Document bBXmgjLZ5N0BjM5oDwO6z1gdD

CONTENTS Some Essentials in Safety Programming....................................... Pierre E. Dery 5 Methods and Procedures in a Multi-Plant Safety Program... .James W. Tysse 9 Selling a Safety Program to Top Management................ Joseph A. Menendei II Selling a Safety Program to Supervision...................................M.C.M. Pollard 16 Selling a Safety Program to Employees......................................... M. G. Bullock 17 Accident Analysis..................................................................W. Eugene Stuffing 22 Inspection Techniques......................................................................Robert Beeson 28 Employee Training Procedures......................................................... Dan F. Brady 31 Safe Design of Industrial Furnaces....................................................... J.B. Smith 31 Safe Operation of Industrial Furnaces......................................... LB. Wocholskl 38 Planning Safety Into Automation............................................. Thomas E. Seavey 41 Off-the-Job Safety---Why? How? Benefits? (Panel Discussion).................... 45 The Growing Importance of Recreational Boating Safety....................................................................Robert H. Ferguson 49 Recreational Boating Safety Under U.S. Coast Guard............................................. Vice Adm. Alfred C. Richmond 50 Legislation for Safety in Small Boats.............................Mrs. George Welles, Jr. 52 Practical Application of Small Craft Regulations Through Local Safety Council................................................... Paul J. Hoover 57 Problems of Administering Multi-Plant Safety Programs (Panel)........... 59 Reports and Reporting Procedures..................................................... D.T. Mould 60 The Safety Engineers Major Problems.......................................Myron L Miller 60 Safety Education by Integration or Specialization.........................G. /. Cambre 67 CONTENTS--Continued Removing a Blind Spot in Engineering Education.............. Thomas H. Rockwall 69 Oxygen--Resuscitation, When, Why and How.......... Ralph E. Deforest, MJ). 72 Typical Emergencies Confronting the Nurse Working Alone.............................................Happy B. Bruder, RN. 79 Emergency in the Plant--Nursing Aspects......................Anna J. Thrasher, R.N. 80 is Training for Safety Different from Other Training......... Ralph M. Hartmann 83 Is Safety Training Different for Management?........................ M. C. M. Pollard 86 On-the-Job Training with Safety-- Is It Different?............................................................Earle S. Hannaford, PhJt: 88 Laboratory and Pilot Plant Safety Toxic Chemicals....................................................... Ralph V. Montello 98 High Pressure Equipment.......................................Darrell D. Frederick 102 Laboratory Ventilation................................................. James C. Barrett 106 An Engineering Approach to Material Handling Safety.......... Walter J. Byme 113 Boy Scout Safety Good Turn--1958; A Report to the Nation........................... 116 Decisions for the Future Introductory Remarlcs.............................................Dr. William P. Yant 118 The President's Conferences.......................................John J. Gilhooley 119 Avenues for Progress The Industrial Conference........................................... Gerard O. GrifEn 122 The Industrial Sections..................................................... W. O. Wilson^, 123 Trade Associations............................................. Gustave L Nordstrom 125 Insurance Organizations......................................... Donald G. Vaughan 127 Safety Engineering Profession.........................................J. C. Stennett 130 Those Who Cause Large Loss Industrial Fires...................... Chester I. Babcock 133 Portable Fire Extinguishers--A Changing Picture,...................... Dale K. Auck 138 Officers, AMERICAN SOCIETY OF SAFETY ENGINEERS, 1958-59............... 143 4 79 <Uf. 80 tonn 83 lard 86 AJ). 88 *//o 98 trick 102 wett 106 yme 113 : r 'ant 118 oley 119 ifRn 122 Ison 123 i/om 125 than 127 nett 130 :oc/c 133 lire* 138 ... 143 SOME ESSENTIALS IN SAFETY PROGRAMMING By PIERRE E. DERY Supervisor of Safety, Dominion Robber Company,Lt<L, Montreal, Quebec A safety program is a form of insurance that helps protect a company's investment in its employees. It is essential for efficient operation. My purpose is to give you what I believe to be the main essentials in safety program ming. Some of these ideas are working successfully in the four large plants and eight smaller plants operated by Dominion Rubber Company Limited in Canada. First, is your management in earnest about safety? There must not be any half-way measure--safety must come first The pre vention of accidents requires official leader ships, since the success or failure of a safety program is dependent, in major part, upon the. attitude of the top operating officials and their participation. Accidents will happen. How often have you heard that remark? Safety must be considered as an essential phase of the daily operation of a plant The elimination of unsafe practices demands a correct mental attitude on the part of every employee, and an indication of this attitude most come from the big boss. Although a safety program must be tailormade to suit a particular plant it must contain certain essentials, and it is my pleasure to outline for you at this time the general safety program of my company and which all plants follow as closely as possible. 1. Executive Safety Committee: a) In order to have full interest and participation, an executive advisory or staff committee is recommended. It is believed that such a committee will provide a sharing of responsibility, the plant manager thus getting the results be expects. b) This committee should consist of as many staff members as possible, as it is the group responsible for the entire safety program. c) Meetings should be held monthly, the factory manager being the chairman. It is important that attendance be mandatory. Each member should be expected to delegate a substitute if away on business or unable to attend. Full attendance is extremely important, also regular meetings. d) In order to obtain maximum results from these meetings, the agenda should be well prepared. Safety is a business. It should have a definite part in the business. e) This committee shall act as a board of enquiry in all major accidents and fatalities, as well as serious fires. 2. Supervisory committee: a) This committee should be made up of as many foremen as possible, the plant superintendent being the chairman. Regular monthly meetings should be held. b) Additional to carrying out the policy program as established by the executive safety committee, this group should develop projects for clearance. It should also be asked to make specific recommendations. c) Each member should be assigned a special activity, such as: 1, safety appli ances; 2, unsafe practices; 3, good house keeping; 4, publicity; 5, training program; 6, fire protection procedure; 7, new produc tion; 8, suggestion plan; 9, job safety analysis, and 10, industrial hygiene. 3. Departmental safety committees or de partmental meetings, whichever is the most* suitable for the needs of the plant: a) A departmental safety committee should be established for each department, or group of departments, on each shift Thor should be composed of a foreman (or supervisor) as chairman, and a certain number of selected employees. The number of employees to be determined by the size and variety of operations. Membership in these committees shall be rotated among all employees of the departments to obtain maximum coverage. These committees should be training committees. They should be utilized to teach accident prevention principles and as they apply to the work of the employees and to enlist their aid through specific assignments to eliminate calls for a formal training program to enable this management group to approach their responsibilities with confidence and S '. i : ' 1958 National Safety Congress competence. Some of the fundamentals are: 1. Attitude that safety is part and parcel of production and therefore the responsi bility of line-supervision. 2. Put over safety by personal and group contact, by precept and example. 3. Frequent inspection of work, keeping a check on work methods, condition of equipment and tools. 4. Guarding of machinery. 5. Good housekeeping. 6. Knowledge of the hazards of all jobs so he can let his people know about them. Where necessary see to it that safeguards are provided, mechanical or personal protective equipment 7. Keep talking safety at every oppor tunity. 8. Accept the responsibility for the safety programme in his department In other words, be the safety director of his area. 9. Fire protection. 10. Employee Training: a) This to be carried out by foremen and supervisors through: a) Frequent on-the-job contacts. b) Safety committees. c) Departmental meetings. 11. Accident Investigation: a) By a special committee in the case of all disabling injuries. This committee shall comprise the plant superintendent and a sufficient number of members within the supervisory committee. With the foreman of the department concerned, the safety supervisor, the committee shall investigate all disabling injuries and recommend stops that should be taken to prevent recurrence. b) By the foreman or supervisor: The foreman or supervisor shall be re quired to investigate personally and deter mine tet the best of his ability the causes of all accidents involving employees, equip ment or operations under his supervision. This includes those accidents which do not result in property damage or injury but which, if allowed to recur, could cause property damage or injury. He will record this information on the employee's pass to First Aid. c) The safety department: 1. To obtain all the necessary particulars to facilitate the work of the accident inves tigation committee, such as: a) Interview injured person or persons; witnesses, etc. b) Procure and analyze employment and medical records. c) Plan corrective action with the acci dent investigation committee and other interested parties and follow-up for action. d) Complete all necessary accident re ports to record and publicise the details. 2. Maintain complete, accurate and up-todate records of all accidents to be used in making statistical studies and cause analysis. a) Prepare a quarterly report for the plant with a copy to head office safety department and listing the following: 1. Injuries by occupations. 2. Plant and departmental trends. -- a) Hazardous conditions, practices and processes requiring attention. 3. Compile records for inter-department contests. 4. Prepare material for safety committee meetings, including speakers, films, safetygraphs, etc 5. Compile and issue all required acci dent reports. 6. Compile and issue reports and sum maries to keep supervision informed as to their accident experience. 7. Safe operation procedures: a) The safety supervisor shall develop and issue through the industrial relations manager written standard practices and safe operating procedures for supervision covering various phases of the accident and fire prevention program. 8. Bulletin boards: a) Bulletin boards, shall be jnainlained by the safety department throughout the plant on which accident and fire prevention ma terial will be displayed. b) Material on bulletin boards will be changed at least once per week. 9. Safety rules: a) The safety department shall cooperate with foremen in developing written safety rules for various operations. b) All rules must be approved before they are placed into effect, and adequate J ; 6 .cot mves- % ins; meat and the acdand other >r action. ndent re details. and up-to te used in e analysis. : for the ice safety mg: is. dices and epartment committee s, safety- ired acci- and sumned as to U develop relations tices and upervision indent and itained by the plant ntion roa- s will be cooperate ten safety ed before adequate Industrial Safety means set up for clearance with union representatives. c) Approved rules will be prepared for distribution to employees and for posting in departments. 10. Inspections: The plant shall establish an effective inspection program covering all items neces sary to insure the discovery of unsafe work practices, and unsafe physical or mechanical conditions, and the control of hazardous operations. a) By plant supervision: 1. Regular inspections by departmental foremen and supervisors of their operations, equipment and machines, to determine un safe physical and mechanical conditions and unsafe operating methods. Z Regular periodic inspections and re ports on special safety equipment such as mill and calendar emergency stopping de vices. curing equipment, "bite" guards, etc. b) By safety department: 1. Regular and detailed inspection of machines, equipment, yards, buildings, work ing surfaces, processes, etc to determine unsafe physical and mechanical conditions, and the use of personal safety protective equipment Z Regular inspections of hazardous op erations to see that established safe pro cedures are bang followed. 3. Regular inspections of all departments to determine the housekeeping conditions being maintained. A rating system should be used with posting of the results each month on a master bulletin board. 4. Regular inspections of emergency equipment and safety devices to determine their physical and mechanical condition. a) Emergency stopping bars, cradles, cables and switches. b) Finger bars at inrunning rolls. c) Emergency tools and equipment c) By outside agencies--safety' supervisor to follow up on reports and recommenda tions of: 1. Insurance companies--elevators, ers and pressure vessels. 2. Gty and provincial authorities. 3. Head office safety department boil 11. Inter-departmental co-ordination for safety: The safety supervisor must establish and maintain the full cooperation and co-ordina tion necessary to insure the success of the safety program between the safety depart ment and all other departments. a) Medical Department: 1. Establish arrangements for the imme diate notification in all cases of serious or unusual accidents. Z Cooperate in establishing and main taining adequate standards in pre-employ ment physical examination classifications to insure the avoidance of injuries arising irom accidents which are the result of plac ing employees on jobs for which they are not adapted, physically or otherwise. 3. Arrange for the giving of periodic physical examinations, of workers,jexposed to harmful or toxic substances and fumes. 4. Arrange for periodic inspections of the plant in order to obtain detailed first hand information concerning the nature and degree of exposures to occupational disesases. 5. Arrange surveys of new operations or processes to ascertain what health exposures may be present 6. Establish a system for assigning in jured employees to jobs they can readily handle in spite of their disabilities, in order to reduce the productive time lost as the result of disabling injuries. b) Employment department: 1. Establish collaboration between the medical, employment, and safety depart ments relative to the placement of em ployees on jobs in the plant, so that those requiring special considerations because of physical or mental limitations, are properly assigned to work which they-are capable of handling safely. Z Arrange for cooperation and assistance in the rehabilitation of injured employees. 3. Establish cross-file controls which will prevent physically or mentally limited em ployees from transferring from their ap proved work to any other work without clearence from the safety and medical departments. c) Engineering and maintenance depart ments: 7 1958 National Safety Congress 1. Establish a system for expediting safety -work requests and giving priority preference to requests for correction of critical hazards. 2. Establish a system for routing all work requests to the safety department for clearance where safety interests and con formity with codes and safety rules are important factors. 3. Establish cooperation between the engineering, maintenance, and safety de partments to such an extent that the safety department is consulted before any work is begun or new installations or changes to existing buildings, processes, operations, or equipment. 4. Establish a system for the incorpora tion of safety requirements in the plans and specifications for the design of machines and equipment at the time of their conception. 5. Allocate from hours available daily for job order work specified time for safety orders. d) Purchasing department: 1. Establish close co-ordination between the purchasing and safety departments in order that all purchases of equipment, tools, materials and personal protective equipment are in keeping with safety standards. 2. Establish a system whereby purchase requests for hazardous chemicals and ma terials are routed to the safety department for investigation and clearance before purchases are made. 12. Contests, awards and publicity: Each plant shall establish a program designed to stimulate interest in accident and fire pre vention among supervision and employees through the use of contests, awards and publicity. a) Contests: 1. Company-sponsored. Encourage active participation in company-sponsored safety contests, both accident and fire. 2. Plant-sponsored. Arrange and super vise contests of various types between de partments and designed to supplement phases of the overall accident prevention campaign. a) Lost time accidents; b) housekeep ing: c) safety suggestions; d) safety slogans. b) Awards: 1. Establish a program of recognition for contest winners through appropriate awards. c) Publicity: 1. Utilize all recognized means of pub licity to call attention to and promote interest in the contests and award winners 13. Correction of hazardous conditions. Establish and supervise a program for the rapid correction of unsafe mechanical or physical conditions or hazardous operations. a) Work requests for new installations: 1. Initiate or cause foremen to initiate. 2. Follow-up for approvals and comple tion of work. 3. Inspect completed work and approve if conforms to safety requirements. b) Repair and maintenance work: 1. Same procedure as "a.--Work Re quests." 14. Miscellaneous Duties: a) Maintain files of up-to-date informa tion pertaining to all phases of the accident and fire prevention program. 1. Federal, provincial and city labor laws. 2. Workmen's compensation act. 3. Provincial and city building and fire codes. 4. Central safety department regulations. 5. Fire protection, personal protection, and miscellaneous safety equipment Maintain liaison with and follow up all recommendation of outside agencies: 1. Head office safety department 2. Accident prevention association, provandal, department of labour. 