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REPORT SAFETY DEPARTMENT YEAR 19 4 7 This is a report of the Director of Safety for the year 1947. It covers the activities of the General Office Safety Department in It's work with the manufacturing and cosmercial divisions of our company. There was no similar report made for the year 1946. This in part was du to the fact that I was not assigned to this position until the middle of June, 1946, and did not devote my full time to it m*t.n October of that year. Consequently, It was not practical for me to attempt to compile such a report but of necessity, some of the activities of the latter months of 1946 will be entered in this report. During the last six months of 1946, ve continued to function in a similar manner as far as we were able to determine as had been the practice prior to this time. However, our monthly and quarterly reports vers delayed due to not having any stenographic force until the latter part of October, and these reports lost whatever value they might have had due to the time elapsed before being issued. Having been engaged In industrial relations work in the Chemical Division since January, 1941, it was necessary for me, in assuming this position, to deter mine the functioning of the safety department in it's relations with the various units of our company, other companies and organisations. In order to gain first-hand knowledge of the organizations, for safety and fire prevention in our plants, it was necessary to visit most of the operations with which I was not familiar. This survey was very enlightening coming as it did a short time after the end of the war, during which period the morale of the em ployees suffered greatly due to the general let-down in employment procedur s, plant physical and housekeeping conditions and enforcement of safety rules and regulations. This is not to assess blame against local managements as I was very familiar with the labor situation during the war years. In some plants, there was no safety organization functioning as such. In others, personnel responsible for safety activities has been changed necessitating induction and training. Seme organizations bad expanded during the war years and seme were continuing to expand. It was apparent that we needed practically a reorganization of our safety and fire prevention program. No program can be successful without the Interest of those in authority whose organization it will affect and the cooperation of such officials in pro moting and backing the program in their respective organizations. I am very grate ful to the Vice Presidents of our various divisions, others in Executive positions in our general office and the managers and superintendents of our individual or ganizations for their interest and cooperation, without which it would have been impossible for this office to function. SL 102834 Safety R port Page 2 I do not consider It the function of a staff organization to attempt to conduct or operate at the plant level. Consequently, In setting up a tentative program, I endeavored to keep In mind the staff function of coordination of activi ties, correlation of Information, counselling, analysing, advising and rendering all assistance possible. In setting up a tentative program, it was necessary to take Into consider ation the general organisation of our company, which is comprised of two main divisions, the Manufacturing and Couserelal. The Manufacturing division Is split into four sub-divisions, namely, Glass, Paint, Brush and Chemical. The Couearclal division has two sub-divisions. Warehouses and Stores. In these various aub-dlvisions the Individual organisations are confronted with hazards incident to their own operation. However, most of them have a coMon exposure In general maintenance and labor work. Individual organisations vary In size from $6 employees to approximately 4100 employees. There could be no standard safety organization which would Amotion efficiently in all plants* Consequently, it was necessary to develop a program broad enough in scope to cover all operations and flexible enough to meet the demands of the individual plants. Following Is an outline of the tentative program formulated. 1. To acquaint management with their responsibility for the safe condition and operation of their plant. 2. To assist management in all educational and promotional activiti s. 3. To organise each plant In a manner suitable to that plant. 4* To maintain channels of flow of safety material to all concerned. 5. To assist management in building up and maintaining a high state of morale through plant Condition-Reduction in lnjurlea-Improved employee services and working conditions. 6. To assist management in the development of guards, safe practices and body protective equipment. 7. To create spirit of friendly competition. 8* Standardisation and enforcement of safe practices and policies. 9* Improved first aid and medical service where neoeeeary. 10. 4 continual and practical program of housekeeping and fire protection and prevention. 