Document Vnxn3MoNVwQg4NmzDDYGR43w

* i PROGRAM EVALUATION SAFETY AND PLANT PROTECTION PORT ALLEGANY PLANT - PITTSBURGH-CORNING CORP. JUNE 15-19, 1964 L % NOT A RECORD .OF V- *j, ' , , 'j 4\"*"* ?' ,4v * ' V i * t '* s< . , / n . ' , . V . ,}sjl r- J ,-4r;. :> '; T-- '. ' ...rW#5T - ! : ..j -,j; *; .v<v!,'c> `4Mj--`.'-v^~^Ia*y-3rT: - - 7 BB 0008616*7 : ;.: >' : -. f vl' ` iV.F SAifeiS, ' %t `t - SAFETY AND PLANT PROTECTION EVALUATION Port Allegany Plant Pittsburgh-Corning Corporation Week June 15, 1964 TABLE OF CONTENTS Capsule Sunnary . Safety Program and Organisation . . Safety Supervision ........................... Managerial Support .................................... Training .......................................................... Medical Program .... ....................... Fire Protection ........................................ Security............................................. Disaster Control ........................................ Vlant Tour ................................ Numerical Evaluation ...................... 4 5 5 6 7 7 8 9 10-13 13-17 -?/,'11' , ' V*> ' ` ^ V*,f,',If.,, . . ' .-,, THIS DOCUMENT WAS N BY PPG INDUSTRIES, INC. , r - .. ,r.i" e. *i\" . ""J'.t*.. "v . -*.r 5P .'A- v I...S , 1 S*1" -1'- \ ' '* : ' . > * ihwiW' rft> ,* (*' ' ' 0-4.' ,1 ,> '' '/ y- tjlL 1 ^V' /V> V-*"' *`"f '\VVv,' v ' v t w- SAFETY AND PLANT PROTECTION EVALUATION Port Allegany Plant Pittaburgh-Corning Corporation Week June 15, 1964 THIS d0C* COME FROM E Ind CANNOr BE authenticate CAPSUU SMWtT ITS n^JSTO1ES, INC. The writer made a complete evaluation of the Safety and Plant Protection Programs in effect. In addition the plant staff, in a Management Safety Committee meeting, personally evaluated the plant performance according to their individual appraisal and with tne aid of a numerical evaluation score sheet. This was not used for the writer's evaluation of the programs, but is a guide for future plant ur^. During the visit the Industrial Relations Manager, his assistant and the Fire Chief were interviewed in depth. The plant manager was interviewed and a detailed plant tour was made, all in addition with meeting in a two-hour session with the Management Safety Committee. The tour findings, the numer ical evaluation and detailed phase evaluation are found later in this report. Some of the readers of this report will find the capsule summary a quick review of the phases of the programs investigated and the highlights of the recommendations. For details, see the report which follows. SAFETY PROGRAM AND ORGANIZATION An incomplete chain of communications found, which does not reach from the staff to the employee and in reverse. Meetings and/or contacts are recom mended. SAFETY SUPERVISION Found to be. incomplete and lacking in adequate coverage, A third man to use at least 75% of his time in safety is recommended. vv - A..'. .,v. MANAGERIAL SUPPORT - ' \ ,.jy**-;.-a, 11 r Not enouehffidadership has been injected into the program. The manager now heads t hejjin^ebamit tee and will do more, if asked. The above recommended addition'ml^^other man to head safety will bring this about. It,is recom mended thMB^^|upervisory appraisal program with safety as a major element, be establr.; l. ' 4 ; TRAINING S~t . *'V *' >S- 1 ' 1 ... , ' , No basic supervisory training,in safety is being done. It .is recommended that one be started immediately;' One training plan has already been mailed. The Observation Perception program is recommended for future use. .v / ft"- A ' 'tsVV, '-i "> cri>SJ A-I H- ' . L T | BB 0008618 | ? \ .w :' i. * 4 *'l$ i . - ?V : 'hfv 2 MEDICAL Pre-employment physicals were found to be incomplete and periodic physicals for certain job holders have been discontinued. Complete blood counts, tetanus antitoxin are recommended for pre-employment examinations and the periodic examinations of some current employees should be re-activated. Complete recording, control, and retention of minor injury records are reccmended. FIRE PROTECTIOH Good as far as it goes, but it does not go far enough. Recosnded that the night shifts be