3. Gty departments, health, safety and fire prevention. - -- -- 4. Insurance companies -- fire, pressure vessels, elevators, compensation, etc b) Fire Protection: The safety super visor shall establish and supervise the following program designed to protect fully the plant buildings, processes, materials and equipment from damage by fire: 1. Isolation and control of hazardous operations. a) Collaborate with the engineering de partment on the design and location of all r pition ap^.opriate ins of pubid promote ird winners. conditions, am for the xhanical or > operations. stailadons: o initiate, ind comple- nd approve ents. rork: -Work Re te informathe accident labor laws. ict tg and fire protection. cnt How up all ties: lent iation, pro safety and t pressure etc tety supericrvise the rotect fully aterials and 8 hazardous leering deltion of all Industrial Safety processes and installations utilizing flam mable liquids or hazardous materials, to insure that the hazard of these operations is adequately controlled and that the in stallations are made in accordance with provincial, city and insurance company requirements. b) Establish inspection controls over these operations to see that adequate safety standards are maintained. 2. Control over receiving, storing and using flammable liquids: Establish proced ures for the safe handling of all flammable liquids during their receipt, storage and use throughout the plant a) Handling equipment including pipe lines; b) area limits, personnel and quanti ties; c) posting of warning signs, and d) fire and accident preventive measures. 3. Installation of fire extinguishing equip ment Establish and supervise a system for the periodic inspection of all fire extinguish ing equipment designed to insure the mainte nance of this equipment in continual good operating condition. a) Immediate repair or replacement of any equipment found to be damaged or defective 5. Plant fire brigades: Establish and supervise the training of fire brigades on each of the three shifts. 1. Maintain all necessary equipment for plant fire brigade in a central location. 2. Hold practice drills for each brigade at regular intervals. The one feature of safety work to which I attach the greatest importance, is that the accident experience of each plant and of the company should be regarded by top management as something worthy of regu lar and serious attention. I am very proud to work for a company whose management follow the practice of reviewing monthly the accident report. We do think" that safety is a business, that it has a definite part in the business and we wish it to be known that we consider it so. METHODS AND PROCEDURES IN A MULTI-PLANT SAFETY PROGRAM By JAMES W. TYSSE Manager of Safety, Republic Steel Corporation, Cleveland, Ohio Recognizing the importance of a sound safety program, we also are aware of the psychology of safety. This is the need for awakening in every man in the plant a reali zation he can make an important contribution to his own safety and that of his fellow workers. Since the inception of Republic's safety program, frequency and severity rates usu ally better than the average for the industry have been achieved. Basic to this planning has been the constant knowledge that every one in each plant must be given a sense of participation in the program with an aware ness of his own personal responsibility in it The structure of this safety effort was established in the early days of the corpo ration. Refined and adapted to changing conditions since then, the program is essen tially the same today. A fundamental consideration was the es tablishment of policies and regulations, con sistent with local, state and federal require ments, that could be followed by all plants. We compiled these policies and regulations into a book called Manual Governing Medi cal, Workmen's Compensation and Safety Procedure.JThis book has grown andjoday encompasses 92 pages which give our safety and operating people explicit instructions in these fields. As the title implies, it is divided into three main sections covering the fields of medical care, workmen's compensation and safety. A few principles laid down under the title "Operation GA.P.," as our 1958 safety pro gram, will provide background for discussion of this manual. CAP stands for "Contribution to Accident Prevention." It was aimed directly at our 1958 National Safety Congress district managers and through them at the men in our plants. CAP was, and is, premised on three principles: 1. A basic program. 2. An objective at which to shoot. 3. Good communications. The CAP program spotlights safety per formance for top plant management, invites their cooperation and that of operating de partment committees. Any local plans can be coordinated into the basic corporate program. Our 1958 objective is to better the out standing performance in frequency and se verity in each steel district, manufacturing division and mining district experienced dur ing the six years from 1952 through 1957, inclusive. Where the best performance was a perfect performance, the objective is to equal that performance. We set forth instructions for teletvping or telegraphing immediately to the general office about any disabling injury. This information requires a brief description of the accident and the apparent cause and is relayed without delay and in the same manner to steel, manu facturing and mine superintendents of indus trial relations and safety people. Corporation operating committees have established similar communications. In the event of serious or fatal accidents, these communications are to be preceded by telephone advice. A performance hasn't been achieved that is considered satisfactory, hut significant re sults have been experienced in a number of plants. Dovetailed with Republic's safety program are specific steps, outlined in our manual. This booklet calls for the establishment of three basic safety committees throughout the corporation: a corporation general safety committee, plant general safety committees, and departmental safety committees. Corpo ration operating committees assign subcom mittees on safety--the first subject on the agenda in their scheduled meetings. The corporation general safety committee is composed of the director and assistant di rector of industrial relations, the manager of satety and the district or plant superin tendents of industrial relations. This com mittee also includes the director of plant protection and the manager of workmen's compensation and social insurance. The committee serves in an advisory ca pacity on corporation matters pertaining to accident prevention, workmen's compensation, good housekeeping, fire prevention, etc Plant general safety committees consist of the district or plant manager and his as sistant, the superintendent of industrial re lations and his assistant, the supervisor of safety, the fire marshal and departmental heads. This committee meets monthly to dis cuss phases of accident, fire prevention and good-housekeeping activities; formulate plant safety policies; and recommend safety rules and accident preventive measures. The departmental safety committee includes the superintendent and his assistant and the foremen of that department These commit tees are required to meet at least once monthly to discuss all phases of safety in the department The meetings are attended by a representative of the safety department in an advisory capacity. In addition to these meetings, each fore man or assistant foreman is required to con duct at least one safety meeting, or discuss safety personally,* with each employee under his supervision at a minimum of once each month. The manual also provides for the establish ment of an accident-investigating committee in all plants and outlines the procedures it shall follow. Subcommittees of corporation operating committees immediately investigate serious or fatal accidents and formulate pre ventive measures which become committee safety policy. The manual encourages the cooperation of local engineering departments with local safe ty departments on matters pertaining to safety in contemplated new or changed installations. The booklet emphasizes the importance of making routine health surveys and provides for a rehabilitation committee to place em ployees disabled in previous accidents on jobs they can perform. Occasionally changes or additions to the safety program are made, and these are incorporated in the manual by reference One such program was the monthly leaflet and poster program. Started in 1948, it has proved so effective that it has been continued. With this program, the safety department each month selects a subject for development by an advertising firm which prepares large, billboard-size posters and distributes them to 10 visory catai^g to ip (ion, i e*consist of id his asostrial reervisor of partmental hly to dissntion and ulate plant ifety rules ee includes at and the * commitleast once fety in the aided by a tnent in an each forc ed to Con or discuss >yee under once each t establishcommittee tcedures it orporation investigate iuT Weco. .attee aeration of local safe st to safety stallations. irtance of d provides place em its on jobs ins to the these are reference, hly leaflet 948, it has continued. lepartment ivdopment ares large, es them to Industrial Safety the plants and districts. Similarly, bulletin board posters and monthly safety leaflets are prepared and displayed or distributed to all employees. After the establishment of general policy on safety, the manual devotes a large section to general and special reports required by the program. Examples include: 1. Monthly Report of Grinding Wheel Inspection. 2. Foreman's Accident Report 3. Unsafe Practice Report 4. Fire Extinguisher Report 5. Weekly Accident Report 6. Ladle Inspection Report 7. Chain Inspection Report S. Crane Inspection Report 9. Ore Bridge Inspection Report 10. Turbines, Fly Wheels, Air Receiver Inspection Reports. 11. Crane Cable Inspection Report Many reports call for the appointment of district or plant inspection committees charged with the responsibility for making inspections on a periodic basis and submitting their findings and recommendations. A section on references to the general safety orders and special rule books con cludes the manual. These general safety or- ders and special rule books are contained in a separate book. In this book are provisions for current meeting material, foremen's instruction sheets, the general safety orders, the special rule books covering safety regulations for specific departments and operations, and dis trict safety orders made up in various dis tricts or plants to cover special local con ditions. Republic's safety program is administered by the industrial relations department, with direction and supervision at the general office and plant levels. Each facility is inspected at least twice a year and sometimes more frequently by representatives from the corporation's gen eral safety office. Inspectors check matters pertaining to the local administration of the basic program and advise on improvements. Each district or plant manager is responsi ble for safety in his own operation. Usually^ safety results achieved are in direct ratio to the manager's interest in the program. We have found safety is more than just following the book. A good program in cludes diversifying educational techniques, maintaining and increasing the interest of the men in the mills in safety and in general advertising, and selling the importance of safety as a program for the mutual benefit of everyone. SELLING A SAFETY PROGRAM TO TOP MANAGEMENT By JOSEPH A. MENENDEZ Safety Director, Falstaff Brewing Corp., St. Louis, Mo. The title of my subject implies that top management is a prospective buyer and we the hopeful salesmen. We have a safety program to offer top management and are here to decide what approaches to use to assure this "sale". Top management, as any prospective buyer, must have a need for a product in order to be receptive. We must reveal to them this need. My first suggestion in selling a safety program to top management is to reveal to them that .aeddents^jyre inefndencies .and an effective safety program is an efficiency measure. We must keep top management informed with facts. Intelligent use of. statistics gives you tangible information and ammunition. Statistics reveal that accidents are ineffi ciencies. It is top managment's responsi bility to its stockholders to maintain an efficient operation and they are interested in measures that produce efficiencies it's good business. 1958 National Safety Congress Frequency and severity rates are statis tics that can aid you in conditioning top management for the sale. Top management welcomes statistics that are concise, which can be readily studied and understood. They are busy people with many reports to re view and digest so reports must be palatable and easily digested. These statistics should reveal trends. I suggest your monthly reports in order to indicate trends include year to date fre quency and severity rates. We use a frequency and severity rate form that is not uncommon. It keeps top management informed by individual produc tion and maintenance departments and by totals for these departments. should be used only for a specific purpose or periodically. Another very effective selling point to top management is the direct injury expense report This report is truly tangible. It points out efficiencies and deficiencies in a language in which top management is very fluent--cost figures. Top management is comprised of people who are, in my experience, very sympathetic and kind. Many have in the past been closely associated with employees, many have visited injured and ill employees in the hospital and in the home. They are just as humane today as they were then, and they do not want to see their em ployees suffering and losing wages. Distinct separation is solely to pin-point They have delegated this personal atten responsibility so that top management can tion to department heads, supervisors, per readily see exactly where a weakness may sonnel managers and safety personnel. This be and who is responsible. responsibility has- been delegated as many The drivers, miscellaneous and semi others, such as maintaining machines and month figures are listed separately for the equipment in which they are still interested same purpose. This entails more effort on our part but gives top management a report that pro vides information they can understand. It is not a report that just states "we are doing but to which they can no longer personally attend. I mention this for the mis-informed who picture top management as interested only in the dollar sign. good or bad" but one that pin-points the Direct injury costs figures cannot be strong and weak areas. juggled. The sharpest pencil cannot alter This monthly report also gives top man agement year to date rates. One month's rates alone are not conclusive, top manage them. They are facts that are cut and dried. One oi our three direct injury expense ment wants to know how we are faring to reports is an annual report of injury costs date. We use another form that is a bulletin board notice, primarily, but is also sent to by plant--per barrel--per employee for the four plant production and maintenance de partments. top management and it gives a simple year It also shows the previous year's com to date plant comparison of frequency and parative costs. severity rates in the upper box-score as These cost figures include the medical well as days since last disabling injury. hospitalization, and workmen's compensa A footnote explains that the figures in tion paid on all closed or completed injury clude only the experience of the plant pro cases and the reserve figure on open or duction and maintenance departments and pending cases.* that they indicate frequency rate standings Another report reveals these same costs and not -inter-plant safety contest standings. by departments, which pin-points for top A lower box-score reveals the current management efficiencies and deficiencies. and previous year's lost-time injuries for Again, this report gives a guide or trend plant departments by month and year to to follow with the previous year's com date, and the frequency and severity rates parison. year to date. A third report picks up the drivers, the It is a simple report with facts at a glance and which indicates a trend. Lengthy re ports showing comparisons of five, ten or more years are too comprehensive and semi-monthly and the miscellaneous group to complete the picture. These figures are obtainable from the in surance carrier or if self-insured from the 12 purpose it )p expense ible. It ies in a is very : people pathetic st been , many iyees in hey are re then, dr em- I attenrs, per il. This s many ies and terested rsonally ed who ed only not be >t alter ut and expense toi k nee de- s com- medical npensa- injury pen or e costs or top iendes. - trend i com- rs, the roup to the inim the Industrial Safety insurance department or accounting depart A word of warning: do not overdo it ment Top management may tire of it or it may These should be presented so that top lose its effectiveness if it becomes too com management can study them by department, monplace. by plant or in general by total costs. A letter from the president to all drivers Incidentally, I know of no company that includes these costs as production costs, which is actually what they are. If a bottler is injured in one of our plants it has cost Falstaff that much more to bottle of company vehicles may be in order dur ing a national or local traffic campaign and no one is better qualified to prepare a sug gested letter on this theme for him than the safety director. the product on that particular shift The frequency and severity rates may These injury cost figures are revealed to the responsible persons, top management, and they are appreciated. They are im portant facts in selling top management a safety program. The safety department sends our plant superintendents quarterly cost reports by department and individual injury cases to keep them posted currently. Several of our plant superintendents requested this report after we started our inter-plant safety con test which includes injury expense as an important category* Quarterly reports, they felt, kept them posted and they could di merit a compliment or a reprimand from the corporate production manager. The safety director who has made a careful study of existing conditions can include pertinent points for emphasis which will be most effective in a suggested letter or memo for the production manager to send to de partment heads and supervisors. Our annual injury expense report is sent to key management personnel by our execu tive vice-president and generaTmanager. He sends a letter of transmittal with these re ports which include suggested remarks pre pared by the safety director. rect their efforts accordingly. This letter in part reads "--this tells me The annual summary previously shown is that not only dollars and cents have been prepared for distribution by top manage saved but also that less suffering has been ment but more about this later. experienced by our Falstaff family and less Statistics are facts that must be used time has been spent in the doctors office, to sell a safety program to top manage in the hospital and away from work.'