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Session I
THE MAGNITUDE . OF ARMCO'S PROBLEMS (1958-62):
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Chart No. 9/
25 - Fatalities 3 - Permanent total disabilities
209 - Permanent partial disabilities 798 - Temporary disabilities .91, 000 - Noh-disabiling injuries 348, 000 - Days lost
E. THE MAGNITUDE OF KANSAS CITY'S PROBLEMS (1958-62):
Chart No. 10.
'6 - Fatalities 0 - Permknent^t&tal disabilities
54- Permanent partial disabilities
6 - Temporary, total disabilities
21,072 - Non-disablme injuries
76, 374 - Days lost
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We still have a long way. to go before our safety problem is licked. You, as.safety observer, can help.
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-SAFETY OBSERVER TRAINING OUTLINE
SESSION 2
T. The Nature of Accidents (Chapter 2, Section 4)
A. .:THE TWO KINDS OF ACCIDENTS:
Chart No. 11
Accidents are unexpected. If we learn what can be expected and that the unexpected can happen, we remove the unexpected.
Personnel Accidents - Key Elements: $ Unexpected occurrence;
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Time:
Man hours;
Damage: Equipment; Materials;
\ Morale.
D. THE BASIC TYPES OF ACCIDENTS:
Session 2 Page -2-
NOTE: Discuss thoroughly, with examples given, so that abbreviations are learned, and the types understood.
Chart No. 14
1. SB - Struck by;
Object moving - contacts person with force.
2. CB - Contacted by;
Substance moving - characteristics of substance, NOT motion, i's injurious.
3. SA - Struck against;
Person in motion - contacts with force.
4. CW - Contact with;
Person contacts - no force - characteristic of agent is injurious.
5. Cl - Caught in;
Person is trapped in an opening or enclosure.
6. CO - Caught on;
Person or clothing caught on protruding object. 7. CB - Caught between;
Two objects - one or both in motion catches person. 8. DLF - Different level fall;
Slip or trip ends up on different level. 9. SLF - Same level fall;
Slip or trip - ends up on same level.
10. EX - Exposure;
11. OE -
Exposure to harmful substance - no force involved, Overexertion; Excessive strain.
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\\ SESSION 3
The Sources and Kind's of Accident Causes - (Chapter 2, Section 5).
An accident cause is anything and everything that^has contributed to the
occurence of an accident^. ^
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A. ACCIDENT CAUSES:
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Chart No. 15
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1. Actions of roan himself; /
2. Actions of co-workers; /
3. Man's physical and mental condition;
4. Defective or unsafe: /
Tools, equipment; machines, materials,
buildings, atmosphere;
5. Actions-which produuud' the luaTmicnis-"conditions.'
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B. DIRECT SOURCES .OF/ ACCIDENT CAUSES:
Chart No. 16
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1. People; / 2. Environment.
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C. FOUR KINDS OF ACCIDENT CAUSES:
Chart No. 17 .
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1. Direci t. r\oan causes; 2. Indirect roan/causes; 3. Direct environmental causes; 4. Indirect Environmental causes.
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D. TYPES 'OF UNSAFE ACTS:
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An unsafe act is any deviation from a generally recognized safe way of doing a job that may cause or contribute directly or indirectly to an accident.
Chart Noi 18
Operating without authority; Failure to secure against unexpected; Unsafe speed; Failure to warn - signal; Removing,or making safety devices inoperative; Using defective tools or equipment;
(continued)
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Chart No.' 18 (Continued)
Session 3 Page -2-
7. Using tools or equipment incorrectly; 8. Assuming unsafe position; 9. Servicing or adjusting moving or energized.equipment; 10. Riding .hazardous moving .equipment; 11. Horse play - distracting - startling; 12. Failure to wear safety equipment.
E. HOW UNSAFE ACTS DIFFER
Chart No. 19
1. The frequency 2. The severity c
"'t before/ihe accident .occurs; ry when it happens.
\/ F. .REASONS .FOR PROMPT CORRECTION;
Chart No. 20
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1. Avoid habit formation;
2. Avoid losing/respect for the hazard or unsafe practice;
3. Avoid feeling that hazards are over-exaggerated;
4. Avoid feeling of false security.
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SAFETY OBSER VER TRAINING OUTLINE
SESSION 4
The Causes of Accidents (Chapter 2, Section 6).