organized. SECURITY Security is lax. Tightening up in many areas recommended, particularly in regard to lighting fence areas at night. Locking the railroad gates at all times and a separate gate for contractors (in the event of his men striking) are also recommended. ,. * 'i | i a DISASTER COMTROL Other than a written program, nothing has been done. It is recommended that training of squads be instituted, a chain call-in list developed and two drills per year scheduled. PLANT TOUR 1 A laxness is evident in guarding in some areas. A detailed list is located later in this report;} SAFETY AND PLANT PROTECTIOM EVALUATION - (Numerical) -* This was done by the'plant management comaittee. It was not used for the foregoiM^teterminatiohs.: Comments and the . average scores are found later in v:,:;.. . *?-- r.>' _ ' ^ ` ... ( ' ' ' . . : } . ' , I'M' ' ACCIDENT STATISTICS TLIIO ` i' - ; --;------------------------------- THIS DOCUMENT WAS NOT A RECORD OF 4' PPG INDUSTRIES, INC..DID NOT COME FROM Frequency = Disabling Injuries x 1,000,000. IT S FILES AND CANNQT BE AUTHENTICATED I ----- Man Hours Worked------ -------W PPG INDUSTRIES;:INC.. . - ' , ? F 4;r i-' ' ^ *.1 ; i. ;., J z, }'/ ':;''- - , : : v: '; Severity = Days*Lost x 1;000,000 ` > l'' * * Man HoursWorked ; .c";! ( ..-.'.A-'.*;- .. v' ; `* , ,* i, * r * * '* '-If ' ** ,r 1 ^ --------*' v..`4. , ... -V - V.TJ\- . ejn. 3 Year 1954 Frequency 9.7 Severity 420 1955 5.2 72 1956 3.2 98 1957 1958 5.9 530 1959 1.0 12 1960 0.9 7 1961 4.0 284 1962 4.3 282 1963 3.4 127 A mixed trend appears in this ten-year accident record. It ia obvious that since 1960 the plant has Maintained a plateau in frequency, with the occurrence of either a serious or permanent partial injury in the years 1961 and 1962. Evi dence points to the need for an extra effort to bring the record down to zero, where it should be. Direct Injury Costs Cost/$100 Payroll Cost/Emp1oyee DIRECT COSTS 1960 1961 $1,411.00 $4,629.00 0.0768 0.2561 4.026 11.266 196 2 $6,170.00 0.3557 13.477 1963 $5,138.00 0.3015 11.811 Four years of direct injury costs are all we have available. Note the trend since 1960 is up -- except for a drop in 1963. Rising compensation rates may account for some of the increase, but no doubt the serious injury occurring occasionally made up for most of the increase. Direct costs are nationally accepted as one-fifth of the total cost which includes the hidden expense due to retraining, nervousness after the injury, lore of production, disruption of delivery schedules, etc.. Therefore, to get a complete picture -- multiply the direct costs by five and interpret that figure as profit and the total produc tion it represents. Follcwing this summary, may be found the detailed comments and recommendations of all phases of the safety and plant protection programs. Clyde C. F.uddick. THIS DOCUMENT WAS NOT A RECORD OF PPG INDUSTRIES, INC. DID NOT COME FROM IT'S FILES AND CAN NOT BE AUTHENTICATED . BV PPG INDUSTRIES, INC. "V'./ , ' ; ; - , ' , t7 ' ' - *,> .\l, , 7 , ' / i-V?. :,,;-A--V' *'''V.. \ ' -v r } BB 0008620^ , ; r-t ' v .V l `--l *> u. > - 'F'-V' ' .Y t ,1M ' vv-M'-'1 %*? 4 PITTSBURGH-CORNING CORPORATION EVALUATION - SAFETY AND PLANT PROTECTION Port Allegany Plant Week of June la, 19to4 SAFETY PROGRAM AND ORGANIZATION A Management Safety Committee functions rather irregularly. The Plant Manager ia chairman and the Industrial Relations Manager acts as secretary. The committee is made up of department heads and the Plant Engineer. No depart ment head or department meetings are held. A union-management committee functions also on an irregular basis. Two union representatives (appointed by the union) and two management men make up the committee which functions, almost exclusively, on a plant inspection basis. The management men on the comittee are the Industrial Relations Manager and one changing foreman per month. About 50 percent of the employees wear safety shoes. Shoes are ordered by mail. A campaign is occasionally conducted with incentives to buy such as 2 pair of sox plus a can of shoe polish plus a chance for every