* ment. If they reveal efficiency the selling "It spells efficiency--better operation of point is that the safety program is needed your respective departments--Congratula to maintain that efficiency. If deficiencies tions, etc." are revealed, the need of a stimulated safety program to eliminate them is in dicated. This message coming from top manage-ment is much more effective than coming from the safety' director. The safety direc My second suggestion to aid in selling tor can prepare such a suggested letter to top management a safety program is for top management people for approval thus the safety director or engineer to be a relieving them of valuable time in prepara ghost writer. tion--and you are selling your safety pro Top management does not have the time gram to them simultaneously. to prepare letters, directives, or memoran For those who are reluctant to offer top dums to key personnel on safety. Neither management -suggested letters or remarks does it have time to prepare them for the for fear they be disregarded, I have found sales or advertising department or the that the bigger the man the more receptive many other departments. and appreciative he seems to be. You haw been delegated the responsibility of selling safety for top management to all personnel and one of die best mediums is an occasional letter to key personnel from top management--from the big boss. My immediate superior, our personnel di rector, has encouraged me to prepare letters for him directed to,his personnel managers and to the higher echelon on safety policies or subjects. If letters are prepared intelligently and Carefully worded, concise letters or mem concisely, top management will appreciate oranda prepared for top management not the opportunity to do its part only help to sell the safety program to 13 ? 1958 National Safely Congress them but also puts teeth into your overall and sends out all pertinent information and program. It keeps top management inter correspondence He has appointed a judging ested and all other levels on their toes. committee which he heads, comprised of My third suggestion is to make top man agement active participants in the safety program. Do not let them become figure heads. This can be achieved without consuming too much of their valuable time and efforts. the company's secretary and assistant treas urer, who heads our insurance department, the personnel director, the superintendent of engineering, the superintendent of construc tion, our workmen's compensation insurance broker and safety director. Mr. Webster defines the word "figure head'' as "a nominal, but not real, head; one who allows his name to be used to give standing to enterprises in which he has no responsible interest or duties." Top management must not be considered figureheads in the safety program. They have interests and duties and are very real. It is the duty of these men, at two com mittee meetings per year, to report to the production manager on the status, as per contest schedule, of each plant They do not make plant safety inspections in the body but as their work takes them to the various plants they are to observe and make note of physical conditions of the plants and attitudes not only for judging purposes but General or steering safety committees in for recommendations to improve existing our operation are headed by the plant super conditions. intendent at each plant He conducts the meetings and inspections. The department head has the same responsibility where such committees exist within the department These persons are top management in their respective areas. They have the re sponsibility of the health and safety of the personnel, equipment, and machines in these areas. We cannot afford figureheads in our or ganization nor can you. Many of you have seen at various man agement levels the individual who could not be sold on safety and who has com pletely and sincerely been converted into one of your best safety salesmen when this This contest . serves top management as a guide and control as the subjects included will readily reveal. Frequency, severity, and costs are the main "point-getters'' in the contest The winner in each of these earn 100 points. All other categories can earn from 40 to 80 points. An index accompanied the point schedule form when the program was introduced. It explained the point system and what was expected in each category. This has made safety tangible as it is bong measured not only by statistics but by effort exerted. responsibility was placed solely on his shoulders. You sell them the safety pro gram by making them active participants. It has given top management a tool with which to work on the prevention of acci dents. If you conduct contests, stay in the back ground. Be script writer and channel ma terials, etc, through top management. Make top management an active participant not only at award ceremonies but during the^ contest. Points were raised recently by the com mittee, after judging last year's contest, when they' realized the importance of prompt and complete accident investigation repom^and discussed housekeeping from an efficiency and sanitation stand-point as well You got only sell the safety program to as its accident prevention valuer top management but to supervisors and em ployees as well by having top management's sincerity felt by all concerned. We have devised a comprehensive inter plant safety contest which has made our top management very active participants in our accident prevention program. The contest is flexible. For instance, one of our plants has one of the best fire brigades in the country, for its size, It is trained by the local fire department and its members are auxiliary firemen to the city fire department and Civil Defense organiza tion. The local fire department sends a fire- It is conducted by our corporate produc truck, fully equipped with a driver and cap tion manager. He announced the program tain to train our plant fire brigade, several 14 Uion and i jtjd^ing rii iof rat _<asJartment, ndent of Mnstrucnsuranee wo comt to the . as per :y do not die body ! various ake note nits and oses but existing ment as included are the st. The l points, n 40 to schedule reduced, hat was as * ds tic |t >ol with af acd- te coincontest nee of tigation :rom an as well ice, one sst fire e, It is and its he city ganizaa fireid capseveral Industrial Safety tunes each year. Of course, they receive full point value. Full points on this item may also be received in a plant located in a large city where they have an organized, trained crew which is discouraged by its city fire depart ment from having fire-hoses in the plant Set standards are difficult on this and many* of the other contest items. Existing condi tions dictate to the committee their deci sions. Also points will be changed by the committee to improve weak areas. The safety training category merits points from supervisory training courses which in clude a safety session and are conducted at plant level by the personnel manager who is responsible for the implementation of the safety program at each plant. Also points are given for a three-hour safety course offered by our insurance car rier at each plant and such courses as off ered by the National Safety Council or local safety councils. Out-of plant meetings merit points for at tendance by supervisors, personnel managers or department heads, at local safety coun cil meetings, A.S.S.E. meetings, safety con ferences or conventions, etc. This is to broaden their scope on accident prevention work. Other activities encourage each plant to develop the safety program by initiating slogans, gimmicks, contests, etc.; to parti cipate in community safety campaigns such as traffic and bicycle safety. Publicity on any of their safety activi ties is taken into consideration as it indi cates added effort and is conducive to im proving attitudes of employees as well as the public. This contest is an aid in selling top man agement our safety program as it has made it an active and interested participant. The fourth suggestion I would make to sell a safety program to top management is for the safety engineer to blow his horn for saiety, to make his wares known by the use of publicity'. It has been stated that "publicity is the voice of safety." We can use this voice to help sell our product. Publicity, that is good publicity, helps achieve better public relations which top management is always striving to attain. Safety, a non-controversial subject with much human appeal, can be and should be publicized. Public relations and publicity for safety is a subject in itself and I will take only a few minutes to touch on it. For those who may be interested, the 1955 edition of the NSC Accident Prevention Manual for Industrial Operations has a very interesting article on this subject. If you have a public relations department you are neglecting your duty if you do not work closely with it Remember that they are publishing newsworthy articles so don't burden them with routine activities. Your public relations department can often use articles and photographs in the company or plant house organs. It can pass on to T.V., radio, newspapers and trade maga zines what they consider newsworthy to such media. If you. have no public relations depart ment, do some leg work, make contacts with above mentioned media, but use dis cretion and send only what may appeal to the reader or listener. Publicity is news resulting from activity --top management knows this and recognizes the efforts exerted and results achieved. Blow the horn for safety. It helps to sell the safety program to top management My fifth and final suggestion to sell the safety program to top management is to sell yourself. I do not think we need elaborate, but I will mention several suggestions that are, in. my opinion, absolutely necessary to sell yourself in order to sell a safety program to top management A safety engineer must be sincere and deeply interested in his work. As a good salesman he must be sold on his product in order to sell it His enthusiasm must be such that it is catching, so it will permeate throughout the organization, including top management This enthusiasm must reveal an intense, profound and eager interest with a liveli ness of imagination and an ardent zeal for this product he believes to be worthy. He must be able Jo accept a "no" answer and yet not to be a "yes" man. He must put up a fight for what he thinks is right yet accept an occasional defeat gracefully. He must respect and be respected. In a nutshell by doing his job well, he 15 1958 National Safety Congress '\ is selling top management himself and his ters or memoranda which they may send .. 'l1K'- safety program. to key personnel. In summary, I have made the following 3. Make top management active partic suggestions for selling a safety program to ipants in the safety program. Do not let top management: them become figureheads. 1. Give top management facts, statistics 4. Blow your safety horn by publicizing presented intelligently, to reveal that ac cidents are inefficiencies and that your safety program is an efficiency measure. 2. Help top management help you by be safety activities. 5. Be sincere and enthusiastic, and do your job well so that you may sell your self and vour safety program to top man ing a ghost writer. Prepare suggested let agement. SELLING A SAFETY PROGRAM TO SUPERVISION By M. C. M. POLLARD Director of Safety, National Gypsum Co., Buffalo, N. Y. This is the most important aspect of any tical. If their ideas are incorporated in the safety man's work. Unless he can success program, they will not have to be sold on fully sell the program to supervision, no following the program because they had a worthwhile results can be obtained in acci part in its development. dent prevention in any plant. In most in stances, the reason for failure to sell a pro gram lies not with supervision but with the safety director. Once the plan lias been drafted and put into operation, it is essential that supervisors are required to make only a minimum num ber of reports, as the effort is followed Younger people in the profession especially through. The supervisor must have a very fail to recognize that they are servants of real role, at least prominent enough so he supervision- Any approach based on the atti fully realizes the safety of his people is his tude that "What I say demands attention, be primary responsibility. cause I am important" cannot help but face It is not enough to tell the supervisor he defeat. is responsible, and then let him figure out The myriad responsibilities of any super what he is to do to meet that responsibility. visor must be recognized. He is held ac He must be given information developed countable for everything that goes on in his from plant experience, from industry-wide department. A safety man who does not results and any literature that would keep realize this is going to be the most frustrated his thinking alert and alive to the problem. person in the plant. He must be thoroughly grounded in the The only way to learn just what makes fundamentals of accident prevention, so he demands on the time of a supervisor is to understands how the application of these visit his area of responsibility-and-learn just-^ -fundamentals will not only lead to accident- what it is he has to do. The safety of his free operation, but to top efficiency in pro people is only one of a thousand things that duction as well. The language of the safety make up his daily routine. program must be the language of the super Any successful safety program must be visor and not that of the safety man. based on a thorough analysis of accident A supervisor will not offer resistance to a experience. This will highlight the locations program, if he knows what is being talked and causes of accidents. With this infor about and recognizes the final outcome as mation, a plan can be drafted to meet the one that will be beneficial to him personally. major accident problem. Any supervisor wants to get good results. The entire plan must be developed through He does not want to see any' of his men consultation with supervisors to keep it prac- injured. He wants to have the highest quali- 16 ray send e iico not let ublictzing and do ;ell yourtop man- ION :d in the : sold on O' bad a and put pen-isors um numfollowed e a very jh so he >le is his v jhe gufc out msibility'eveloped try-wide uld keep problem, d in the n, so he sf these icddentin proie safety * superi. nee to a g talked come as rsonally. esults. his men st quali Industrial Safety ty, most production, lowest cost of any oper ation in the plant He wants his boss to pat him on the back and tell him he has done a good job. If he operates his department without accidents, he should get the credit not the safety man. Without a strong top management policy for safety, almost any attempt made by a supervisor is thwarted. There is no question but that a matter of policy comes first in any company. When that policy is explained to the supervisor in a manner that hi under stands, it is to his best interest to carry it out He will not have to be sold on a safety program but will be continually asking as sistance with this phase of his responsibility, and the safety man will be very busy satis fying those demands. A safety supervisor may do a thorough job of selling a production supervisor the safety program and may have all of his work undone because the supervisor's boss thinks that the safety man is the fellow who has the responsibility for safety in the plant When such a situation exists, then the safety man must make the attitude of that boss known to his superiors, and the correc tive action can then be applied to the errant part of management Regardless of what a safety man thinks about a supervisor's attitude toward safety, he should never express his opinion to any one except his immediate superior. A state ment to the wrong person at the wrong time could pull the rug out from under any safety program, and it takes a long time to put such a house back in order. The problem of selling safety to super vision becomes not one of forcing something down someone's throat but rather of shaping the approach in such an attractive fashion that the supervisor soon realizes he had better give accident prevention some attention for his own good. SELLING A SAFETY PROGRAM TO EMPLOYEES By M. G. BULLOCK Supervising Engineer, Transit Casualty Co., St. Louis, Mo. I believe it is obvious that one must first have a safety program before one can at tempt to sell it. To avoid any possible misunderstanding, I prefer to preface my program subject with some personal observations and opinions as to what constitutes a safety program. I do not claim to be a Solomon, but 20 years in the field of safety engineering has produced some opinions as gained from the school of experience. I believe that effective accident controMs more than the indiscriminate and "scattergun'' use of gadgets and gimmicks, bulletins and bull, posters and pins, meetings and movies, and dollars and don'ts. Every stage play has a plot; that's your safety goal. The window dressing to create interest and atten tion is your scenery; that's the gadgets and gimmicks department I urge you not to make the mistake of having a safety meet ing, or to put up posters, just because it seems like the proper thing to do. I think one should first establish a definite and well organized program, based upon facts, with selected objectives, and then sell. In other words, establish a "compass bearing," or goal, to know where you are going, and why. You don't make a trip, for instance, without establishing a destina tion. Treat accident control the same way. Another important point to always remem ber is to stress how safety benefits the employee: After all, keep in mind that the emplsyee. represents the consumer of your product, which we call "safely." If you can sell the employee on buying your com modity, you should automatically sell and resell your management The employee must be convinced that safety benefits him personally. Many em ployees believe that'safety is good only for the company, primarily because most of the management promotion, all too often, deals directly with the prevention of acci dents involving company property, or con- 1958 National Safety Congress trolling losses to the company. The em ployee, on the other hand, is usually only selfishly interested in himself. A few years ago a Mr. Powers of the General Motors Corporation said, "Selling is like fishing. If you want to catch fish, you bait vour hook with something the fish likes. You may like strawberries, but the fish may only be interested in worms." Safety must be sold as a 24-hour product, and not as an S-hour "tool kit"--good to use only on the job. Ofr-the-job safety programs promoted by the company help convince the employee that safety is a product producing mutual benefit, and to be effective, it must be practiced 24 hours a day. To summarize my comment regarding a safety program; be sure you have a safety program worthy of selling. I suggest you consider these factors: ~ 1. Analyze--to determine the facts. tacts, and to make safety a regular part of their supervisory job. As a tip to any safety man, I think you must concentrate on selling your self first--before you can hope to sell an idea or safety program. Un fortunately, when a person is dis liked or not respected, others will automatically close their minds to his ideas or proposals. 