11* The elimination of or protection from Occupational Disease hazards* 12 . The development of manuals. Safety Report Pag 3 Operating under this tentative program, I wish to make the following comments regarding these various topicsi 1. We have continually stressed to management their responsibility In furnishing and maintaining safe practices throughout the plants. In the letter accompanlng the monthly reports, we have continually called this matter to the attention of superintendents and general managers, and on my visits to the respective plants, we have discussed some of the state regulations, Insurance regula tions and company policies* On several occasions, I have attended meetings of the general safety eonltteee, foremen's committee meetings, plant policy coamittee meetings, and several dinner meetings of foremen at which I have given talks regarding the safety program of cur company, and In all of these talks have tried to be specific In assessing responsibility for compliance with all rules, regulations, state codes covering safety and fire prevention as a direct function of local management. 2. On plant visits It was apparent that some of the organisations did not have literature covering the latest In safety and fire prevention pamphlets and consequently, in order to build up the files In all of our manufacturing operations, the following Information was fur nished to them. A complete set of Factory Mutual Loss Prevention Bulletins national Fire Protection Aso* book on Industrial Fire Brigades Training Manual bound volume of Industrial Data Sheets from tbs national Safety Couneil Accident Prevention Manual for Industrial organisations from tbs national Safety Council bound volume of Manufacturing Chemists' Aso. Data Sheets Where volumes are loose leaf and other material Is supplied period ically these books are kept up to date through distribution by this offlos. We have also furnished moving picture films, slide projector films, posters and other Information to all organisations in order to assist them in their educational and promotional activities. <=>v Safety Report Page 4 3* In most of our larger plants, & definite safety organisation existed and In most of then a safety program was being carried on* Other plants had safety men but no safety comlttee program or any defin ite outlined program* In discussing safety organization with the local plant managers, I hate stressed the necessity of a definite program which would be followed in their organization and 1 have suggested the holding of meetings from the top management standpoint as a general committee meeting, meetings with foreman and the plant Safety Xngimeer, and department committees or plant representative committees according to the size of the plant and the else of the various departments. 4s a result of these suggestions, we now have ocwittee organisations in some of the plants that did not have them before, and some that had previously had them, but had not kept their meetings up for some time, and I feel that with the revival of these meetings, we will get much better results In these respective organisations* 4* Ve continually mail various safety and fire prevention literature to all organisations which we feel would be instructive and may assist them In their activities* Such material would Include booklets, posters, pamphlets, codes, and any reports which we may obtain from our plants or other plants, and which ve determine should he called to the attention of all plants of our company* At present ve receive reports from some of our own plants on occurrences which they feel ve may wish to broadcast Immediately to all of cur organisations, and this spirit of cooperation on the part of the individual organi zation Bhould bring us good results* 5* VS have continually stressed housekeeping conditions, sanitary con ditions, improving wash and toilet room facilites and the reduction In injuries as the beet means of building up a high standard of morale among our employees. However, In this respect, ve must depend upon the employee for their cooperation In helping us to maintain good conditions in our plant, and for compliance with rules and regulations which will assist us to reduce Injuries* 6. In most plants where a safety engineer has been employed, most f the machine guards have been taken care of hut in some plants especially woodworking plants, ve do need protective guards at point of operation, and as yet I have not been able to convince some local managements as to the necessity for such guards* In sons of the smaller organisations, and also In some other organisa tions where new man have been assigned to safety work. It has been necessary to give more assistance and education for compllanc with state and insurance regulations and company policlee as regards mechanical guards and furnishing of body protective equipment* V have also assisted, and at present are working, on the devel pment of safe practices and improved body protective equipment in our various organisations. Safety Report Page 5 7. As of January 1, 1947, we made a change in cur monthly reports endeavoring to give fullest coverage td each division, sub-division, and individual plant. In so doing, it was our idea that we would stimulate competition between the Individual plants of a division, or sub-division, and also create additional Interest of the Vice Presidents in the standing of their respective divisions. In the plants, we have continually stressed this point of friendly competition, and have asked most of them to endeavor to create this same spirit from a department standpoint. Some plants have done this in the past, and have obtained vary good results, and X feel that the plants just starting to do so will benefit. 