fifty pairs on a transistor radio. The plant is considering the substitution of a Waltham watch for the radio. j J r There are no eye protection programs, outside sign showing "days since", no safety incentive program nor a plant safety rule book. A practice exists of permitting retired employees to cosie into the plant to use tools and equipment. THIS DOCUMENT WAS NOT A RECORD OF V PPG INDUSTRIES, INC. DID NOT COME FROM Recoawendat ions IT'S FILES AND CANNOT BE AUTHENTICATED Managcnt Safety Conalttaa -- BY PPG INDUSTRIES, INC. Li ; ' r'- , A PPG "agenda" form should be used. Form 5342. Meetings should be held monthly on a designated day and at a specified time. ` J' - 'rr 1 - r 1 * * `` ' ' ,'fv^ ,< -x . * , Members^dfclthe consoittee ,should wet with their foremen after each management ~ ~ 11 inaa&llSte'Cj i ' T 11 " Fores , ..v . . r. - lid.hold meeting with their, employees or ute the "Contact Plan" - All of "thie- hbove should be done to complete the chain of comunications' to develop good .safety'attitudes. .... A complete .eye protection program should be installed in the Machine Shop. ""'- * v;y,r:7' A plant safety rule book should be developed. SafeTyishops! should .bestocked . in the storeroom, and attendants'trained to'fit them..-.-?'-' w. -11- > .v;-, -v - - ' An outside sign should be erected (something like the.Wagner sign used in many PPG plants) to shew a simple Safety slogan and how many^days hav elapsed with out a disabling Injury.* , jvC.-,, ; ,, *;V. ' V; . . , k. 'O' ' 1 ' k~,l , A ; , ' v- ,r- v-s v* |* BB 0008621 4 '"/fc 'T'.V' '! '.i-'v-' -:~'J TMS *&' "Jot come moJ fri niK> CANNOT BE AUTHENT.CATED 5 A cleaning service should be set up for respirators used in Unibestos. Each day a clean one should be issued and the dirty one returned at the end of the shift. SAFETY SUPERVISION Two Men are involved in safety to a limited extent. They are, the Industrial Relations Manager and his Personnel Assistant. A breakdown of time devoted to safety follows: % Time Devoted to Safety % in Plant Paper Work fot Safety Industrial Relations Manager 20 5 15 Personnel Assistant 15 0 15 It can be readily seen that little or no ti foremen and employees. is devoted to plant contacts with Injuries are followed up and investigations of injuries are made by botfy fore men and personnel men. Form 5704, "Supervisors Investigation of Injuries"- is used for doctor and disabling injuries. Mo analyses of all iujvfries, Includ ing significant minor ones, are made. Form 5149 (short form for investigation of minor injuries for foremen) is not used. it 3 I * Very little literature is routinely sent to foremen. There is some orientation of new employees by the Industrial Relations Depart ment and littlevor none done by departmental foremen. Recommendatioi ns rl9 A third man should be hired for the Industrial Relations Department.; He should 'spend at least,* 75 percent of?his time on safety. `( 4 - j i- , . -t1 w-.-v'a; t-- - ' . , --- ' \ Analyses .ofall in juries should be made as a basis of discussion in the Manage ment SafetjjGommittee and as a guide'to safety activityw r Form 5149 is recom- mended t6 id' to determine causes of injuries, departments in which: they ; , occur, t on which they occur, etc. i-, r Literature^ ^Be^kS; reproduced'NSC "Five Minute Talks" should be routinely sent' to all fore! \o supplement meeting material. ; , t m:- L.v . A better safety orientation program should be, developed in'both* Industrial ' 1 Relations =and plant departments... ! x h" MANAGERIAL SUPPORT The Plant Manager runs the plant Management Safety 'Committee, injects himseIf { ' ' > in the investigation of disabling and doctor injuries an<f anything Ise he is f- asked to do. The limited time spent on safety by Industriel Relations limits V:7 requests for his help to a minimum. " . v -- ft,v this document was not a record of PPG INDUSTRIES, I NC. DID NOT COME FROM 6 IT'S FILES AND CANNOT BE AUTHENTICATED BY PPG INDUSTRIES, INC. There is no formal program for the manager to interview foremen who have doctor and/or disabling injuries. Few, if any, plant