7. Take periodic inventory--re-evaluate your activities and your results at periodic intervals. Change tactics to meet the changing problems. Ii you are wrong, you had better beat the boss to this conclusion. As in foot ball, a strong alert offense is the best defense. Analyze the market before you sell. Ex perienced safety men know that safety is a difficult .product to sell. It is ironic that it should be so hard to sell something that can save the buyer's life. 2. Scrutinize--to determine the primary problem. 3. Mobilize--to create corrective action. 4. Be objective--apply effort with a purpose and where you can expect the greatest returns. To illustrate: If you handle safety, management hired you to control accident costs; find out what they are, and design your activity to aim at the major cost problems. You can't cover the whole "waterfront," so don't try. but at least apply effort where it will do the most good. 5. Be organised--I have reference to necessary committees, inspections, follow-up procedures and communi cations within the company. No long range,,safety .activity. iias.,lasting^ qualities without proper basic organi sation. What then, are their mental blockades? I think the movie, "Knowing's Not Enough," as produced by the U. S. Steel Corp. summed it up very neatly. For instance, they point out that most accident situations are created by four basic human traits, namely: Improvising, Impa tience, Impulsive, and Impunity. I will not take time to dwell on each, but I urge you to see this movie, or at least analyze your accidents in correlation to these basic causes. The obvious cause of a traffic accident may be "speeding,'' but he was either "impatient," or had a feeling of "impunity." They may think, "So it can't happen to me." The graveyards are full of people that believe this. Recently an official of the State of Iowa stated that approximately 50 per cent of the traffic deaths in Iowa last year were by people who had their first and last accident 6. Motivate and personalise--think of ways to slant your program that will convince the employee that be will benefit by cooperating with accident prevention activities. Personalize the approach so that the employee will feel that the program was meant for him. Urge supervision to take a personal interest via direct con The shop man fell from a ladder; you may say he was careless to put a block of wood under one leg. Actually he was "im provising." Other illustrations could easily be given. I stress these points because you should slant your safety selling campaign to fit the basic causes. Be objective and be realis tic IS i regular jab As .1 & ing yourhope to am. Uni is dislers will ninds to -evaluate esults at actics to - If you beat the in foott is the ell Exfety is a mic that ling that ades? I enough," J Corp. at most ur basic , Jmpa- m each. tse of a but he eling of ppen to pie that of the ately 50 wa last irst and tr; you lock of as "im1 easily should to fit ; realis- Industrial Safety Speaking of bang realistic, let me com ment mi another point before you misunder stand me. We know from experience that certain groups of human beings cannot comply with any form of regulation unless there exists some form of forceful control. That's why we have laws and police forces, and industry has supervision. Let's face it, some em ployees, therefore, can only be sold on safety when supervision is "breathing down their backs." It is true that discipline and good super vision are necessary to maintain reasonable safe job performance. It's impractical to have a supervisor for each employee, and besides, who would supervise the super visor? What percentage of the employees can we hope "to reach," therefore^ by direct selling tactics? As one illustration, studies that I have made of a number of city transit operations show that usually 10 per cent of the drivers go throughout a year without any kind of traffic and passenger accident. These are the "old reliables." Approximately 13 per cent, however, will produce about 35 to 40 per cent of all the accidents. I call these drivers members of the "13 Per Cent Club." Generally, about 77 per cent of the operators fall into the category' I refer to as "marginal per formers." They waver from "not too good," to "not too bad!" Those in the "13 Per Cent Club" will re quire dose supervision and discipline. Super vision b needed to guide the "marginal performers," but in general, I believe they will respond to safety education providing they can recognize some personal benefit. To sell safety to employees, therefore, I am a firm believer in first selling it to supervision, but that direct selling to em ployees is effective providing itis promoted as a 24-hour product, and not as an 8-hour "tool kit." I think a strong "off-the-job" approach with lots of reference to safety in the home, helps tremendously to estab lish the practice of safety on the job. All of these conclusions, however, are based upon one important fact Manage ment has to be backing your safety selling campaign; or you will be like the man with an automobile, but without gasoline--you may have a nice vehicle, but you won't go very far. Fortunatdy for us, H. L. Martin, vice president of Transit Casualty Co., be lieves in safety, and so does John Baine, president of the St Louis Public Service Co., plus a number of other top management people involved with Transit Casualty Co. operations. Let's Review a Few Ideas, To Sell Safety To Employees. I would like to preface these few ideas with the comment that I realize some might appear new, and some old, de pending on your drcumstances and experi ence: I offer them only to illustrate. Refer ence to most will be very brief. For specific illustration, the following ideas have been used primarily at the St Loub Public Service Company, the local transit system. I do this as a tie-in to re sults--because the National Safety Cbundl's "Award of Honor" has been earned for the past three consecutive years, plus other safety honors. For purpose of possible comparison, St Loub Public Service Co. employs approxi mately 2^00 people and its buses and street cars travel about 30 million miles annually. You will observe our use of the "home influence." 1. "The Key To Safety" b a special car toon illustrated pamphlet that was sent direct to the home of the employees during a special campaign in December. Traffic mid passenger acridents for a transit opera tion during December usually average 20 per cent higher than an average of the other 11 months, thus the reason for a special campaign. The title page, with appropriate illustration, reads, "The Key To Safety-- It's In Your Hands." We Have a Prob lem--Your Choice--Ether Help With The Solution, Or You Become Part of The Problem! Safety Is a Personal Responsi bility-Get "Keyed Up" Over Safety! "On the inside page we have the broad cap tion "Fight Holiday Hazards--Wherever They May' Be." Underneath are cartoon illustrations of hazards at home, on the job, off the job, in the streets, etc. Throughout the entire publication we stress the slogan "Safety b a Personal Thing." Thb pam phlet was accompanied by a letter of trans mittal from the Vice President and Oper ating Manager of St Loub Public Service Co. to again stress the phrase "Safety is a Personal Thing." 1958 National Safety Congress 2. As another part of our December cam paign for the holiday period, we prepared an 8J4" x 13' bulletin entitled "Safety Is A Personal Thing" In the margin are these tion, and other transit properties will soon show us up. As a matter of pride, we believe you will want to do your part to improve your safety record by comments, "What's Your Safety IQ?," "Who Prevents Accidents?," "Safety Begins At Home," "Facts You Should Know." Op working safely. Of more importance, of course, is that you are giving your self and your family the greatest ben posite these statements in the margin are facts or answers. Each operating employee was interviewed by his foreman or superin tendent and given one of these handouts. This personal contact helps to give importance to the drive, and to re-establish proper rela tions between the boss and the men. The data sheet gave them a proper subject to discuss. This year we plan to number each data sheet with a consecutive number, and later give out a few $5 gift certificates to holders of the lucky numbered sheets. We hope this idea will get the sheets in the home, and delay the "wastebasket treat ment."----- ~ -- efit when you avoid accidental injury! Remember: "In life, as in baseball, it is the number of times you reach home safely that counts." Accidents can be avoided, if you think before you act!" (Signed)--Employee Safety Council St Louis Public Service Co. 5. About 3 years ago, a special feature in the "Public Service" company newspaper was entitled, "How Safe Is Your Hornet" A three column check list of things to look for was listed, and a scoring system devel oped. The underlying theme was "Safety Begins At Home." 3. An eye opener as to the influence of the family was brought out in what we call the "Why-B-Safe Contest" The members of the employees* families were eligible, such as the wives, daughters, or sons, to participate in a contest wherein they were to submit an article of 100 words or less as to what it meant to them to have the Public Service Company employee remain free from accidents, and to return home safely from the job without injury. (A few U.S. Savings Bonds were the rewards.) The articles were heartwarming and dis closed that the folks at home represent a powerful influence. It also helped us to eval uate a current safety campaign, because at the time, we were pushing "Zero Accident Days," and many referred to the term of "Zero." We also published the pictures of the winners in the company newspaper. 6. An eye protection program, was brought directly to the workers' attention through small meetings, movies, and handouts. This was on company time. The importance of vision to the ability to earn a living was particularly stressed. In fact, we said, "Without your eyes and fingers, could you earn a living? They are your working tools. Protect them!" In this manner, we stressed what safety meant to them. 7. A First Aid program with specific attention to the control of bleeding, and artificial respiration techniques--have been actually demonstrated to employee groups. Each employee was urged to take the lessons home and teach them to his family. We point out to each employee that if he passes this training on to his family, it may some day save his life. 8. Periodically, the use of fire extin 4. In the summer of 1957, the employee guishers are reviewed at the division oper safety record was losing ground. A special, ational plants, with actual demonstrations.. --direct"mailing was prepared, with cartoon Fire prevention in the home was also illustrations, which stated: stressed--to give it a personal meaning. " "Safety And Your Job--They Go To 9. The elimination of carbon tetrachloride gether Like a Lock and Key; Like as a solvent was difficult, because workers Bricks and Mortar; Like Ham and Eggs. Yes, safety on or off the job should be with you always! Although The National Safety Council has hon ored your company with various awards to recognize the reduction of injuries recognized the efficiency, but did not recog nize its dangers. No one knew of any spe cific trouble for the past 40 years, so it was therefore difficult to convince them of the hazard. This was finally done by direct salesmanship, wherein the safety engineer to employees, the current record is up and the foreman were equipped with actual and shows that we are losing our posi case records in industry. I know of one Industrial Safety operties will Iter q pride, p your ty . -Jord by : importance, giving yourgreatest benental injury! i baseball, it i reach home ients can be re you act!" ;ty Council hard headed individual that I finally told, "Yes, it is difficult to find a substitute for carbon tetrachloride. It really does the job. The only trouble with the stuff is that it will kill you." I then proceeded to show him case records. He was finally sold. Inci dentally, I told him he had better caution his family too, because the lethal effects are usually delayed a few days following ex posure, thus often difficult to trace back to the cause. 10. "Coffee and Donuts" days are used occasionally throughout a selected day, when lie Service Co. a department has been successful in accumu edal feature in my newspaper Your Homet* things to look ; system develt -was "Safety lating more than one million accident free man-hours, or as a result of a contest which we call "Improv-ur-Record." In the latter contest, when an operating division shows the greatest improvement in traffic and pas senger accident experience over the corres ponding month of the prior year, manage ur. was brought mion through taniouts. This importance of : a living was act, we said, ers, could you working tools, er, we stressed ment gives them free coffee and donuts for a day. It's surprising how the men respond to these celebrations. 11. "Improving the Braking Distance IQ" is the title of a package training pro gram that has been used at a large number of fleet operations throughout the country. We use a braking distance device manu factured by the Wagner Electric Company, called a "Wagner Fifth Wheel." It is a with specific bleedmg, and es-; jre been ploy_/ groups, ake the lessons s family. We at if he passes , it may some- trailing bicycle wheel device, and is very effective to portray and demonstrate brak ing distances of trucks, autos and buses. The driver can subject his vehicle to a typical emergency stop condition, and the device will immediately record the initial speed and the total braking distance in volved. This is a very effective safety tool in fleet work, because an experienced driver of either a bus or a truck is not going to jf fire extin- accept braking distance figures as presented division oper- by a safety engineer, or anyone else, for lemonstrations. that matter. He has to be shown. Our sell me was also - ing point is that thermit gives'him"facts, meaning, thus if he ever has to be on the witness ft tetrachloride stand, he will know what he is talking about cause workers Actually, it makes him also respect follow did not recog- ing distances when he can see the actual w of any spe- braking distances involved. We also tie ears, so it was in the result with the safe driving of his ; them of the personal automobile. one by direct \fety engineer ed with actual know of one 12. We have a "package" program to get drivers to secure witnesses if involved in traffic or passenger accidents. Our chief motivation is tied in to the slogan "If in court, you need support Get those wit nesses." Naturally, witnesses are also very necessary to the claim department 13. Refresher courses have been used ex tensively at the St Louis Public Service Company, and also at a number of other properties that Transit Casualty Co. insures across the nation. These packaged programs are of various lengths, from one hour to two days, but they are primarily designed to educate. Each man receives a booklet such as shown. Both on and off the job safety problems are included, with particular stress on traffic accidents. The broad subject of "Time" as related to speed and distance, is discussed and related to the cause of acci dents. Audience participation, gimmicks, and a blackboard help to keep it interesting and effective. The one hour course has been particularly well received wherever it has been use<L_ 14. Safe-T-Coach--a Mobile Safety Clinic. The Transit Casualty Company's special bus has traveled irom coast to coast. It is equipped with tests for sight, hearing and reaction. Special electronic devices, and two-way mirror glass, help to make it attractive to visitors. The coach has traveled over 50,000 miles, and we have quit counting the number of visitors. A "Transitometer" was especially invented and built to portray reaction in terms of distance traveled, plus the elapsed time for any selected speed up to 80 mph. The Safe-T-Coach has been very effective for selling safety direct to employees, and for general public relations promotion. 