A personal factor cause of accidents is any personal-characteristic or condition that may cause or influence a person to act unsafely.
A. . CAUSES OF UNSAFE ACTS:
Chari No. 21
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>Lack of knowledge or skills: Unaware of hazards;
Does not know safe procedures; Does not know precautions; Ufi3^derlepen=iri,ind-or~\jody.
Conflicting motivations and attitudes:- (uo /,'7 /
Desire to save time; Desire to save effort;
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Desire to avoid discomfort;
- Desire to attract attention;
Desire to assert independence;
Desire for group approval;
Desiree to express resentment.
Inadequate physical or mental conditions: Temporary - Physical Intoxication; Fatigue; Illness;
Non-temporary - Physical Visual; Hearing; Malnutrition.
Mental Pr e oc cupation; Resentment - anger; Worry; Frustration.
B. TYPES OF UNSAFE CONDITIONS:
Unsafe conditions are any conditions of tools, equipment, machinery, . materials, structures or other elements of a roan's environment that
may cause or contribute to an accident.
Chart No. 22
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1. Inadequate guards and devices; 2. Inadequate warning devices. 3. Fire and explosion hazards; 4. Unexpected movement hazards; 5. Poor housekeeping hazards; 6. Protruding object hazards; 7. Close clearance - congestion; 8. Atmospheric conditions; 9. Arrangement - storage; 10. Defective tools and equipment; 11. Poor -illumination; 12* Noise. 13. Hazardous personal attire.
SOURCES OF UNSAFE . CONDITIONS;
Chart No. 23
1. Production workers; 2. Maintenance workers; 3. Designing and engineering; 4. Purchasing practices; 5. Normal wear and tear; 6. Abnormal wear and tear; 7. Lack .of preventive maintenance.
SAFETY OBSERVER TRAINING^ OUTLINE
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SESSION 5
I. The Results of Accidents (Chapter 2, Section 7). "])/<
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A. TYPES ,OF DIRECT RESULTS OF ACCIDENTS:
Chart No. 24
1. No r.esuits; - * ///'-? 2. Minor injury; 3. Major injury; 4. Property damage.
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B. HEINRICH'S .RATIO:
When a major accident happens, the chances are that the same
accident has occurred 29 times, producing a minor-injury, and
another 300 times producing no injury.
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Chart No. 25
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1 - Major 29 - Minors 300 - No injury
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C. INDIRECT RESULTS OF ACCIDENTS:
Chart No. 26
To Workmen: 1. Loss of earnings; 2. Family disruption;
(/\{. -3. Normal activity disrupted;
To Company: 1. Injury costs; 2. Productivity loss;
. 3. Property damage; 4. Lowered morale; 5. Community relations hurt; 6. . Guatomer^eTations-hurt.
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H Principles and Procedures .for Establishing Accident Causes (Chapter 3, Section 8).
Principles are the guidelines or what has to be done to have an effective accident prevention program; Procedures are the tools which put the principles to work. They spell out how to do it.
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PRINCIPLES OF ACCIDENT PREVENTION:
Session 5 Page -2-
Chart No. 27
vV 1. Establish both the potential and actual causes of accidents
yX 2. Eliminate both the potential and actual causes of accidents.
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PRINCIPLES FOR DETECTING POTENTIAL CAUSES:
Chart No. 28
1. Detect all unsafe conditions promptly; 2. Identify all sources of unsafe conditions; 3. Detect all unsafe practices promptly;
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PROCEDURES FOR DETECTING POTElKEfce=eAUSES: ) a Tfc>j >
Chart No. 29
F&ffr- M A '' ` 1. IJor-eman-----Obeenvex-inspectiorra1;
. .2 Assigned area inspections;
3. Superintendent inspections;
4. Adminialxative-hianagement'-inspections;
.5. Safety Department inspections;
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.7. Inter-departmental inspections; "
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...9. E-r^rr- *^hnnr-nr i-nap0?*^"0;
10 Inter-Plant inspections.
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PROCEDURES .FOR DETECTING UNSAFE
ITTCES:
Chart No. 30
1. Job.Safety Analysis; 2. Foreman-Ohnoiwor observations; 3. Safety Department observations; 4. Employee-Representative-observations.