visits for safety are ma^e. Any supervisory appraisal program in use does not use safety as a major element. Recommendations The manager should insist upon being asked to inject his leadership into the safety program, more often. All foremen having doctor or disabling injuries should be privately interviewed, after being fortified with all facts of the injury. More visits in the plant for safety should be made. This is a good impact for attitude forming. A supervisory appraisal program incorporating safety as a major element should be adopted. / ? TRAINING * No basic training in safety has been given to supervision. In first aid training, 18 foremen were given the Red Cross Course about four years ago, but no refresher training has been offered. Employees have not been giv.n first aid training. It was agreed to send a delegate to the Glass Division, Observation Perception program to be given at Works No. 14. Recommendations --i ' v'- . , , '* A controlled home study'course in basic safety for foremen for all supervision is proposed^. Control by assigning lessons with a deadline for completion and a once a month discussion of lessons covered Is recommended *\th this or any other home study course. - ', ; . The forep[swho had first aid training should have a refresher course. fire b^^^^Kmbers should be given the basic training. ' All ' Mouth-fb^miput^^tesusicitatioin training should be given all; foremen and offered ` to employee's.`` ;. ' / . \ External .heart massage training should be incorporated in all first aid training. All employees should be offered a modified first aid training course,> consisting- of the four basic elements: transportation, control of bleeding,. resuscitation and control of shock: ;, j . | BB 0008623 ] MEDICAL PROGRAM THIS DOCUMENT WAS NOT A RECORD OF PPG INDUSTRIES, INC. DID NOT COME FROM 7 - IT'S FILES AND CANNOT BE AUTHENTICATED' -' BY PPG INDUSTRIES, INC. The pre-employment examination of new employees includes - strip physical, chest and two back x-rays and a urinalysis examination. Mo blood count, typing, RH factor or serological examinations are given. There is a hospital in Port Allegany where the injured are hospitalized, except for specialized care. Four doctors are used on a fee basils; however, one of them is used more frequently and he has visited the plant, on occasion. There is no dispensary in the plant and thus no attendants to administer first aid. There are five first aid kits in five locations, all under the control of foremen. Little or no effort is made to record or investigate minor injuries. Form 1549, "Foreman Investigation of Minor Injuries", is not used. Periodic Physical Examinations - All periodic examinations have been discon tinued except for the batch and other employees having a chest x-ray by the county mobile unit, annually. Recommendations The very nature of some operations and the shifting of employees due to seniority indicate a blood count should be made of all new employees. It would then be 4a simple matter to also do serological, typing and RH factor examinations. It would be well to consult with your plant physician about this matter -- making sure to stress the exposure to T.D.I. and solvents in the polyurethane foam department and the need to keep from hiring infectious syphilitic applicants. The plant doctor should be consulted about the advisability of installing a tetanus toxoid program for all current and new employees. Better control of recording first aid injuries should be instituted. Legal opinion indicates these industrial injuries should be carefully taken and retained for a ten-year period. The information needed is --date, name, department, injury number, nature of injury, nature of treatment. Foirm 1547, '^Foreman Investigation of Minor Injuries" should be used and serve .as the basis of .injury ,, : analysis. 