15. Calibrated Cardboard Reaction Timer --This little gimmick has been very effective to demonstrate eye to finger reaction. The bottom of the timer is held just above the opened thumb and first finger of the sub ject's hand, and when the instructor drops the card, the subject closes his thumb and finger to catch it It usually falls about 8 to 10 inches before being caught (elapsed time of about 2 second), thus proring that everyone has a "built-in" accident handicap called "reaction," or delay of action. This principle of delayed muscular re sponse can easily be related to traffic acci dent causes, to accidents in the plant from falling objects, etc. We particularly use it in connection with our Safe-T-Coach, the braking demonstra- 1958 National Safety Congress dens, and with die refresher courses. Fol lowing its creation and resultant publicity, my employer, die Transit Casualty Com pany, authorized me to give the idea to the National Safety Council. Copies can be secured from them. In conclusion, I again review these points: A. Before you attempt to sell a safety program, be sure you have a program, and obviously it is necessary' to know your problem. Don't rely alone on gadgets and gimmicks; posters and pins; bulletins and bull. B. Be factual and objective. Analyze, scrutinize, and then mobilize for action; apply effort with a purpose and where it will do the most good. C. Sell yourself first. Remember: If safety sold itself, we would not have 95,000 persons killed each year by accidents. D. To sell the employee, be sure and stress how he benefits. E. Be instructive; educational, and inter esting. In other words, the employee is no fool, so don't treat him like one. Give him facts, but with interesting "window dress ing" and in simple language. F. Take frequent "compass bearings," or inventory of vour activities. Prepare an annual report of safety activities, and sub mit recommendations for the new year. G. Selling safety is not 4 "one shot" deal. It must be continuous and with a variety of approaches. H. The safety story must be told again and again. ACCIDENT ANALYSIS By W. EUGENE STUFFING Director of Safety, Carrier Corporation, Syracuse, New York Gathering accident statistics and analyzing them, is, in the main, a lengthy, boring, cumbersome and expensive process. Time is money, so don't waste the time of your self and your associates in the time-con suming process of analyzing accidents. Don't do it--unless you wring the last bit of information out of jour analysis and, secondly, but infinitely more important uti lize this information to its fullest in your endeavors to reduce your accidents and in juries. Of course you must analyze your acci dents. How* else are you going to know how to best utilize the resources at your disposal in order to achieve your optimum effective ness in reducing or preventing accidents. I am sate you have all heard the sales man's credo: "Plan your work and then work vour plan." Let me advance the question, "How can you possibly plan your work, much less work your plan, unless you have at your disposal the information you need to develop a plan of accident prevention?" I submit to you that accident analysis is basic. It's fundamental. No accident pre vention program can really be successful or effective without first analyzing your acci dents and, secondly', using this information gained from the analysis to give you direc tion in developing your plan. I am sure that if I were to ask any safety engineer if he had ever known a safety engineer who laboriously developed monthly and annual accident analysis reports and then didn't use them, I would get an affirmative reply. I know I have. And I can tell you very honestly that he wasn't doing the job of accident prevention that he should or could have been doing. Because he did not plan his work, he could not work a plan. So all his efforts bad a "shot-gun" effect instead of a rifle effect. He spread his efforts over such a wide area that he spent entirely too little time, energy and effort on those problems which would have paid off handsomely. If I have been able to drive home the point to you that you must analyze your accidents and from this analysis develop a plan or plans to prevent future accidents, then my efforts will not have been in vain. I fully realize that just because I say you must analyze your accidents is not enough- 22 Industrial Safety hayM>5,000 id(f lf t sure and and interloyee is no Give him dow dress- arings." or 'repare an >, and sub year. `one shot" id with a told again f your acdiformation you direc- > any a developed sis reports Id get an tad I can sn't doing he should ; he could rts had a He effect i a wide ttle tune, ms which the point accidents . plan or then my F say you t enough. So my next step should be to describe some of the benefits or results that can be ar rived at through accident analysis. Here are come of the more important ones: 1. To reveal the nature and scope of ac cidents by departments, plants or by occupa tions. 2. The identification and location of the principal sources of accidents, by determin ing the materials, machines and took most frequently involved in these accidents and the jobs or procedures most likely to pro duce the accidents. 3. Disclosing the unsafe practices that are causing the majority of accidents. 4. Determining the need for engineering or engineering revision by the identification ot the principal unsafe conditions of various types of equipment and materials. 5. Disclosing improper operation-processes and procedures, such as poor layout or in adequate methods bring used, which are overtaxing workers. 6. The disclosure of the improper place ment of personnel. . 7. To assist supervisors or safety com mittees to use their time to the best advantage in their accident prevention activi ties by disclosing to them where the prin cipal hazards or unsafe practices are in their departments. 8. To permit the objective evaluation of a safety program by noting, as the result of continuing analysis, the effect of different safety measures, educational techniques, cam paigns, contests and other methods adopted to prevent injuries. 9. To disclose the proportion of property damage accidents, as opposed to injury acci dents. 10. To determine the costs of accidents. Now there are many other benefits or advantages to be gained from the analysis of accidents. Rather than take the time to list them for you here and now, may I sug gest that you think about the problem and I am sure that other reasons or benefits will suggest themselves to you. I should also like to point out to you that it is just not possible to analyze your ac cidents unless you first investigate your ac cidents and then prepare complete reports of your accident investigations. The information which should be contained in the accident in vestigation reports will come to you with experience and also as the result of an alyzing your accidents. To dwell on the finer points of accident reports is not part of my assignment The designing of your own accident analysis forms is an area full of many pitfalls. Of course, the forms should be de signed to give you information in the cate gories that you want but keep the forms ample and concise. At this point many ot the men who develop a form get in over their beads because they endeavor to place too much detail into their reports. Before you settle on a form, may I suggest that you design a simple form and then try it out In all probability you will want to make some changes in it after you have given it a fair trial I just can't overemphasize the im portance of keeping your forms simple and 'mduttered with unnecessary detail Many a man with good intentions of analyzing his accidents has become discouraged or con fused after trying to analyze a report that was so detailed that he couldn't find the significant factors that he knew must be in the report. So, make your reports simple and concise, and then if you wish more detailed information in a specific area, the designing of another form which contains more de tails and the using of only the part of the simple form that pertains to the problem at hand will help you arrive at the facts you need. Naturally, you will not be able to use one form for all of your analyses. For example, a form used to determine the larger group ings of accidents by departments will be much different than a form used to determine the predominate types of unsafe acts on the part of injured employees. For this reason, you will need different forms for different purposes. If you are inexperienced in the field of form design, let me suggest that you seek the help of other safety engineers of your acquaintance. Your local ASSE chapter should be an excellent source of help in this respect So don't hesitate to ask for help if you need it As many of you know who are acquainted with me, I never hesitate to ask the help of other safety engineers if I feel they have information I can use. I think it is a real compliment to my fellow workers in the accident prevention field that in all my years as a safety engineer, I have 23 1958 Xalional Safety Congress never been rebuffed or put off by anyone In are of much more importance to you in help the safety field I have turned to for help. ing you analyze your accidents. You try it, if you feel the need for help or guidance. I am sure you will be pleasantly surprised at the help you get The American Standards Association, in conjunction with the National Safety Coun cil ; The Association of Casualty and Surety Companies; National Council of Compensa tion Insurance and the Internationa] Associa tion of Industrial Accident Boards and Com missions has completed a tremendous amount of work in developing three codes which are used as guides and references by those en gaged in accident prevention. Z16.1 Code, "The American Standard Method of Recording and Measuring Work Injury Experience" has to do primarily with the classification and reporting of accidents. The original work on this standard dates back A<L,~an. initial bulletin- issued by the LT. S. Bureau of Labor Statistics in 1930. Many revisions have been made to the original work, the latest being approved by the American Standards Association in De cember of 1954. The first of these is the ASA standard Z16.2, Part I, entitled "American Recom mended Practice for Compiling Industrial Accident Causes, Selection of Accident Fac tors". The purpose of this standard is to provide a statistical method of recording the accident facts which are so essential to know in order for you to do a better job of acci dent prevention. Upon examining this standard you will find that a great deal of care was exercised in order to restrict the number of factors that you will have to work with. Only those factors most closely related to the accident and which are of most value to you as working tools for accident analysis have been listed. The rules for using these factors are quite .simple and, if followed, will give you a large degree of uniformity in your statistical results. One of the outstanding features of the standard is its flexibility. It can be utilized equally well by a small plant which has only a few accidents a year, all the way to a state industrial com The original purpose of this standard, and mission, or the U.S. Department of Labor, l might add, the current purpose is to pro which handles hundreds oi thousands of dis vide a practical and uniform method for abling injury cases per year. recording and measuring work injury exjterience. Injury rates compiled in accord ance with this standard may be used to evaluate: The key to this standard is the fact that only six factors are needed in order for you to analyze vour accidents. These factors are commonly re<gnized by safety engi a. The relative need for accident preven neers as being those most closely related tion activities in different departments or to the accident, and as bring of the most plants. value to you in your practical accident pre b. The seriousness of the accident problem in a department, plant or industry. c. The effectiveness of safety activities in vention work. Each essential point of in formation about an accident is referred to in the classification as an accident factor. establishments with comparable hazards. d. The progress made in accident pre vention within a department, plant or in I am going to list these factors for you now and define each of them for you. They are as follows: dustry. - The Agency--The agency is the object or The methods outlined in this standard for classifying work injuries are independent of workmen's compensation laws and rulings of substance most closely associated with the injurj'. and which could have been properly guarded or corrected. workmen's compensation agencies. The Agency Part--The agency part is the Every safety engineer must have a thor ough working knowledge of this standard for the reasons I previously mentioned. Al though some analysis of the effectiveness of particular part of the selected agency most closely associated with the injury* and which could have been properly guarded or cor rected. your accident prevention program can be The Unsafe Mechanical or Physical Con realized by applying the formulas contained dition--That condition of the selected agency in this standard, two other ASA standards which could have been guarded or corrected. 24 Industrial Safety j-Qi' ip helpl \) jA standard can Rccom5 Industrial cadent Facndard is to cording the tial to know job of acd- d you will is exercised of factors Only those he accident to you as Uysis have lese factors 1, will give ty in your jutstanding flexibility, jy a small mts a year, trial comof Labor, nds of dis- i fact that er for you se faaors fer pgily . _atcd the most ident prent of in;rred to in actor. s for you you. They object or with the properly art is the ncy most nd which ; or cor ial/ Con 'd agency orrected. The Accident Type--The manner of con tores, etc, due to striking against, kneeling tact of the injured person with an object on or slipping on objects). Struck by (fall or substance; or the exposure, or the move ing, flying, slipping or moving objects). Fall ment of the injured person which resulted on same level. Fall to different leveL Ex in the injury. posure to temperature extremes (resulting The Unsafe Act--That violation of a com in burning, scalding, freezing, heat exhaus monly accepted safe procedure which resulted tion, sunstroke frostbite etc). Inhalation, in the selected accident type. absorption, ingestion, (asphyxiation, poison The Unsafe Personal Factor--The mental or bodily characteristic which permitted or ing, drowning, etc). Contaa with electric current occasioned the selected unsafe act 5. Unsafe Act--Operating without au The six faaors I have listed and defined thority; operating or working at unsafe for you are only the general classification speed; malting safety devices inoperative; groups omitting all details. From here we go using unsafe equipment, hands instead of to what is called major groups which fall equipment, or equipment unsafely; unsafe under each of the six accident faaors. I loading, placing, mixing, combining, etc; would like to list just a minimum number taking unsafe position or posture (under of the general classification groups under suspended loads, lifting with bent back, etc); each of the six faaors to demonstrate distracting, teasing, abusing, startling, etc . how detaikd the classification can be. 6. Unsafe Personal Factor--Improper atti 1. Agency--Machines (lathe, punch press, tude (disregard of instructions, failure to saw, drill press, etc.) Prime movers and understand instructions, nervous, excitable, pumps (engines, pumps, compressors, fans, etc); lack of knowledge or skill (unaware etc.) Boilers and pressure vessels (steam of safe practice, unskilled, etc); bodily de boiler, super heater, condenser, etc) Ve fects (defective eyesight or hearing, fatigue, hicles (motor, animal, railway, water, air intoxicated, existing hernia, weak heart, craft, etc) Animals (domestic animal, insect, etc) ; no unsafe personal factor. snake, fish, etc) Hand tools (axe, cleaver, chisel, file; knife, etc) Chemicals (explo sives, vapor, fumes, etc) Miscellaneous agencies (ladder, window, tank, can, etc) Part 2 of the ASA code Z162 goes into much more detail in describing the accident factors. There are literally thousands of de tailed classifications which could be used in 2. Agency Part--Agency parts are not accident analysis which are listed in this part itemized because the parts differ so greatly. of the code It is possible to select from Without referring to a list, however, you these detailed listings only those faaors can usually figure what part of the agent? which apply to your own particular in- ' is involved. A word of advice, however. dustry. This will cut the list down con Don't spend much time in selecting "agency siderably. On the other hand, yon may need parts", as they don't develop too much im to supplement the selected faaors by what portance in the over-all analysis picture ever degree of detail you consider neces 3. Unsafe Mechanical or Physical Condi sary. tion--Improperly guarded agencies (un guarded, inadequately guarded, etc) Defec tive agffides (rough, slippery, sharp, etc) Just to give you a slight taste of how plentiful these detailed classifications can be suppose we run through a couple of them Hazardous arrangement, procedure etc, in, on or around the selected agency (unsafely stored, congestion, overloading, etc) Im proper illumination (insufficient light, glare, at this time. You will recall that the first of the six accident faaors that I listed was "The Agency". Under this heading there appeared several general classifications, such etc) Improper ventilation (insufficient air change impure air source etc) Unsafe dress or apparel (absence of or defective gloves, aprons, shoes, etc) No defective agency. as "machines", "prime movers and pumps", "vehicles" and "chemicals". For the sake of our example, suppose we select the general classification of "machines". Under this classi fication we selea "presses". In order to get 4. Accident Type--Striking against (re more specific, let's look at some of the types fers generally to contacts with sharp or of presses that we can selea from in the rough objects, resulting in cuts, slivers, punc- code. Press (Metal)--arbor press, assem- 23 r n si I" 1958 National Safety Congress bling press, blanking press, drawing press, kick press, stamping and forming press, etc. The last of the six factors I mentioned was "The Unsafe Personal Factor". If I haven't lost you yet, you will recall that there appeared several categories under the general classification, such as "improper at titude", "lack of knowledge or skill", "bodily defects", etc Under the first of these--"im proper attitude"--we find more detailed breakdowns, such as: willful disregard of instructions, violent temper, absentminded ness, willful intent to injure, nervous, ex citable, and failure to understand instruc tions. Now that we are all completely checked out in how to use the detailed and general classifications for the six accident factors, suppose we run through a couple of theo retical accidents and classify them together. Although you as the analyst will identify every'accident factor in detail, it is sur prising how many times you will find both the detailed and general classification to be the same For example, let's classify this accident: "A ladder slipped causing a mill wright to fall to the floor and fracture his arm. The safety shoes on the ladder were worn smooth and the millwright used it con trary to the instructions of his supervisor." Earlier in my talk I advised you to keep your forms simple and concise: At this time I want to extend this same advice to you regarding the amount of detail you use in the classification of your accidents. Try to keep your analysis simple. If you can't find the factors or combinations of factors that are causing a large segment of your acci dents, then go to a more detailed classifica tion. In most cases you will find that you can obtain the results you are after by sticking to the general classification of your accident factors. Experience has proved that the most ef fective way to reduce accidents is to con centrate on one phase of the accident prob lem at a time rather than to try to stop all accidents at once. There are many dif ferent ways in which the problem can be approached on this basis, any one of which should prove effective; One type of analysis that you should make is a study of the injury frequency rates computed by departments. These studies will