '91 09:58 H-C INDUSTRIES P.39 VI. INDUSTRIAL HYGIENE & MEDICAL SURVEILLANCE E Effective Respiratory Protection / Pulmonary Surveillance Program Rating Poor Respirator training has occurred. Fit testing done Beard policy implemented. Written program developed. Pre-employment medical certification. Recommendation * Enforcement for over-exposures (welding). Ongoing medical surveillance. Compliance with Alcoa medical protocols. Eliminate unapproved respirators. 962356 0087 OCT 15 '91 09=58 H-C INDUSTRIES P. 40 VI. INDUSTRIAL HYGIENE & MEDICAL SURVEILLANCE F.Hearing Conservation Rating - Fair New hires - baseline Baseline audiometric listing. Noise surveys conducted. Noise signs posted. Noise program written. Training. Recommendations Complete noise evaluations Annual audiometric testing. Noise abatement plan needed. 962356 0088 OCT 15 '91 09=59 H-C INDUSTRIES P.41 VI, INDUSTRIAL HYGIENE & MEDICAL SURVEILLANCE H, Health Hazard Control Rating Fair Critical jobs evaluated. Toxic materials may exist. Material substitution (lead). Engineering controls needed (welding, grinding). Engineering controls implemented. Recommendations Eliminate toxic materials. Project safety reviews. Engineering plan. RFA's noise. Evaluate skin absorption. PPE chemicals - corrosives. Maintenance of local exhaust ventilation. Welders without respirators. 962356 0089 OCT 15 '91 09--59 H-C INDUSTRIES P.42 m WORK PRACTICE CONTROl ft A. Effective Safety Rules Rating Poor No evidence of group input. Recommendations Include committee members, job levels or assign a special committee. 962356 0090 OCT 15 '31 10:00 H-C INDUSTRIES P.43 VII. WORK PRACTICE CONTROLS B. Contracted Services Safety Batina * Poor Program not yet implemented. Recommendations * Approve written plan and fully implement. * Also, carefully implement the mandatory standards. 962356 0091 OCT 15 '91 10:00 H-C INDUSTRIES P.44 VII. WORK PRACTICE CONTROLS 0. Job Safety Analysis Rating Poor S/R has completed some JSA's but not effective (notebook). Very little to no JSA activity in the remaining plant(s). Recommendations Develop JSA list (Sell Core). Develop JSA's for most routine and non-routine jobs in each department. Use PJO's to update JSA's. i 962356 0092 OCT 15 '91 10=01 H-C INDUSTRIES P.45 V/l. WORK PRACTICE CONTROLS D. Equipment Safety Analysis Rating Poor Very limited activity and usage (S&R). Recommendations Develop ESA job list for most routine and non routine equipment in each department. Construct ESA'a using hourly involvement. Update while performing PJO's. 962356 0093 OCT 15 '91 10:01 H-C INDUSTRIES P.46 vtl. WORK PRACTICE CONTROLS E. Planned Job Observations Rating - Poor Lacks formal observation program that requires task observation (JSA/ESA) at some required frequency by supervising personnel. R ecommendations Implement PJO Supplement with Duponts Stop Program and/or B.S.T. 962356 0094 OCT 15 '91 10=02 H-C INDUSTRIES P.47 VII. WORK PRACTICE CONTROLS F. Special Safety Standards and Operating Procedures Rating Fair LO/TO and emergency guidelines are in place (have other plans ready but not yet approved by Management). Recommendations Pending plans to be approved/implemented. Develop OSHA Electrical Training procedure and annual electrical survey. 962356 0095 OCT 15 '91 10:02 H-C INDUSTRIES P.46 VIII. TRAINING A. Training Plan Rating - Poor Lack of formal training plan. Recommendations Identify areas of needed training for plant-wide and departmental assistance. Schedule an annual calendar to include who, when, type of training, and completion date. 962356 0096 OCT 15 '91 10:03 H-C INDUSTRIES P.49 VIII. TRAINING B. Regularly Scheduled Toolbox/Department Safety Meetings Rating Fair Attempts and attitudes to conduct some department meetings are lacking in frequency (exception T.H.E.) and planning. Recommendations Conduct on regular basis. Written outline of annual topics Topics meet plant's needs 962356 0097 OCT 15 '91 10:04 H-C INDUSTRIES P.50 VIII. TRAINING C. Special Training Efforts Rating - Fair Limited special training is available for emergency response, first aid, and corporate sponsored activities Recommendations Provide very proactive special training for emergency response, hazardous materials, defensive driving, back to school via national safety council, local universities, and OSHA sponsored courses. I 962356 0098 OCT 15 '91 10:04 H-C INDUSTRIES P.51 VIII. TRAINING D. Supervisory Training Rating Fair Some training is provided/offered to supervision Recommendations Provide additional time and training resources to improve critical basics of task observation techniques. 962356 0099 OCT 15 'hi 10:05 H-C INDUSTRIES P.52 VIII. TRAINING E. Core Training Rating - Fair Most supervisors, have received some core training but records are incomplete Recommendations Provide effective and timely core training for new supervisors * Provide refresher core training for all supervisors Maintaincomplete training documentation 962356 0100 OCT 15 '91 10:05 H-C INDUSTRIES VIII. TRAINING F. New or Transferred Employee Orientation Rating - Poor Training is informal Recommendations Develop a formal program to include: Checklist of items to cover Resources for quality presentation Suitable place void of interruptions OCT 15 '91 10:06 H-C INDUSTRIES P. 54 IX. MOTIVATION A. Formal Indexes For Monitoring Performance Rating - Fair Do not collect/analyze injury statistics for off- the-job and contracted services. No formal schedule for departmental audits. Recommendations Regularly conduct departmental audits and document findings. Collect and analyze off-the-job and contractor statistics j Safety Department should confirm results of departmental audits on regular basis. 962356 0102 OET 15 'hi lu: 06 H-C INDUSTRIES F'. 55 IX. MOTIVATION B. Fair and Consistent Enforcement of Safety Rules and Work Practices Rating - Fair No consistent enforcement of corrective measures No written policy on enforcement Line management responsibilities for corrective measures not clearly defined. Recommendations Policy endorsed by both union and management should be written and communicated. Line management responsibilities should be written and communicated. I 962356 0103 'XT X '91 10:07 H-C INDUSTRIE' PXb IX. MOTIVATION C. Safety Awards/Incentives/Contests Rating Fair Awards/incentives/contests not consistently offered. No formal communication system to promote ideas. Recommendations Create consistent program. Develop a formal system of communicating safety recognition messages. I 962356 0104