1 Periodic Physical^Examination - All foamthane employees should have an annual blood-^ cpllnt'All:,Batch House employees should have an annual "full size" chest * x-rayl bestos employees should have an annual chest x-ray FIP.E A fire brigade bfpllfV.men on the day shift (nany of them.foremen) functions in monthly fire.drilliuilThe,two night shifts are poorly covered except for the fcremen'on duty who fiave, been trained in fire fighting and one guard on each shift. No drills'sre held at night because; it;is claimed;'thework force is too mobile due to seniority. `` V-'"-v There is a fire : loop around the plant and 1250 ft.' of ,2%r rubber^ lined2, fire hose': available. This hose is tested annually with 100#. air; .^Drills in summer utilize water in the big hoses. . ' ", ` V , *r ? -;; v,a ' ' X J "XX | BB 008624 I ,'t. -6- ..ii> LiO-UfviEi-iT WAS NOf A rttwD-.u OF PPG INDUSTRIES, INC. DID NOT COME FROM IT'S FILES AND CANNOT BE AUTHENTICATED BY PPG INDUSTRIES* INC. The local fire company has made visits to the plant and more recently has demonstrated fighting foamthane fires at the dump in view of the fire brigade* There is no formal welding permit system in the plant. The fire chief super vises two welders and controls their activities but three others are not under his supervision. Multiple extinguisher boards are not used. However, extinguishers and other fire equipment are regularly inspected and serviced. Recommendations Second and third shifts should be better organised in fire brigade work and regular drills held. The 2V and lV rubber lined hoses should be annually tested hydrostatically at 150#. A formal welding permit system should be established. Try out one multiple extinguisher board with a view to converting to that type, gradually. Suggest ordering 100% Dacron hose in the future. It is a little more costly, but resists chemicals, abrasion, is lighter and needs no drying after use. SECJRITY Four men are on the guard force mostly controlling the main gate. The night men lock the railroad gates and possibly others which are left open during the day. Security at the maingate may be lax, since the writer was able to drive through and park on his initial appearance at the plant. f - Separate gates are not used for outside contractors. Good.liaison is had , between plant engineer's.office and contractors. Contractors are made familiar with plant safety rules and plant utilities are not touched without permission. Badges are/not required for contracgor's employees. ^\ '* Plantemgloyees do not have badges, nor are they fingerprinted or photographed. It was^^Uted that' nfew. hires are generally well known, reconended and thoroughly. and empty box,cars are not checked upon leaving the plant. Lunch boxes are not regularly examined, LockeriPare not given an inspection. J;.. \ The periphery of the property is completely fenced --,<,two railroad gates left , open allday. Lighting appears to be not too good. On the second and third shifts, the guards are supposed to make four or; five rourds'of the fenced area.; Visitors (salesmen) visit in the factory office and are 'escorted into and out of plant departments when it is necessary for them tcrem.ef,' ~ _ 4. 1; I BB 0003625 M` " -9- THIS DOCUMENT WAS NOT A RECORD OF PPG INDUSTRIES, INC. DID NOT COME FROM IT'S FILES AND CANNOT BE AUTHENTICATED BY PPG IMDUSTRiES. INC. The guard* encountered appear to be above average* There are no written instruc tion* for guard* nor a guard manual. Several of the gaten other than tbe main, were found to be too high whan cloned. Recowwndat ion* Tighten security at Main Gate. Lock raLlroad gates at all times and either provide keys for the rail crews or arrange to open when shifting. Designate a separate gate, with control, for outside contractor* in view of trikes and picketing by contractor's eaployees. Badge* for contractor's employees should be required or furnished. Establish badges for eaployees. Fingerprinting recoaaended for new employees to eliminate criminals in the work force. 1 V Check cargo trucks and empty box cars when leaving plant - a frequent source of theft. Monthly irregular inspection of lunch boxes recommended. Semi-annual inspection of lockers recommended for sanitary reasons. Lockers usually store company tools. A night study of lighting should be sude of the plant property periphery. , A guard's manual or other written instructions should be developed. The ground under high gate and fence areas should be filled in or otherwise closed. - ^ '..