undoubtedly point out that injuries occur at sharply higher rates in some departments than in others. If such is the case, an analysis should be made of the accidents, the sources of the accidents and their causes. Agency: Agency Part: Unsafe Mechanical or Physical Condition: Accident Type: Unsafe Act: General Classification Miscellaneous None Detailed Classification Ladder Safety shoe Defective Worn Fall to different level Fall to different level Using unsafe equipment, etc. Using defective equipment Un-afe Personal Factor: Improper attitude Willful disregard of instruction Let's try another one. For example: "An employee in a chemical manufacturing plant in willful violation of posted orders entered a gaseous and unventilated tank before it had been tested and cleared for entry by the tank inspector. An explosion occurred, causing him to be severely burned." Agency: Agency Part: Unsafe Mechanical or Physical Condition: Accident Type: Unsafe Act: Unsafe Personal Factor: General Classification Boiler and pressure vessel None Improper ventilation Contact with temperature extremes Taking unsafe position, etc. Improper Attitude Detailed Classification Tank None Insufficient air change Contact with temperature extremes Entering unsafe vessel Willful disregard of instruction 26 to beep hi V to ,,du use in Try to in't find Jrs that jt acciissificaiat you fter by of your tost efto cont probto stop ay difcan be which d make ' rates ies will xur at tments sc, an its, the causes. nent : tank tusing Industrial Safety This method will permit concentrating your efforts in those locations where accidents are occurring most frequently. If your injury frequency rates reveal that a high rate of occurrence is general through out your plant, you may wish to group the agencies of the injuries. In this manner you will be able to identify the principal sources of injuries; or by accident type to find out how your employees are being injured; or by unsafe act or unsafe condition. Any one of these accident factors may be used as a starting point for your analysis. Tabulations of your accidents may be made by hand sorting and tallying. For analyzing a small number of reports, this method is the most efficient. The principal advantage is that the original records can be used, and all the information is immediately available for ready reference should you need to refer to it For analyzing a larger number of reports, keysort cards may be used. This card would be similar to the original accident report in that all the information shown on the orig inal appears on the card. In order to use this type of analysis, all the factors will have to be assigned code numbers. The code num bers are then punched on the individual cards and your analysis is made factor by factor by sorting through the cards with a special needle. Sorting would be a hand operation. A third method of tabulation employs mechanical tabulating equipment The ac cident factors are coded and then punched onto the cards. They can be accurately and very quickly sorted into various groups. This method reaches maximum usefulness when the number of reports to be analyzed is quite large, when many classifications and cross classifications will be required, or when tabulation of numerical data, such as days lost, will be made. Of course, merely obtaining the informa tion will not prevent recurrence of the ac cidents. The conditions which contributed to the accidents must be corrected. If your analysis shows the improper use of particular machines, then you have grounds for instituting or implementing your employee training programs. The very defi nite and specific causes of your accidents, as obtained from your analysis, can be stressed in your training activities. Your statistical evidence will furnish you data for developing your own safety posters and for other safety materials which you may wish to use in your all-out assault on the types of accidents which you now know you are having. Your analysis will show you the causes of your machine accidents in such definite terms that all guess work is completely eliminated from your activities. We have covered a lot of ground on the subject of accident analysis. My only con cern is that I may have been too detailed or too technical and lost you along the way. I am sure that you will agree, though, that armed with the information I have presented, you will be able to "plan your work" and then to "work your plan". If you don't al ready have copies of the three ASA Stand ards that I have discussed, I recommend that you obtain them so you can "bone up" on the information contained in them. You will need them in order to arrive at a standardized method of analysis that is used throughout the United States and, I suspect, in many foreign countries. In conclusion, allow me to return to the point which I stressed at the beginning of this talk, "Don't analyze your accidents un less you fully intend to utilize the informa tion that you obtain from your analysis." "If you don't, you are wasting your time and you will never know what the factors are that are causing the majoritv of vour acci dents." re 1958 Xationa! Safety Congress INSPECTION TECHNIQUES By ROBERT BEESON Plant Supervisor of Safety and Training, Perfect Circle Corp., Hagerstown, IncL In our business, manufacturing piston Stairs rings, about one-third of our employees' Are the stairs in good condition? time is spent on inspecting the product Every industry has a large inspection de partment checking its product before ship ping to the customer. Trying to manage Are handrails provided and are they in good condition? Is lighting adequate over the stairs? a safety program without safety inspec tions would be like trying to manage a business without an inspection department You just can't do it and succeed Elevators What is the maximum weight limit? Do your men overload your elevator? Are signal systems, cables and other The No. 1 purpose of safety inspection safety devices in good working order? is to spot unsafe conditions and practices and have them corrected, but you accom plish other things at the same time. When you correct unsafe conditions you prove to Is the floor of the elevator in good shape? Is there adequate light in the elevator? vour employees that vour company really Ladders believes in safety. Are your ladders the right type for the Inspections help to sell safety to em ployees. Every time an employee sees an inspection bang made in his department it job? ' Are thej* of suflident strength and in good condition? demonstrates the company's interest in Are they provided with safety features? safety and perhaps will encourage him to inspect his own work area. Safety inspec tion will give you an opportunity to come in contact with the employee at his work place. You will often get good safety suggestions from employees during these Floors Are floors free from protruding nails, splinters, holes, oil, water, greases, and loose boards or tiles? Are floors overloaded? inspections. This brings the employee into the safety program and tends to make him more safety conscious. Machinery Checking machines to see that they are properly guarded is a very important part There are thousands of unsafe conditions to look for but here are a few of the general ones: of vour inspection tour. Remember that al though you may have the machine guarded for safe operation conditions, your mainte Housekeeping nance men may be in places the operators do not go. Your oiler may have to climb Good housekeeping is a "must" if you on top or behind the machine to see that aim to have a good accident prevention the machine is guarded for him also. - program. Are ^aisles marked dearly with painted lines? Are aisles kept dear of any objects that could cause tripping hazards? Are machines cleaned regularly? Are comers cluttered with scrap ? Are tops of lockers and bins dirty? Are windows and light fixtures dean? Electrical Hazards Is your electrical equipment grounded? Are extension cords in good condition? Do you have sub-standard electrical equipment? Are electricians required to work on hot lines when it is not necessary? Do you check the condition of coffeemakers, teakettles, fans, and heaters which Are vour toilets and washrooms dean ? your employees bring into the plant? > ! * 28 Industrial Safety n, Ind. e they in iirs? limit? Do nd other rder? in good evator? e for the 1 and in eahires? ng nails, ises, and .) they are tarn part ' that alguarded maintejperators to climb see that . mded? lition? ctrical : on hot coffee 's which :? Fire hazards Are exits dearly marked? If you have smoking areas, are they During this inspection you should watch clearly marked? for unsafe practices. These are some com Do you allow flammable liquids to be mon ones that have probably taken place stored and carried through your plant in in every plant in the country: glass containers? Improper lifting. Are there places where flammable vapors can collect that should be ventilated? Not wearing safety equipment. Improper dothing, loose sleeves, rings and Are your fire extinguishers, hose and watches. other fire-fighting equipment checked regu Improper use of band,tools and equipment larly to see that they are in good condition? Is your fire-fighting equipment easy to get to, or is it blocked by material being stacked in front of it? Are fire doors in good working condition? If you have sprinkler protection, are the valves open? Are the alarms working? Are enough men trained to know where the shufcofL valves are so the water can be shut off quickly after the fire is out. but not too soon? Do you really know what explosive materials you have in your plant? Using defective tools. Riding on trucks and doilies. Geaning and oiling machinery while it is running. Throwing material and other objects. Gimbing over tote boxes, machinery, etc Running In aisles and on stairways. Operating machinery without proper authority. Making safety devices inoperative Distracting attention, teasing, abusing and horseplay. Working on dectrical equipment without locking out main switch. Protective Clothing Is protective dothing (goggles, safety shoes, hard hats, etc) mzde available to the job? Providing own first aid such as bandaids, merthiolate, etc The more people you get on your inspec tion team the more effective your inspection Is protective dothing in good condition? First Aid Are first aid fadlities adequate? Do your supervisors know the new method of artificial respiration and do they know how to control serious bleeding? Are stretchers provided in the plant? program will be Here are a few of the people who should be making inspections: Foreman Safety Director Insurance Company Safety Engineer Plant Manager or Superintendent Methods and Time Study Engineers Tool Room and Maintenance men Do your employees know where the firstaid room is and that every injury is to be reported? General Conditions ~fs Special equipment (boilers, air com pressors, hoists, etc) regularly inspected? Safety Committees Every employee Foreman The foreman is the key to any safety program. He is right there with the problem. The foreman should constantly Is material handled, piled and stored in a safe manner? Are hand tools kept in good condition? * Are any adds or corrosives handled? If so, are they handled and stored in a safe way? be looking for unusual conditions that might injure his employees, and should see that his employees follow all safety rules. If you get him to do a good inspection job you are well on your way toward your goal of preventing injury. If you use safety posters, are they changed Safety Director regularly or are the}* allowed to become Like the foreman, every time the safety dirty? director goes into the plant he should be 29 1958 National Safety Congress looking for any hazard that might be lurking in a spot that has been missed. The safety director should plan regular inspections. He may have a general Inspec tion each month, fire extinguisher inspection every three months, and hoist and overhead crane inspection every six months. These inspections should be based on need, reports should be made out and follow-up work done to see that the unsafe conditions are corrected. The Insurance Safety Engineer This man can be of much value to you in your inspection program. He does not live with your problems every day, there fore may see things that others have over looked. This man has the benefit of a broad experience from bring in Several plants and being familiar with mam' differ ent types of accidents and injuries. He is -a- specialist, and you should' make every effort to correct conditions that he lists on his report. Plant Manager or Superintendent Your plant manager knows tliat unless he operates a safe plant he is not qualified to operate the plant at all. He can be a very valuable member of your safety inspec tion team. It may be a little high pressure on the foreman but if he knows the plant manager is looking for safety hazards, he sure will try to keep him from finding any in his department. Methods and Time Study Engineers These men are dealing with the details of gettting a production job done. If you have them looking for unsafe conditions they will make it a part of their everyday job to report hazards to you that they tnav uncover while working in the plant. Many times they will be in a position to correct the hazard by the method they establish in getting the production job done. Tool doom and Maintenance Here is another group of men who should report hazards. These men are every place over the plant from the roof to under the floors. They should report unsafe tools and equipment and can surely strengthen your inspection program. In many plants, because of the nature of their work, this group may receive numerous injuries, but if they are a part of your inspection program, they will be more safety conscious. Safety Committees A committee to make plant inspections is common in most safety' programs. The purpose of this committee is to detect and report unsafe conditions that could cause an injury. This committee does much to bring your employees into your safety program and acquaint them with the safety problems. If your plant is small, one committee perhaps can inspect the whole plant If it's large, perhaps you will have committees for specific areas in the plant You may find it would be better to have employees inspect some other than their own depart ment since they are so familiar with their own problems they could easily overlook some serious hazard. .... Since you want to get as many into this safety inspection as possible It is suggested that you rotate the committee members occasionally, perhaps every* three months. The way you explain the purpose of the committee and plan your inspections will determine whether or not you accomplish your goal or fail to reach it. The employees on this committee should take their assign ment seriously and not consider it a chance to get out of work or a chance to snoop into some other employee's business. Items found during the inspection should be discussed with vour committee. Also, it is a "must'* that committee members be informed of. unsatisfactory conditions corrected. Machine Inspection Committees Another type committee is one to inspect and approve all new' machines and equip ment before they are truned over for pro duction use. Logical members would,be the foreman, the engineer who designed the machine, the tool room man who is familiar with the machine, and the safety director. Every Employee Every* employee should be instructed that it is his responsibility to report unsafe conditions. After you have completed your inspection and have a list of conditions to correct, I would suggest that you use very careful judgment in demanding their immediate cor- 30 Industrial Safety inspection I re -*qfety | rection. If you really have a serious condi with them. I don't mean let these conditions tion, see that every effort is put forth to ride, but put the important ones first and correct it immediately, but don't put every do the others as soon as possible. item you find in this category because if I know that a carefully planned inspection pections is it is maintenance work you must be fair program will reduce your injuries. ims. The detect and 1 cause an it to bring program EMPLOYEE TRAINING PROCEDURES problems. committee By DAN F. BRADY plant. It Manager of Safety, The Maytag Co., Newton, Iowa ommittees You may employees n departvith their overlook into this suggested members nonths. se of the ions will xomplish mployees r assigna chance to snoop '| I 9 n ] | I | Is there anyone in this hall this morning that feels there is no need for continuing employee training? If so, why not take a good look at your present accident experi ence and see who is responsible for your statistics. Is.it the new employee you just lured, indoctrinated and trained, or is it the employee who has been with you for a period of time; long enough that his job has now become routine. Analyze your own past. Most of you, no doubt, came into safety work from other phases of industrial work, such- as machin ing, assembly, personnel, engineering, or some type of office work. During those days you were performing such work, how many times did you stop and check your your plants. If you are not getting the re sults you want, you are striving to revise your program to obtain the ultimate in ac cident prevention. The first step that is most important is to create interest of employees by using new ideas and giving the employee an op portunity to participate in the overall plan of accident prevention. Many of these ideas and new ways of presenting safety can be obtained at safety meetings, such as this. Our safety program is made up of a num ber of ideas I picked up from other safety men at special meetings I have attended. I feel certain that we, at the Maytag Company, are on the right track with our safety program. We are far from hav job so far as the safety aspect of it was ing the perfect program, but each year r concerned? I am sure you gave safety far shows a definite improvement To illustrate less thought then than you do now. this point in 1950 we have just put a new nbers be onditions I'll wager that there isn't a person in the room that would think of putting a part in a lathe chuck before the chuck came to a plant into operation and had hired several hundred new employees at such a fast rate' that adequate training was not given them. stop, or would any of you think of using a Our accident experience for that year was } inspect d equipfor prod be the ned the familiar rector. straight ladder not equipped with safety feet. Why? It's simply because you are aware of "safety" every minute of the day. It is reasonable to assume, therefore, that if "thinking" safety has accomplished the desired attitude for us as individuals in safety work, it can do the same for our employees if administered correctly and ef fectively. far from desirable. We had 79 