E. PRINCIPLES "FOR~'DETECTING' ACTUAL " CAUSES:' '
Chart No. 31
The basic tool or p pcedursfhat activates these principles is
th e''.'sa'-cWcCid-e-.n-. tO.'ifn-ve stiga:
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1. .'^-EstablishaU/contributing conditions; 2. ' Determino'all causesspf contributing conditions; 3. Establish all contributing actions; 4. Deterpune all causes of contributing a ctions.
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SAFETY OBSERVED X CV:AI*\x*>4 O OUTLINE
SESSION 6
Preventing Struck By and Contacted By Accidents (Chapter 4, Section 10).
A. SITUATIONS -WHICH RESULT IN SB NORMALLY MOVING OBJECT ACCIDENTS:
Chart No. 32
1. / 2. / /. / / 3,
Those which permit man to get into the path of the object; Those which permit man to be in the path when it moves unexpectedly; Those where normally moving objects stray from path.
B GENERAL AND SPECIFIC SOLUTIONS TO SB NORMALLY MOVING
/OBJECTS ACCIDENTS: t
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Chart No. 33
. \ General Solutions: \ 1 1. Make it unnecessary or impossible to enter path; \ 2. Increase awareness of path; x 3. Place signals on moving objects; 4. Emphasize - "Stand clear of path"
Specific Solutions: 1. Install cross-over or under; 2. Place barriers; 3. Mark path; 4. Illuminate; 5. Install warning devices; 6. Install guards; 7. Eliminate blind corners; 8. Remind frequently
C. GENERAL AND SPECIFIC SOLUTIONS FOR UNEXPECTED START UP OR MOVEMENT ACCIDENTS:
Chart No. 34
General Solutions: T. Make it impossible for object to move by accident; 2. Require those who cause movement to signal and .clear path; 3. Keep others out of area.
(continued)
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Chart No. :34 (continued)
Session 6 - Page -2
Specific Solutions: 1. Make use of locking or tagging; 2. Make use of blocking or tying; 3. Use start-up signals; 4. Use warning signals; 5. Make clearance checks; 6. Put up barriers; 7. Install guards'; 8. Emphasize: "Anything capable of moving will move -- sometimel"
D. GENERAL AND SPECIFIC SOLUTIONS FOR PREVENTING OBJECTS FROM LEAVING THEIR NORMAL PATH:
Chart No. 35
General Solutions': 1. Reduce' likelihood of mechanical or electrical failure; 2. Reduce likelihood of operator failure; 3. Assume that it will happen and act to protect.
Specific Solutions: 1. Use qualified operators - train; 2. Have physical examinations; 3. Check operator fitness; 4. Check for recklessness; 5. Make equipment inspections; 6. Use traffic barriers; 7. Use guards; 8. Emphasize caution - alertness.
E. SITUATIONS WHICH RESULT IN SB NORMALLY STATIONARY ACCIDENTS:
Chart No. 36 1. Transporting objects; 2. Storing, piling, positioning objects; 3. Using or handling objects manually; 4. Working overhead.
F. WAYS TO PREVENT SB ACCIDENTS IN MATERIAL OR EQUIP MENT TRANSPORTING SITUATIONS:
Chart No. 37
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.1. Establish and abide byt safe load capacities;
2
3.
4.
.5. Establish and abide by safe.^speeds;
6 Wear personal protective equipment;
7. Emphasize caution - "Out froms under" - "Off to side." S -14-
Session 6 - Page -3G. WAYS TO PREVENT SB ACCIDENTS IN STORING PILING AND
POSITIONING SITUATION: Chart No. 38
1. Establish and use safe methods; Z. Select safe location; 3. Inspect materials; 4. Use protective barrier's; 5. Use personal protective 'equipment. H. WAYS TO PREVENT SB ACCIDENTS USING TOOLS, MATERIALS AND EQUIPMENT MANUALLY: Chart No. 39 1. Use right item for the job; 2. Inspect before use;
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3. Inspect regularly; 4. Emphasize safe manner of use; 5. Emphasize and use caution:
Firm grip; Awkward holds; Greasy gloves; Too heavy loads. I. WAYS TO PREVENT SB ACCIDENTS WHEN WORKING OVERHEAD: Chart No. 40 1. Barricade or rope off; 2. Place temporary signs; 3. Use look-out men.
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SAFETY OBSERVER TRAINING OUTLINE
SESSION 7
Preventing .(CB). Contacted By Accidents (continued) (Chapter 4, Section 10).