-fffv.t , -7' 11 . , -- .i... .. * '.u, dir?. DISASTER'' CONTROL <! J . 0* :* *Ky . . ten is in existence but no training or drill* have been devel ped. V1 : The program -should bei activated. A chain cal 1-in procedure should be developed in the event of a disaster at night 'and training should be-instituted of all /s squads fin preparation for having two* drills annually. ,: :: .$ : <-, . -, ", ;w - /Li' v :; A j . ' -f''. - ' ". '' .. . * 1'.'V ,y\- ' : . :, V: ,w.\'> , ^ > , * i `, t1 '--p' 1 : j,*. ' ,'v . 1f-;-:?'.".' . , . " . .. ` . ' '.Jl 1 08626*7 10 rugL *-*<**-- u> \m BpviMtal aprap paiatlag ( ait kacaaaa at ywlity - awirapray >***** n--iila tra* MU iocr. fatamm IiIUiM mm 4a aot life* mpltalm. (lifTint < tala* mi gaai.) WM nyw ((It* amtaoa aat ally - (lrt Mini - itan iteaiai UtoitM. tlaak paiata aaaO faarOaO (aataiOa apraakata). Magalar aammpar ft (Ftaaa ta laalar) paI lap arpaaaO at atap - karrlar aaaM. lagalar aaaaapaa 01 - tka aaa aaaiUlaaa aa&at. filial aM pm* aartaaa aaa alaaa ta lakr (aaatar at Oapactaatt). mis uuLUivihN l WAS NOT A RECORD OF PPG INDUSTRIES, INC. DID NOT COME FROM IT'S FILES AND CANNOT BE AUTHENTICATED BY PPG INDUSTRIES, INC. MC >t la Croat o< a . ,s 1 at tka akl plla aC kaga at aadiaa aItrata. A wall aaaAad la aaaa at fira (aa epriaklara kara). 14 lalac iigaat. Vatar md kafractorr` ' r. Liaan kaaa OV*> taplaaa aitk 1001 Oaeran r lim4. ' ' , J 4 `'v ! . ' /' ' -.iH'1! A - ' f ' -v't ' .'-.t - .. ' 144 (aorta aai> law* akaU Or&aaa F* '< - 7 s 1 iv t - ` f' ; ` * ' V apt pratactlaa program kata at Cialaklag aatf ta*' paakata aa cattara* . ' v-\ .. v. f . ' v..- . V 1 ' 1 '*r '. / :;/ ' ' .. ,_| _BB 0008627 11 - Balcony ofM at aad used for hoisting. Suggsst spring loaded gsts - chains insffsctivs. A good 10 V vaecm clsansr nay help housekeeping. Kys protectioo aad rubber gloves indicated for aen who charge batteries* Guard off 06 lehr - #b drive. Also 3rd aid Sth oa left aide 05 Lehr. 05 lehr - 1st and 3rd guards off. 02 Lehr - 3rd guard off. Both enpty pea conveyors hews exposed sprockets at loner end of discharge. ,^1, | Roofboard Tar Coating Down draft ventilation needed at taka. Fabricating - Pleat 5 TH|3 DOCUMENT WAS NOT A' RECORD OF PPG INDUSTRIES;, INC. DID NOT COME FROM IT'S FILES AND CANNOT BE AUTHENTICATED BY PPG INDUSTRIES, INC. At spray booth * a snail quantity of 1CK should be kept In a Protoseal caa (beach type - with spring loaded plate for Imersion purposes). i. xposure to asphalt fanes a probable source of toxicity. Vill investigate. -* Please sand identifying anna, grade, coapoeitoa and/or ma*er of asphalt used. Suggest investigating a heavy duty vacuun clean.r for thin area (as well as for Plant 2 - Coming end). An excel lent plastic guard has been developed on one guil lotine cutter - the bach side of blades need additional guarding. The second cutter should be inaedlately guarded along the pattern of the other cutter guard. V Plant 6 :i ;r y-rv; r. Switch ansa cluttered. Planer - V-belt drive Miter shaft - exposed (MOO rye). Open washipg in **- suggest large beach can (Protectoeenl). Cowpliaga be 1W forming and - unguarded. at bulb stecage tank. ;t aisle sidd (1-1 ft.) at squaring sans. , : - . ............. /V i >'1 % { Tool rests an large and naell twin grinders too far fron grinding wheels. . , \ ; 4i '. . .- 1 ; `^ ^ * ,V--\ iy- , "* `"if. Paint of operatian ventilation suggested in welding roan to rod tunes bafst* enter igg the welder** breathing area. costed' >, - r T >. , % * - ; r, -'- . .v ^,-h * l--!L2208628~7 * ' * ' 'vL- * '; ' r 0` ~, *s**V * -* * -* \ * v- : C' v y , r 'V: * { .