disabling injuries with a frequency rate of 10.46 and a severity rate of 1.865. Severity was high because of the many amputations, result ing in high insurance costs. - -- Top management became quite concerned and a combined effort was directed towards an effective safety program, the results of which, showed quite an advance toward our ted that unsafe Our aim is to establish a program in our plants that will stimulate this idea of "thinking" safety in our employees. This goal of "no-accidents". Our experience for 1957 was a frequency rate of 1.54 and a severity rate of 1.000. spection met, I careful ate cor trill result in better accident experience in our plants, in the homes and, most of all, on our highways. I assume that all of you have what you feel is a good safety program in effect in We were quite pitoud of this accomplish ment, but to indicate that a better job can be done, our record for the first nine months of tins year is now at 0.55 frequency rate and 0.060 severity rate. 1958 National Safety Congress In order to accomplish this reduction, we approved by the safety department before have used every means available to get the it is used. idea of safety over to our employees. We began, and are still using, all the standard methods, such as posters, signs, special notices on bulletin boards, letters to the employees and, in general, have tried to keep the plants so covered that, no matter where you walk or look you will see evidence of safety. We mail a copy of our safety manual to The information given to the employee from this sheet naturally' includes the method of operation, however, it's main ob jective is to point out all safety factors in volved in the operation, which means any definite hazard, the presence of pinch points, the control buttons used, methods to stop and start, guards and their purpose, and protective equipment required. the employee's homes following his proba tion period of thirty days. This manual is illustrated and in color. We think that the family will have an opportunity' to see the manual and understand that the company is interested in the well-being of their hus band, father, brother, etc We know this has prompted safety discussions among the family and helps them to be concerned when someone of the family comes home from the plant with a bandaged finger, toe, etc These means, while effective however, are hardly enough to obtain the desired re sults. A direct contact with the employees, as individuals, must be made They' must be made to feel that their safety* and the safety of their fellow workers depends an To continue our program, so as to keep the employee mindful of his original in structions, we have posted, periodically, sections of our safety* manual on our de partmental bulletin boards. Supervision is required to discuss these rules each time with his employees and a group of ques tions is provided for the specific section that is posted for the supervisor^ pse to assure that he covers the important items concerning his specific area or department The next step in keeping the employee participating in our program is in our de partmental safety committees. Most of our departments have one such committee, but in the larger ones three committees are formed. their attitude interest and effort in the These committees function on a regular matter at hand. weekly basis. They are composed of one Our program of employee training begins immediately following their entrance as a Maytag employee, when the employee attends a two-hour indoctrination meeting. One general foreman, one line foreman (super vised by the general foreman) and one hourly employee (supervised by the line foreman). hour of this meeting is devoted entirely to In most cases the hourly member of the our safety program. They are given a copy committee is selected by his safety record of the general rules of the company and and his attitude. We aim to select the the company employee in charge of the poorer employee in this regard io serve meeting goes over the entire list with the first. group. This gives them a chance to obtain the initial background for the more speci alized instructions that will follow when they are placed on specific jobs. These committees are given two hours each week to inspect their areas and to hold a meeting to discuss and take action or recommend action on the conditions ob The conference leader makes it clear that served. This inspection and meeting is held the rules covered in this indoctrination meet during the normal work period. During the ing dq, not cover all the safety rules which meeting of this committee, the department will apply to their different work areas. head acts as chairman and is responsible Special instruction is given when the em for taking the necessary action to eliminate ployee is assigned to a specific department the conditions found and discussed. The and is placed on a job. report of this meeting is submitted by the The supervisor is in charge of adminis department head on a special form to all tering this phase of the employee training. management personnel concerned. This is done with the aid of a safety* In most departments, all of the employees training sheet which is written by the super have served on these committees at one time. visor for every operation. This sheet is However, they merely rotate back through 32 Jen before .) 5 employee dudes the 's main obfactors inmeans any nch points, ds to stop rpose, and is to keep riginal iniriodically, n our de:r\-ision is each time of quesic section >r to use iant items ipartment. employee t our dest of our ittee, but ttees are i regular 1 of one ! (superand one th 'pe r of the r record lect the o serve a hours and to ction or MS ob is held ring the artment xmsible iminate L The by the to all ployees e time, hrough Industrial Safety the group again, a second time. When an employee is selected to serve on this com mittee he is scheduled, prior to his first inspection tour, to attend a one-hour spe cial instruction period. constantly aware of safety. The employee must see that corrective action is taken on his recommendations and, if not, it must be effectively explained to him why his recom mendation was not carried out. The safety engineer conducts these meet ings and tells them why the committee functions, the purpose of the committee and why they have been selected to serve. He outlines the items they are to look for in their inspections, such as what constitutes poor housekeeping, what the company stand ards are in regard to housekeeping, what constitutes a hazard, the importance of ob serving unsafe acts of employees, etc After this instruction period is over, the employee is ready to serve for a period of four weeks. In addition to the departmental commit tee, we have another erne which the hourly employees serves on as a member. This committee is called the plant safety com mittee, and is composed of the safety en gineer, who acts as chairman, plant man ager and the head of the maintenance department These three are all permanent members of the committee The union officials select three members on their own, without any instruction from the company, to serve for a period of three months. At the end of the three months one member is dropped and a new one added. The member that has served the longest is automatically the one who is replaced. This committee's function is. to review the reports submitted by the departmental com mittees just discussed. In addition to this, they review plant-wide activities and recom mend changes and new ideas that will broaden our program and make it more effective A report of this meeting is sub mitted to top management The plant safety engineer follows up with the past members of the above committee to observe their attitude and their safety habits. He -discusses the conditions preva lent in their areas and encourages them to continue looking for items that are of im portance and to report them to the present members serving on the committee so they can report the items as a committee for proper follow-up. Constant contact of the safety engineer and the supervisor with the employees is the only way we can make the employees In order to impress the employees with our real interest in accident-free operation, every member of management must do his part in discussing safety with the employees, listening to their safety suggestions and complaints and then doing something about them, in one respect or another. If this part of the program is not carried out, the employee cannot maintain his interest, as he is not absolutely sure the company is behind him 100 per cent All is not perfect, however, in employeesafety relations. Disciplinary action is some times necessary and must be a part of the program also. No matter how many safety-- - - --* conscious employees are employed, there are always some that are belligerent and fail to respond to the well-meaning efforts of management Action has to be taken to combat the unsafe actions of this type of employee or the matter is likely to get out of hand and the other employees will lose interest We have a plan for disciplinary action which, when an employee wilfully violates a safety rule for the first time, he is given a verbal warning. On the second offense, he is given a wanting in the form of a letter which he is requested to read and sign. This letter is placed in his personal history folder. If observed a third time, he is automatically given time off from work.' The length of time is determined by his supervisor. If he commits a fourth offense, he is discharged from the company. As of the present time, we have had to resort to the third step on only a couple of occasions and have never had "an occasion to enforce the fourth step. -- Our experience has shown that some de partments do a better job of promoting safety than others. Recognizing the fact that safety problems differ with each de partment. the fact remains that the attitude of the department head is largely respon sible for the safety experience in the depart ment, regardless of the nature of the work. Because of this we have tried to impress our department heads with the fact that their safety program should be one of 33 195S National Safety Congress their own planning, since they are more closely acquainted with the problems in thdr area than anyone else. it is necessary that more effort be given on the part of top management To accom plish this, the vice-president of production, To promote the plan for individual safety programs, the safety department, the divi sion superintendent and the plant manager meet individually with each department head at the beginning of each new year to dis cuss with them thdr experience for the past year. The safety department provides the necessary statistics regarding the num ber of minor injuries, type of acddents, reasons for acddents, etc periodically, will make a complete inspec tion of the shops. He will contact the de partment head and have him accompany him through his individual department and the Vice-President will observe the house keeping standards, safe operation of the equipment, unsafe acts by employees, etc. He will also stop now and then and dis cuss safety with employees during his in spection. As a result or this meeting, the depart ment head is expeaed to review the infor mation to make his plans for the safety program for the new year. He will sub mit an outline of his proposed program within approximatdy two weeks following the original meeting for approval. The group will suggest additions or corrections We have found this idea is very effective, since most of the employees are impressed by the fact that top management takes time and shows enough interest to make an in spection of their areas. They seem con vinced that the company is interested in maintaining a safe and clean place for them to work. in his program, if necessary, and if all is agreeable, the department head formulates a final copy or his safety program which is primarily his responsibility for the com ing year. Recognizing the fact tFSl everyone likes to receive recognition for doing a good job, sane -of our departments are issuing in dividual letters to the employees in their department, complimenting them on a good As a follow-up, the same group as men accident record. A record is maintained at tioned previously continues to assist by all times on each employee's accidents. scheduling meetings with the department heads at approximatdy three-month inter vals. This meeting is to review his accident experience and to see if his department is carrying out the plan of action as outlined. If changes are necessary, this group assists in revising the program if it is failing to After an employee has had two injuries, his foreman and department head will dis cuss these accidents with the employee, in a _ constructive manner, and ask him for recom mendations to eliminate recurrence. In most cases, the employee can recommend some thing that will eliminate future acddents. accomplish its original purpose If practicable, the department head will This particular phase of our program has eliminated the general feeling that the safety department's program is not effective. Since see that his recommendation is given the proper attention, if not, he will explain why something else must be done. the department has outlined its own pro To show the value of this part of our gram, it has the responsibility to see that program, in 1955, we were averaging 160 it works. Department people take more minor injuries a month, and as of this pride in doing a good job since, because of year our average has been 75 minor injuries the program being thdr own, they reedve per month. the credit for accomplishing thdr goals.- --The mate thing,"as I stated in the be With the employees taking an active part ginning, is that the sooner we get our in the^program of safety and with depart mental supervision meeting with top man agement to discuss safety, we fed sure employees thinking and discussing safety with the same interest that we in safety do, the sooner we will eliminate, not only everyone is convinced of die company's at industrial acddents, but off-the-job accidents titude towards safety. However, many times as well. 34 : given on o ?^om>rc Son, te .-apecct the deccompany Blent and he housen of the yees, etc. and disg his in effective, impressed aims time ke an ineem conrested in for them one likes good job, suing in- in their n a good itained at lents. injuries, will disiyee, in a >r recomIn most id '"tne10. Its. lead mil [iven the ilain why t of our ging 160 of this injuries the be get our l safety n safety not only accidents Industrial Safety SAFE DESIGN OF INDUSTRIAL FURNACES By J. a SMITH Chief Engineer, Factory Mutual Engineering Division, Norwood, Mass. Industrial furnaces for metallurgical proc essing usually consist of a steel frame and steel caring with a refractory lining suitable for furnace operating temperatures and the work processed. Ordinarily, we define a furnace as a heating device with a work chamber that operates at more than 700F. Consider the most common type of indus trial processing furnace, the heat-treat type, from the standpoint of explosion safety. There are three baric requirements for an explosion in a furnace: a combustible ma terial in gaseous or vapor state; an accumu lated mixture of the combustible and air within the flammable range, and an ignition source. In industrial heat-treat furnaces, there are two kinds of explosion, designated according to the source of the combustible. First is the fuel explosion in which the combustible is the fuel used to heat the furnace, usually fuel gas or fuel oiL Second is the flammable special atmosphere explosion; here the com bustible is the flammable spedal atmosphere used in the furnace for metallurgical pur poses. Fuel Explosions The most common type of furnace is the direct-fired, where the products of com bustion from the beating flames enter the main furnace work space. In the indirectfired type the products of combustion are re stricted to the heating system and do not enter the furnace work space. There are two methods of heating: with an external heater and a recirculating fan, and where the heat is distributed uniformly throughout the furnace by an arrangement of a multiplicity of burners. The second type we designate as a multi-burner furnace. To understand how explosions occur, it must be recognized that the periods of burner operation consist of lighting-off or relighting, and firing. During a recent 10-year period, 100 explo sions from the fuel hazard alone occurred in industrial furnaces. In general, the amount of property damage loss was proportional to the furnace size. The explosion hazard which could result from a passage of fuel into the furnace through a valve left open or leaking during shutdown will be minimized chiefly by ap proved, manual-opening, automatic-closing, safety shut-off valves, and by adequate peri odic testing of all valves and safety control devices. Trained burner men are essential. At best, automatic safety controls furnish only partial protection against explosion. Entire depend ence is placed on burner men for completing these vital precautions: Before opening individual burner fuel jocks to light up, a reliable ignition source should be placed in front of the burners. Too long or repeated unsuccessful attempts to light off can lead to accumulation of an explosive air-fuel mixture within the fur nace. To minimize this hazard, the burner man should limit each trial for ignition to five seconds. If unsuccessful, fuel should be shut off, door reopened, or the furnace purged by the best available method before repeating the attempt Avoid the practice of tiring the burner mixer compressors or blowers to furnish a preventilation purge in the furnace. This method may introduce the hazard of purging with an explosive mixture created by draw ing gas through a leaking shut-off valve as the combustion air passes through the mixer. A properly arranged F. M. cock gas safety control system mayjbe used tqprotect against this hazard. Effective explosion vents are generally im practical on industrial furnaces. Gas-Fired Furnaces Ninety-two of the 100 explosions men tioned occurred in gas-fired furnaces. Of these, 50 per cent occurred during the light ing-off period, 40 per cent during operation (firing), and 10 per cent during relighting after burner flame extinguishment No ex- 35 1958 National Safety Congress plosions occurred while the work space tem 2.Provide automatic preventilation. perature was more than 1400F. A number There are also several safeguards recom of explosions did occur while warming up mended during firing: v furnaces, in which normal operating temper atures exceeded 1400F. The majority of the lighting-off explosions 1. The recirculating fan should be reliably interlocked. 