8. Throughout the various divisions and the individual plants com prising them, there has been very little standardisation of safe practices except in outstanding or hazardous jobs. Also there has not bean standardisation of enforcement policies as regards com pliance with safety rules and regulations in regards to methods of proper performance and wearing of body protective equipment. We have attempted to improve this condition through meetings of safety engineers in identical plants in our company. In Hovember, we had a three - day meeting at our Works #9, Crystal City, Mo. plant with the safety engineers from Works #1, Works #4, Works #6 and Works #9 and myself present at which time we discussed various parts of our safety program covering meetings, housekeeping, standardised safety practices, enforcement procedure. In December, we bad a similar meeting at our Works #11, Kt. Vernon, Ohio plant, for the safety Inspectors from Works #10, Works #11, and Works #12 and syself. I feel that much good has been accomplished by having these meetings and discussing our mutual problems in the glass plants, and that by a continuance of these types of meetings, we will be able to obtain some degree of standardisation in our safety policies and practices. I hope to continue these meetings and to also cover the other divisi ns of our company. We have In our Crystal City plant and Creighton organisation set up a policy of definite equipment to be worn on certain occupations and a disciplinary procedure for failure to comply to such regulations. Where it is necessary, I feel that we should extend this procedure. However, at the present time 1^ is not feasible to do so in our window glass plants due to tW unions existing in these plants, one of which, the Cutters' league, has never been convinced that the wearing of protective equipment is obligatory on certain jobs. SL 102838 Safety Report Page 6 However, 1 an still pressing this natter and hope same tine in the future to be able to control sane In our plants the sane as we con trol the wearing of equipment on Ben in other organizations* 9* In most of our large organizations, ve are very well equipped from the standpoint of first-aid hospitals located in the plants, and in nost instances the doctors who take care of our injury cases are on call, when an emergency exists. We have equipped the first-aid hospitals at the suggestions of the local doctors and upon the request or suggestion for additional equipment, seise has generally been procured* In the larger organisations, we have registered nurses who, according to the operating schedules, way work only the day shift or any work the three shifts giving fall coverage seven days a week - 24 hours a day. In our glass plants, I would say we are very well taken care of from the nursing standpoint, but in sene of our smaller plants, we do not have first-aid rooms, as such, nor do we have nurses even on the day turn* Since some of these plants have been in operation for years, and have never bad nurses* service they feel it is not necessary to have It. It would be ny recommendation in those plants where we deaa It necessary, that this service should be Installed. I feel that In practically all locations, the doctors handling our work are very competent, and have rendered us excellent service during tines of emergency. There nay be one or two instances where we are not com pletely satisfied with the doctor handling our work, hut I feel that In the future, this matter can be straightened out In cooperation with local plant management. 4s regards our physical examination program, most of our plants and organizations have had pre-employment physical examination and recbeek examination for specific operations. However, thia has not been the case in our Brush Hivision. In the laene, B. H. plant, ve have no physical examinationa and In the Baltimore plant only the colored applicants were given examinations. This matter will no doubt be corrected in the future. 10* Ve are continually stressing the need of a practical program of house keeping in all of our plants, and I do feel that ve have made progress in some organizations. However, we still have a long way to go in getting our plants in the condition In which ve feel they should be maintained. Ve have stressed the point of eoamlttee Inspection and attention to recommendations which would not only Improve the condi tions in the plant but would also assist us in buidllng morale. Although the fire protection and fire prevention program was formerly handled through the Insurance department of our company, I have con tinually pressed this point In all of my dealings with local management as I have found in many instances our fire protection program had lagged very much during the war years, and ve have been very fortunate that no serious fires have occurred. In many instances, the safety engineer or Inspector in the plant Is also in charge of fixe prot ction and we have worked together during my visits making a complete loo*' ' n i Safety Report Page 7 of the fire equipment in the plant along with our safety inspection. We have made many recommendations regarding additional fire protection equipment. It is my contention that the safety and fire protection program must go hand in hand in all organizations. 