*./v . *- 1 . * - . Outside - Plant Periphery PPG IN^UsS in^NT A RECORO - 'IT'S FILES AND BY PPQ INDUSTRIES, ,Nc HENTICATED Railroad track, fence area, needs need treataent Little control - during the day, to keep children off preaises at two railroad gates. Three truck gates (possibly railroad gates, too) have high openings at bottom which would permit entrance of children. Fire hazard on west side of Plant S - skids, frames, wood boxes and pallets. Guard drive on fan shaft of dust collector outside of Plant 2. V-belt guarded on outside only, guard inside as well. Plant S - UniU-^tos Plant Identify steps to locker and lunch room with paint - a step-down hazard. | Crusher fan drive; chain drive on saw conveyor; all V-belt drives of cutting f and grinding; sew - have the inside of V-belt and chain drives unguarded. $ Inside at operator's area - stitchers have unguarded drives. Two "builders" have chain drives open. V-belt unguarded on top of "builders". Pressure left "on" on oxy-acetylene unit. Feeders have'*! chain drives on sides - unguarded. Guard couplings on clay mix drives. Suggest rails to guard opening to basement. v'f-' '".-i:" ; ' l .: r' ~*r" 1 < J V * _ ` t:'a ' ' t'- , * , - , SZ ,1 i . - ** .*. 4 ` r ''"ft' t ' . " A BB 0008629 | \ 13 r PITTSBURGH-CORNING CORPORATION EVALUATION SAFETY AMD PLANT PROTECTION Port Allegany Plant Week of June 15, 1964 SAFETY PROGRAM AND PERFORMANCE EVALUATION (a* evaluated by the plant staff on June 16; The attached evaluation was made by the plant management safety committee. It Is an average of the six individual evaluations and does not constitute a basis for the entire plant evaluation. It is intended only to represent the Staff opinion of the various elements in the attached chart and, as such, is a guide to future del ilDe rat ions of the committee in devising and considering programs to strengthen the overall score. It is a device for comparing that plant program, only and is not to be used as a comparison with other plants. The total score of A7.82 is quite low and due to the lack of "Organisation" and "Training" elements, it is recommended that the committee first tackle these two items for improvement. Elsewhere in the plant evaluation report are recommendations for consideration and discussion by the plant conittee. .' ^ The dollar losses tell a significant story when i960 is compared with the years which follow. Clyde C. Ruddlck Evaluation Leader WSTME?^Sn?eAUtHEWICATED. -t &,, W .a -,,;V /, V-kVf? ; "I, '' " `' j i BB 0008630 | ? ' ;?'V. v-' ' ' . >r j- ' . *' 14 PITTS B U KG H PLATE CLASS COMPANY SAFETY PROGRAM AND PERFORMANCE EVALUATION THIS DOCUMENT WAS NOT A RECORD OF PPG INDUSTRIES, INC. DID NOT COME FROM Sefety Program. Eveleetien IT'S FILES AND CANNOT BE AUTHENTICATED BY PPG INDUSTRIES, INC. The numerical values to oe inserted below are the weighted ratings calculated from th attached evaluation sheet -.. the plant or location. The total of these ratings becomes the overoU rating for Possible Score Percentage 1. Organisation and Administration - 9.39 25 38 2. Hazard Control 12.7li . 20 6Li 3. Industrial Hygiene Control - _ 12.58 20 63 4. Training 1.83 15 12 5. Motivation U.88 10 U9 6. Accident and Injury Statistics 6.U0 10 6h TOTAL U7.82 ** Overall plant rating Frequency end Severity Trend 1 Frequency Severity L > Trend 1960 . jj 19 61 0.9 . 7 h.O ; 28U. v' CM CO OJ 19 62 1 U.3 19 63 3.U 127 ' i* ' ' ' ... ... -- c . Y\. jjfwI863 1 If. THIS DOCUMENT WAS NOT A RECORD OF PPG INDUSTRIES, INC. DID NOT COME FROM .2 - is - IT'S FILES AND CANNOT BE AUTHENTICATED . %r: N to: BY PPjG INDUSTRIES, INC. k* 000(1 ' Score 'each --c|.'*K'nt by appropriate rating headinq. 1. ORGANIZATION AND ADMINISTRATION n.11 N> 0N ''1A' c e X - E L *x. t. N A i\ T Comment an "Naas' sad "RniItems Poor Menagemen) Solely Committee 0 & 'u|. 20 6.>s3 Management Safety Committee Meeting Preparation end Follow-up 0 va> V 10 6.13 Stall Safety Supervision Safety Obeervation Program Special Committees 0 r6' '(& 15 y<3> 12 15 0 *0) * 5 9.33 1-33 2.9 Statement of Plant Safety Policy, Posting and Distribution Plant Safety Manual 0 y<P '<> 'CD 5 2.0 8 10 o.9 Federal, State and Local Laws and Regulations 0 ''<D 5 2.9 Safety Standards and Reference Material Line and Safety Staff Communication and Contacts TOTAL VALUE OF CIRCLED NUMBERS 0 'CD *<S> 5 3.5 0 10 6.'i3 x .25 Rating 9.39 2. HAZARD CONTROL Plant or Department Layout, Safety Consultation '<2> J<3> *<S> 10 U.17 New or Altered Equipment, Safety Consultation Machine Tool Guarding ;r ' ^ -V-\ , General Area Guarding-and Illumination/. If ' yd> 8 10 2.00 04 ' 12.50 0 4 4 15 12.00 Mainten< Guards physical Equipment, Tools, ? etc. "rty" ; / Special 'IjWpEfjjjlodlc Plant Safety Inspec^o^^fSeasonal _ or Infrequent Oper. Material Handling Hand and Mechanized 0 V > 5 2.90 5, 0 JCD 'CD 10 5.5o 0 '<D V<8) 7.50 .