A. SITUATIONS PRODUCING CB ACCIDENTS:
Chart No. 41
1. Manual handling of injurious materials; 2. Repairing and servicing equipment containing injurious
materials; 3. Mechanical'failure in equipment containing injurious
materials.
B. .WAYS .TO PREVENT CB ACCIDENTS IN MATERIAL HANDLING SITUATIONS:
Chart No. 42
1. Eliminate manual handling; 2. Use safer substitute materials; 3. Use only approved containers; 4. Use better designed containers; 5. Use per sonal protective equipment; 6. Inspect containers; 7. Establish and use safe methods; 8. Identify contents.
C. WAYS TO PREVENT CB ACCIDENTS IN EQUIPMENT REPAIR OR SERVICE:
Chart No. 43
1. Use safe opening-up procedure; 2. Lock-out or tag; 3. Wear personal protective equipment; 4. Give pre-job instruction; 5. Identify:
Lines with color; Valves with tags. 6. Purge lines.
D. WAYS TO PREVENT CB ACCIDENTS CAUSED BY PRESSURE EQUIPMENT FAILURES:
Chart No. 44 .
1. Use only safe procedures; 2. Repair minor leaks promptly; 3. Inspect equipment regularly.
Session 7 - Page -2-
II. Preventing Struck Against, Contact With, and .Caught In, On and Between Accidents. (Chapter 4, Section 11).
A. SITUATIONS PRODUCING SA ACCIDENTS:
Chart No. 45
1. Terxnporary positioned protruding objects; 2. Permanently positioned objects requiring extra effort to avoid; 3. Cramped and congested areas; 4. Application of great manual effort.
B. WAYS TO- PREVENT SA ACCIDENTS INVOLVING PROTRUDING MOVEABLE OBJECTS:
Chart No. 46
1. Use boundary markings; 2. Inspect walk' and work areas; 3. Illuminate; 4. Use warning;devices; 5. Rope off; 6. Use caution - "Walk - don't run." "Look before leap."
C. ' WAYS TO PREVENT SA ACCIDENTS INVOLVING PROTRUDING FIXED OBJECTS:
Chart No. 47
1. Eliminate when designed or installed; 2. Check new installations; 3. Correct obstacle conditions; 4. Use attention-getting devices.
D. WAYS TO PREVENT SA ACCIDENTS DUE TO CRAMPED OR CONGESTED QUARTERS:
Chart No. 48
1. Use good housekeeping habits; 2. Improve storage areas; 3. Improve equipment lay-out; 4. Clean house periodically.
E. WAYS TO PREVENT SA ACCIDENTS DUE TO APPLYING GREAT MANUAL PRESSURE:
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Chart No. 49
Session 7 - ..Page -3-
1. Prevent "sticker" conditions;
2. Show how to handle "stickers" safely;
3. Change methods requiring great "push-pull" exertion;
4. Inspect tools and equipment before use;
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5. Use the right tool for the job;
6. Use "controlled" force.
in. Preventing.Contact With (CW) Accidents (Chapter 4, Section 11).
A. SITUATIONS PRODUCING CW ACCIDENTS;
Chart No. 50
1. Working with or on electrically-charged equipment; 2. Working with or near hot materials or equipment; 3. Working with chemicals or handling.containers.
B. WAYS TO PREVENT _CW ACCIDENTS DUE TO WORKING ON OR NEAR ELECTRICAL EQUIPMENT;
Chart No. 51
1. Work only where authorized to work; 2. Check with experienced men; 3. Insist upon de-energizing; 4. Insist upon locking-out; 5. Use protective equipment; 6. Cover exposed areas with insulation; 7. Use ground insulating mats; 8. Use barriers; 9. Develop respect for voltage; 10. Assume part is energized until checked; 11. Ground all electrical equipment.
C. WAYS TO PREVENT CW ACCIDENTS DUE TO WORKING WITH OR NEAR HOT OBJECTS:
Chart No. 52
1. Install guards; 2. Post warning signs; 3. Use precautions - "Feel for heat" "Maintain distance"
D. WAYS TO PREVENT CW ACCIDENTS WHEN WORKING WITH OR HANDLING CHEMICALS:
Chart No. 53
1. Promptly clean up spills; 2. Use protective equipment; 3. Take prompt action after contact.
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SAFETY OBSERVER TRAINING OUTLINE SESSION 8
Preventing Caught In, On and Between Accidents (Chapter 4, Section 11).