11. A survey was made ten or twelve years ago of all of our operations as regards occupational disease hazards, and a follow up has been made in our various organizations from time to time concerning hazards existing. Through the safety engineer in the plants, we are carrying on a program of elimination of dust and tone hazards In order to give protection to our workmen. Exposures are probably greatest in our paint. Glass and Chemical plants. The Glass plants have a silicosis hazard, the Paint plants have lead and solvent exposures and the Chemical plants, solvent and other chemical compound exposures. Various surveys have been made in our plants by the Industrial Hygiene Foundationas we are a member company of this organization, and recheck surveys have been made to determine the effectiveness of compliance with their reconzendations. The Foundation has also done a lot of work for our Barbdrton organization in the matter of toxicity to various chemicals, during the stage of research and devel opment work. The Information secured from the Foundation Is not only sent to the plant requesting the investigation or research, bat Is dent to the various divisions of our company where there may be similar exposures. We have never been able to develop a satisfactory set up for "stone dressing" in our plate and window glass plants and it has been necessary to attempt to enforce the wearing of respirators when doing this job. However, we are still working through our engineering department, and we hope to be able to control this dust so that men working on this occupation for an eight-hour period will not be forced to work in a dust-ladden atmosphere requiring the wearing of respirators. 12. Ve have assisted the local plants on many instances in taking care of special jobs occurring in their respective organizations. This has been necessary in many of our plants do to the fact that we have never had a complete set of safety manuals developed by the company, and in most plants the safety library has not been kept up to date. Ve are at the present time developing the following manuals for use in plants where same are applicable: Industrial Truck Drivers' Training Manual Overhead Crane Operators Training Manual Automobile Drivers* Manual Safety Hand Book for Foremen and Supervisors revision of Safety and Insurance Manual c,V Safety Report Paga 8 Ve have worked very close with the engineering departments in the Glass, Faint, and Chemical divisions reviewing blueprints and plans for new Installations and revamping of the old installations. In the chenieal division this was especially true with regard to the new organic chemical plant installation in Mew Martinsville. Special conferences were held with insurance company representatives, the engineering departBents of both Barberton and Hew Martinsville, representative of the personnel department in Hew Martinsville and myself to review all suggestions and recommendations aade in connection with safety and fire prevention applianc s to be Installed and fire equipment and safety equipment to be purchased for this entire project. This office has supplied such information for the handling and storage of Benzene, said information being secured from other companies and organizations who are familiar with the h**mnwg of and the hazards incident thereto. At this tine all the engineering on this job is being done in Hew Martinsville and ve are following same closely with their engineering and personnel department. Ve realize that this is one of our first ventures in the organics field and consequently, wo do not wish anything left undone which nay refleet unfavorably through accidents or fires after we start operation In the glass division, our oontacts have been with Mr. K. D. Bole, chief engineer, and many of his assistants who were working on special jobs In the various plate and window glass plants. In the glass division, Mr. Bole has appointed Hr. H. V. Gardner electrical engineer to work with us on dost and fume control in the glass plants. Since Mr. Gardner has been working on the various projects is the different plants over the pest several years, he la very familiar with our problems and ha and 1 have worked very close together in some of our dust problems In connection with stone dressing In the glass plants. In the paint division, ve have worked with their engineering department on the various installation in the paint plants and our contact has mainly bean through Mr. T. V. Griffin and Mr. P. 8. Kmtdsen. This work has mainly been from the fire protection and ventilation standpoint. i Oar work tith the Pittsburgh Coming Corporation has been very pleasant They have complied with a number of suggestions and recommendations mde to them during my visits to their plants In Port Allegany, Pa. and Sedalla, Mo. The Sedalla plant started operation in July, 1947 lm the production of glass blocks, but the foam glass plant was still under construction and will not be ready far operation until probably March or April of this year. Our surveys in these plants also covered fire protection and ve aade a nustoer of reooameadatiane concerning first-aid fire protective equipment. These plants do not have a first-aid room as such, and do not have nursing service but I anticipate that some time in the near future ve may be able to impress them with the necessity of this type of service due to the number of employees that they have in their organization and the benefits to be derived from providing sueh service. Safety Report Page 9 Oaring the past year, I have attended a number of nestings of the board of directors of the Veetera Pennsylvania Safety Council, of which I an a member, and also the neetings of the Executive Committee of the A-sariean Society of Safety Engineers, Western Pennsylvania Chapter, Safety 'erencea attended were the National Safety Congress held in Chicago, All-Ohio Safety Congress held in