\ Personal Protect!** Equipment ; Adequacy ond;,Enfecement\,^TvT^s. r;;. -// Public Liability Control'' - Housekeeping ': Storage ^of Materials, etc. TOTAL VALUE OF CIRGLED.iNUMBEBS 0 '<D io. :.7;.i?. '*<) 5 2`.B5 0 '<3> y& ++ !- j., 7.50 ;n- :V-V' A X ,20 Rating 3.2.7L s IL,-. - -. - . ; ;i I BB 0008632 | *. ' . ..* / !T'- T" . . / ViCi' * r 16 Not*: Score each element by circling number located under appropriate rating beading. > 3. INDUSTRIAL HYCIENE Toxic Material Control Flammable and Explosives Control. Storage, and Labeling Ventilation Air Sampling Skin Contamination Control Sanitation Environmental Control - Radiant Energy, Heat, Noise, e:c. Ch mlcal Reference Sheets Utilization of Safe Practice Data Sheets Waste Disposal - Process of Trash TOTAL VALUE OF CIRCLED NUMBERS o Ceaueeet ee `'Nee*' rh--t end "*a' Items Poor U3 21.00 8.67 5.50 12.00 U.17 L.17 8.00 2.67 2.00 . 7.35 -C " t) X - u> 3=2 ^ m O D O --2 cLn. c O c CO oo sZtoO?%m2. 2>L m22 y>z0 _o 5Ho o oo n a 2 O > c 2 O H -t . > IOjj mom 2-3 =!> O O PJ 5^30 O nig O O2m 12.58 X .20 Rating. 4. TRAINING Line Supervision Basic Course Line Supervision Follow-up Training 4 Indoctrination of New or Transferred Employees ( Safety Observation ^Formal Training , v . : ' ' `-ii; Safety Observati^jfe.,follow-up Training ' : V -i'- Job Safety ,' Safety Meeting r\ ` ^ Training for Specialized'Operations-- - ' Fork Truck, Crane, Die Setters, etci * i.. Job Analysis Program f! ' '* Artificial Respiration - First-Aid - 1 :j \ ' y'J.'v, TOTAL VALUE OF CIRCLED NUMBERS 4 12 15 o,,oc 8 10 1..00 *<3> 3(D 'CD 10 2.85 4 (5) 4 12 15 0.00 4@ 3 8 10 .0.00, 0 60) 4 5 1.00 0 *<D 4* 5 6.50 I r. 0 4 <9 10 li.So v@ fin 12 15. 'l.5o 45 +` '0.T8r'5A1 x ,15 '"'PV# Rating i .V . . . -f 5 V 1.83-- --:-------- : * 'V / V : >- '.V *' V'- ''4 - if- "'*. -v -.iV. ' P '?--V ; ;'T > 1 ---. * 1 .-;v,t;t;H_BB^0008633 J /'f-Jt;;."'; T'.' T"i-;>^Vv'Vv ; ^ .. i 'fcfv - 17 - tuiq nncUMFNT WAS NOT A RECORD OF m^SSmS. INC. DID NOT COME.mas rrs FILES. AND CANNOT BE AUTHENTICATED BY PPG INDUSTRIES, INC. N*t*i Score eoch element by circling number located under appropriate rating heading. - $. MOTIVATION Bulletin Board Uee for Safety Item* Special Safety Dieplaya and Demon* trattone Individual Coining Uee of Vieual Aide. Safety Film*, etc. Employee-Foreman Safety Contact and Communication ,, Example Set - By Supervieore Enforcement of Safety Rulee Off-the-Job Safety Activitiee and Promotione Uee of New* or C her Mean* for Safety Articles Local Community and Public interest and Participation V TOTAL VALUE, OF CIRCLED NUMBERS tr. E X H O N C G >0 O D c e L C E H ?,. / T 0 &> O" IS Ce- n e **N ee" < end "RReeSSOtf?f Item* Poor ?.33 '<r y<?j *P *0) 8 4 s 1.M3 10 2.00 5 o.5o 0 3 (tl 15 3.00 0 a? J<|) lu 7.17 0 "d? 10 > .50 0 *<) iD 20 - 0 'G> 5 2.00 '(5) 'CD '<3> L.88 x .10 Rating 6. ACCIDENT AND INJURY REPORTING , . . ' '-4: V-: Maintaining Accident and I.*., R*eo,d*,,f: ' .. 03 10 8.00 1 - - . Medical'Treatmrjtl lnjury 'Reporting ;.a .. Disabling Injtl^Heporting% \ ,A..- ........ , 0 .3 01 10 '3.00 - ''V'- v * 1. : 1 L.17- Js- ' Off-the-Job IoISrSwReportina `-'v'p. * 01 5 Injury Investigation *.by" Safety Staff. 7 Injury investigation by LinePersonnel ~ 0% 3ioo: v^'\ 2. 0 '0 m 35. . .''vw'-..wj *< . , --i , ' V - -i,.',, S, \ .......... .. - Accident and'Injury Cause Analysis- vA - . .P - V V, ^ 7$ & "a> 8 TO' f 'A'' ` P riodic and Special Studies ^ 7Q) % ST'Vl- C Submission of Reports (Completeness,. ;`>'jLL^rA;A 4*4;/' -` U * `> Accuracy and Timeliness) * - r .A' Li i' 3 JSE. M , V-XT? -r :;:k ./-L TOTAL VALUE OF CIRCLED NUMBERS - > -kt. ++ *sr-' .r. x .10, Ratfngh V *, ' 1 -a- < -U: , '