A. SITUATIONS PRODUCING
ACCIDENTS:
Chart No. 54
1. Working in areas with only one entrance - enclosures; 2. Exposure to small openings; 3. Working in tight places.
B. WAYS TO PREVENT Cl ACCIDENTS WHEN WORKING IN SINGLE-ENTRANCE ENCLOSURES:
Chart No, 55
1. Use inside opening doors; 2. Use look-outs -- outside; 3. Block or tie exit covers; 4. Post warnings.
Small Openings: 1. Inspect periodically; 2. Use barriers; 3. Improve illumination.
Tight Places: 1. Select small man for the job; 2. Use pre-entry precautions; 3. Eliminate hazard if the job is repetitive; 4. Ask for aid.
C. SITUATIONS PRODUCING _CO^ ACCIDENTS:
Chart No. 56
1. Stationary projecting objects; 2. Moving projecting objects-.
D. WAYS TO PREVENT O0_ ACCIDENTS WHERE STATIONARY PROJECTIONS ARE INVOLVED:
Chart No. 57
1. Avoid creating the hazard; 2. Make regular housekeeping inspections; 3. Eliminate permanent projections; 4. Guard permanent projections; 5. Use contrasting high visibility paints; 6. Use safe personal attire; 7. Use carrying methods in order to see.
Session No. 8 - Page -2WAYS TO PREVENT CO^ ACCIDENTS WHEN MOVING PROJECTIONS ARE INVOLVED:
Chart No. 58
1. Shut down machines for servicing; 2. " .'Use .lock-outs; 3. Establish and use safe start-up procedures; 4. Guard moving parts; 5. Eliminate projections; 6. Inspect equipment regularly; 7. Use safe personal attire; 8. Keep safe distance.
F. .SITUATIONS PRODUCING CB ACCIDENTS:
Chart No. 59
1. Normally moving object approaching a stationary object; 2. Two normally moving objects approaching each other; 3. Normally stationary object caused to move toward a
stationary object.
G. WAYS TO PREVENT CB ACCIDENTS INVOLVING STATIONARY NORMALLY MOVING OBJECTS:
Chart No. 60
.1. Install cross-over - under;
2 Install barriers; 3. Install guards; 4. Mark path of travel; 5. Improve illumination;
.6 Install warning devices;
7. Block or tie down;
.8 Lock-out or tag;
9. Use start-up signals;
.10 Use pre-start-up checks;
.11 Operate only if qualified;
.12 Have physical examinations;
13. Make equipment inspections.
H. WAYS TO PREVENT CB_ ACCIDENTS INVOLVING TWO NORMALLY MOVING OBJECTS:
Chart No. 61
1. Install guards; 2. Shut down before service or repair; 3. Lock-out; 4. Emphasize apparel hazards.
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SAFETY OBSERVER TRAINING OUTLINE SESSION 9
Preventing Falls, Overexertion and.Expo sure Accidents (Chapter 4, Section 12).
A. WAYS TO PREVENT SLIP AND FALL ACCIDENTS:
Chart No. 63:
1. Inspect floors; 2. Use non-skid floors; 3. Clean up spills promptly; 4. Correct source causes of chronic spots; . Wear safe shoes; 6. Illuminate; 7. "Look-Where Walking" caution.
B. WAYS TO PREVENT TRIP AND FALL ACCIDENTS: Chart No. 64
1. Place items in storage facilities; 2. Use disposal'equipment; 3. Clean up during and after work; 4. Inspect - good housekeeping; 5. Illuminate.
C. SITUATIONS PRODUCING DIFFERENT LEVEL FALL ACCIDENTS: Chart No. 65
1. Working above ground or floor level; 2. Working at or around large ground or floor openings.
D. WAYS TO PREVENT DLF ACCIDENTS IN OVERHEAD SITUATIONS: Chart No. 66
1. Inspect equipment before using; 2. Position equipment safely; 3. Inspect equipment periodically; 4. Learn safe use of equipment; 5. Use toe boards - rails; 6. Use safety belts or nets.
E. WAYS TO PREVENT DLF ACCIDENTS WHEN WORKING AROUND FLOOR OPENINGS:
Chart No, 67
1. Use barriers; 2. Use warning devices; 3. Use safety look-out man; 4. Use safety belts; 5. Use false bottoms.
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