Columbus, Ohio, Western Pennsylvania Safety Conference held in Pittsburgh, Industrial Hygiene Foundation neetings held in Pittsburgh, and the organisation nesting of the Glass and Ceranle Section of the National Safety Council held in Columbus, Ohio. This gave ne a cross-section of the various programs in localities where our plants are located besides the overall Congress held in Chicago. The speakers and subjects at sons of these neetings are the sane as at others, hat the contacts made with safety engineers and directors from other organise^ tions st sene of these nestings Is very much worthwhile. In attendance at sons of these nestings wore also safety engineers and inspectors from our local plants in the vicinity of the city where the safety conferences ware bald. Through ny connections with the Western Pennsylvania Safety Council and the American Society of Safety Engineers, I have aade many contacts with local organizations and companies regarding safety, hygiene and nedloal practices In their respective organisations, and I have also fully cooperated vith these men when they requested information or data regarding any of oar practices or policies. contacts with tbs various state departments of labor, inspection bureaus or workmen's compensation bureaus have been very congenial and cooperative and 1 have at all times tried to work with the state men in assisting them on any matters requested. Comcrcial Division My personal contacts with men of the ooenwrolal division has mainly been in our Pittsburgh office as I have not attempted to contact tba various managers and superintendents of the warehouses or stores, lbs man In cur Pittsburgh office have been very cooperative with me in matters pertaining to their respective divisions. We have continually sent safety posters and other literature to all of our warehouses and stores together vith reports on automobile accidents occurring in the commercial division. We ere campaigning against the incidence of automobile accidents among drivers of our trucks and automobiles, and I feel that vith the in terest taken by some of the warehouse managers, ve will be Able to make a better showing in the future. During the year ve revised the safety manual for use in warehouses and stores and through the cooperation of Mr. G. E. P. Wright ve disbursed between 250 and 300 copies of this manual. Ve are continuing to furnish ther material for inclusion in this manual, and as we develop new material it will be forwarded to the various warehouses and stores in order to keep their manual * up-to-date. * Safety R port Page 10 With regards to the results of our accident prevention program for the year 1947* At the time of writing this report, I do not have the figures frost all the plants. In order to give the exact rates in frequency and severity* An approximate figure for the year would be about 41 million hours of expobut , total number of lost time injuries occurring A03, giving us an accident frequency rate of 9*8* This gives us an approximate redaction in frequency of 1% over 1946* Due to the fact that at the year's end the respective organisations must give us an estimate on the ''open" cases, as to how many days they will lose in the year 1948, and since we do not have this figure, it is Impossible to give any approximate rate from the severity standpoint. To make an exact comparison of the figures of 1947 with those of 1946 is impossible as during the year 1946 there were only 26 organizations shown on the report while during the year 1947, we have included our general office organisation. Southern Alkali Corporation and other new organisations which have been brought Into the Pittsburgh Plate Glass Company and new plants which have started up during the year, and In December of this year we are listing some 34 units* However, for the year 1946, we showed an exposure of 33,631,842 man hours and the estimated 41 million hours of exposure shows an increase of 22$. This increase is not only due to new organisations being listed but also due to the fact that a number of the older organisations have expanded during the year. Increasing the nueber of employees* Tbs yearly accident summary report should be completed same time in the first pert of February and at that time, we will furnish a copy for attaching to this report* Far the year 1948, our program should he along the same lines as during the year 1947, as I feel that we have included in this program, tbs basic elements of safety and fire prevention work* I feel that we have created through the past year a safety consciousness in all of our organisations and an incentive to d a better Job in accident prevention and housekeeping* As has been stressed through the past year, we can he materially assisted by the promulgation and Installation of procedures of job analysis, job methods, job training, induction training and follow-up. In all of my contacts, I have stressed these matters and feel that our personnel departments in our plants realise that they can do a meh better job through these procedures not only from the standpoint of safety hut also from the standpoint of building up employee morale, and doing a better job in production* To sum up my program far the year 1948 - Engineering - Education Enforcement - with plenty of enthusiasm Injected, should bring us much better results and give ub a much more favorable experience than we have had in the past years. TRD/aeo Respectfully submitted. /> .1 Thos. R. Donoghpm7 Director of Safety SL 102843