2. Provide combustion safeguards. occurred in multi-burner furnaces where the operator failed to close all individual mainburner gas cocks and to establish reliable pilot flames at all burners before opening the main furnace gas salve. 3. For heaters having burners with lowpressure-atmospheric inspirator-type mix ers: (a) The burner should generally be used only for constant firing at a fixed Firing explosions were equally caused by rate, or "on-off" firing with continu the operation of burners with scant air for ous pilot perfect combustion, resulting in formation of an explosive carbon monoxide and hydrogenair mixture; and by the accidental flame failure with no means for automatic fuel shutoff. (b) Provide adequate combustion air by maintaining the suction in the heater produced by the recirculating fan above -0.20 in. water column. (c) Provide a high-temperature limit The majority of relighting explosions after switch at the heater outlet accidental burner flame extinguishment were caused by failure to first purge the furnace before re-introducing an ignition source. 4. For heaters having burners with mix tures utilizing-separate blowers or com pressors, limit turndown so the proportion Recommendations for direct-internal- of air does not fall to less than 83 per fired multi-burner furnaces. These four cent of the amount needed for complete safeguards are needed to prevent explosions combustion. during the lighting-off period: There is one safety measure recommended 1. Use the F. if. cock and gas safety control to prevent explosions upon relighting. After system. an unscheduled shutdown, resulting from ac 2. Proride individual burner cocks, where cidental burner extinguishment the com practical. bustion safeguard should be interlocked to 3. Install fixed pilot burners, where practical. provide a five-min. prevcntilation purge by 4. Provide manual preventilation. the recirculating fan. Three safeguards are recommended to pre vent explosions during firing: 1. Well-designed and maintained mixers are recommended to safeguard against the accumulation of explosive, unburned, cornbustibles-air mixtures. 2. Provide continuous pilots, if practical, on furnaces operating at less than 1400F. 3. Interlock the fuel supply and the com bustion air so failure of either trill im mediately shut off and lock out all gas supplied to the burners: Thera, are two safeguards recommended to prevent explosions during relighting periods: 1. Provide manual purge before relighting. 2. Relight burners individually. Recommendations for direct-externalfired recirculating one- or two-burner fur naces. Two principal safety measures are recommended for lighting off: 1. Where fixed pilots are installed, they should be supplied with premixed gas. Recommendations for indirect-internalfired radiant-tube-type multi-burner fur naces. Radiant-tube-type burners are ex plosion resistant and, unless in poor condition and leaky, there will be no fuel explosion hazard in the furnace. To protect against the discharge of unbumed gas into the furnace room or into the products of combustion ex haust duct system, the fuel supply and the combustion air should be interlocked so fail ure of either will immediately shut off and lock out all-gas to-the burners. Incidentally, many basic safeguards needed for gas-fired units are also applicable to oilfired furnaces. Flammable atmosphere explosion haz ards of special atmosphere furnaces. In Factory Mutual plants during a recent 13vear period, 27 explosions occurred in heattreating furnaces using special atmospheres. Twenty-five explosions were caused by the ignition of an accumulated explosive flam mable special atmosphere-air mixture. 36 5 r*-->m- ) reliably ith lowype mix- be used a fixed continu- th mixor comoportion i 83 per complete imended j. After from acle comtcked to urge by icr Qare oudidoa xplosioa linst the furnace don exand the so failoff and ; needed e to oil- >n hazces. In :ent 13in heatspheres, by the e flam- Industrial Safety The most important factors in minimizing the explosion hazard in special atmosphere furnaces and generators are: selection by management of competent, well-trained oper ators to properly conduct phases of furnace and generator-operating procedure, and es tablishment and execution of periodic testing of controls and of a maintenance program. generator so an inert atmosphere is obtained almost free of combustibles (more than 82.5 per cent aeration) as well as oxygen. Peri odic checks of the generator output by gas sampling devices are desirable. In special cases, it may be practical to obtain an inert gas for purging from a bank of nitrogen or carbon dioxide cylinders. The two critical periods of furnace oper ation with a flammable atmosphere are: starting the flow of flammable atmosphere, so the air is reptaced with flammable atmosphere; and stopping the flow of flam mable atmosphere, so the flammable atmos phere is replaced with air. During both periods the atmosphere in the furnace passes through the explosion range. Accidental interruption of a continuous supply of the flammable atmosphere is also dangerous--air may immediately start to en ter the furnace. Experience has shown that 140QF furnaceoperating temperature is a reliable piloting or ignition temperature, above which com bustible-air mixture cannot accumulate and build up to dangerous amounts. A special atmosphere, if it has a con centration exceeding 8.8 per cent of flam mable incomplete products of combustion, will enter the explosion range when mixed with air. To obtain such a flammable special atmosphere from the combustion of common fuel gases, the aeration of the gas must be reduced to approximately 82.5 per cent or less. The term "aeration'* means the propor Given sufficient time, gases of different densities diffuse and form a uniform mix ture throughout a container. The minimum amount of mixing permits the most rapid purging with the least amount of gas. In furnaces with vertical chambers, such as the tower type; lighter-than-air atmosphere gas should be admitted at the top of the furnace and heavier-than-air atmosphere gas at the bottom, the air being discharged at the oppo site end. Where it is impractical to obtain an inert atmosphere, it becomes necessary during starting-up~fS~tnim oanb6"air," and during " shutting-down to burn out the flammable atmosphere: During starting-up when the air in the furnace is replaced with flammable atmosphere and during shutting-down when the flammable atmosphere is replaced with air, the possibility of explosion is avoided if all parts of the furnace are at more than 1400F. If at the point where flammable atmos phere or air enters the furnace the tempera ture is less than 1400F, a reliable ignition source should be provided. In special fur naces such as the tower type which has an almost totally enclosed work chamber, tion of air furnished to the burner to that whether the furnace is more or less than amount of air required for chemically com 1400F, an inert gas should be used to purge plete combustion of the fuel, expressed as a the work chamber, and the burn-out method percentage. should not be used.' Where practical, rinsing or purging with With certain batch-type furnaces such as inert gas before starting and after stopping the bell-cover, box-cover, car and elevator the flow of flammable special atmosphere is furnaces, explosive mixtures cannot always the preferred method of avoiding explosive be avoided; the process requires tuming-on flammable atmosphere-air mixtures. This is and shutting-off the-special-atmosphere while especially advantageous where furnaces or the furnace is cold, and inert gas purge is sections of furnaces are less than the gener not practical. ally reliable gas ignition temperature of Explosion safety depends on keeping igni 140QF. Flow rate indicators and time clocks tion sources away from the furnace interior should always be used to insure that the ex- ' and from the mixture' issuing from the fur plosive mixtures have been eliminated. nace vent pipe while the furnace atmosphere On the average, an amount of atmosphere is in the explosion* range on starting-up, and gas equal to five times the volume of the again on shutting-down. chamber is required. Often it is posable When starting-up, if the base of the fur during starting-up and shutting-down to ad nace contains a fan, it should not be oper just the air-gas ratio of an atmosphere ated until after completion of the purge. 37 r-J P-1 'm S ; if? 1958 National Safety Congress Where the recirculating fan has supply and return ducts in which the gas may be trapped, it will be necessary to operate the fan throughout the purge. The furnace heating shell must not be placed over the inner cover until the cover contents are proved to be almost free of air. Complete replacement of air by flammable special atmosphere should be proved by sampling the gas issuing from the vent pipe by a gas analyzer-type indicator or recorder which would not present an ignition source. By flow meters and clocks, the time required by purging with a standard flow rate should be determined. The vent pipe of the furnace work chamber should be equipped with a properly arranged, approved automatic fire check to protect against flashback during the purge period. Efflux should not be lighted until after positively determining that the mixture is not explosive. Usually contact with air cannot be per mitted until the work is cool. Under these conditions, special atmosphere should not be shut off and the work removed until the temperature of the work chamber has dropped to 300F or less. Immediately on shutting off the flow of special atmosphere, the work chamber should be purged of flammable atmosphere by the burning-out method. This is accomplished by placing a reliable ignition source at the lip of the inner cover and lifting the inner cover slightly to allow air to enter so the atmos phere may be burned gradually. SAFE OPERATION OF INDUSTRIAL FURNACES By L. B. WOCHOLSKI Associate Chairman, Physics, Heat Transfer and Electrical Department, General Motors Institute, Flint, Michigan Safe operation of industrial furnaces is a highly controversial subject that has no sim ple approach or solution. It involves equip ment and people. Since furnace explosions occur in practice and not on the drawing board or in the talking stage, it is important that industry be staffed with alert, careful, competent and well-trained personnel that can operate the available furnaces safely. Therefore, the purpose of this paper is to present an approach to training and a sug gested program to develop operating furnace personnel. It is important to consider that the avail able industrial furnace is only as.safe as:-- 1. Engineers can recognize a safe instal lation. 2. Furflace personnel can recognize safe furnace operation. 3. Maintenance personnel can recognize the importance of proper maintenance. 4. Safety engineer? can recognize the safety aspects of furnaces with their related equipment and their operation, 5. Manufacturing can recognize the im portance of keying production with safe furnace operation insofar as personnel, physical equipment and quality of the product are concerned. If the above recognitions are made accu rately and completely and are meaningful for safe operation, this paper would be un necessary. However, I would like to review the severity of the four main areas of fur nace explosions that occur in practice which were presented by J. D. Smith, chief engi neer, Mutual Factory Engineering Division. First, 46 per cent of the gas fired furnace explosions occur in the lighting-off period. Most ^f .jhese^explosicns occur when the furnace operator fails to close all the indi vidual main burner gas valves or he fails to establish a pilot flame at each burner be fore opening the main gas valve. Second, 36.8 per cent of the gas fired furnace explosions occur during the firing operation. The common causes of these ex plosions are: Formation of an explosive mixture of carbon monoxide, hydrogen and hydro carbons which accumulate in a furnace when a burner operates with insufficient 38 he --vge m jttii : niiAitire be perier these Id not be until the ber has flow of x should i by the ished by : the Bp er cover abnos- ES xal sound, of the a\ ung. J be un review f furwhlch engirision. trnace eriod. n the indi fails x be- fired Sring : ex- e of 'dronace dent Industrial Safety air for complete combustion and acciden tal flame failure with no means for auto matic fuel shutoff. Third, 92 per cent of the gas fired furnace explosions occur during the relighting opera tion. Most of these explosions are caused by faik e of the operator to purge the furnace before relighting. Fourth, of all the explosions that occur in protective flammable atmosphere furnaces, 92.8 per cent are caused by the ignition of an explosive accumulation of flammable at mosphere gas mixture within the furnace. From the above facts, one can easily say that most of the explosions can be prevented if the furnace personnel are alert, careful, competent and well trained. Operators with these qualifications can recognize a hazardous condition and can initiate the necessary cor rective measures to eliminate the condition. The approach to training requires the sin cere participation of all key personnel di rectly associated with the successful opera tion of the plant, and it must indude the following steps of policy making, designing, creating, training and follow-up. It is essential that top management must recognize the need for greater-on-the-job safety training and to start the organiza tional set-up for the program. This action should be a preventive measure rather than one of meeting an emergency. Therefore, improvements in the quality of the product, decreases in processing cost, and decreases in scrap must be recognized by management as secondary' results of this program. The results of this type of train ing must be evident in personnel safety, first, and second, in physical plant equipment safety. The policy group, made up of key super visory members of management from areas, such as heat treat, safety, plant engineering, maintenance, metallurgy and manufacturing, must form a cooperative group to dissemi nate pertinent information concerning the safety aspect of their activities. By the inter change of this information, the personnd directly associated with furnace operation indicate acceptance of their responsibility for safety. The important work of this group is in the area of determining policy and of de ciding the organizational action required to meet the objective approved by top manage ment. The appointment of the right people in the organization to design the training pro gram is also made by this group. The design group decides on the content and coverage to satisfy the objective and de sired end results of the training program. This group sets up the necessary guide-lines, such as titles, objectives, major topics and desired results for eadi session. In addition suggested methods of applying furnace principles and nomenclature to on-the-job furnace operation are included in the guides for the writer. The final act of this group is the selection of plant people best suited for creating the various sessions of the program. This creative group consists of the writers and training aid builders who develop the best training methods, techniques and text materials necessary to effectively meet the desired results,^.established by the design group. This group must work very closely with the various processes in the furnace area, as their efforts must specifically em phasize safety of operation of these processes at all times. Integration of training with plant opera tion includes the organization of training to obtain the greatest picture motivation for the application of the knowledge gained in the training program to his job, resulting in greater on-the-job safety. After the operator completes the regular training program, a follow-up preventive measure is necessary to keep him alert, care ful and competent At definite intervals, lectures, demonstrations, films and/or con ferences should be scheduled. A check list of safety measures and simulated emergency drills should be used to determine the effec tiveness and the retention of the furnace operator's knowledge of safety. This follow up is necessary for safe furnace operation. -The following are-suggested sections of a training program for people directly asso ciated with industrial furnace operation. An objective and suggested topical coverage are included in each section. The first section must be a resume of the factors winch create hazardous conditions in the furnace area. All hazardous conditions must be discussed .with emphasis placed on fires, explosions and toxic characteristics of materials used in the furnace area. This sec tion is necessary to develop the purpose of the program and to motivate the interest of 1958 Xational Safely Congress the operator. History of some of the hazard ous conditions which resulted in accidents arc important to this section. The second section must give the operator an understanding of the nature of combus tion as well as developing an appreciation of the hazards inherent in combustion. Basic in formation concerning fuels, combustion, re lated chemical reactions, products of complete combustion, products of incomplete combus tion, flash point, fire point, explosive limits, toxic limits are included in this section. This material can be keyed to the factors covered in the first section and to the fuel* used in the plant The third section must give the operator an understanding of the principal function, important construction features, operations and specific uses of the furnaces operated in the plar:. Schematic drawings, models, manu facturer's brochures and inspection of the furnace on the job can be effectively used as training aids. Controlled atmosphere as well as noncontrolled atmosphere furnaces should be included in this discussion. For plants that use protective atmospheres, the next section must give the operator a familiarity of the protective furnace atmos pheres generally used in industry and a working knowledge of the specific atmos pheres used within his plant. For industrial furnaces, the main types of atmospheres to be considered are endothermic (RX), exo thermic fDX). dissociated ammonia, raw ammonia and steam. The association of the protective atmosphere to a specific plant application gives the operator a better under standing of the protective atmosphere. Dis cussion should include: effects of the pro tective furnace atmosphere on people, the duct, heating elements, thermocouples and furnace rcfractorie-: gas analysis of each type of atmosphere: and inertness and com bustibility characteristics_of each. This sec tion must associate the characteristics of the furnace atmosphere to the methods of secur ing a furfiacc. The next section must give the operator an understanding of the principles of the com monly used generators and dissodators with their related equipment. Emphasis must be placed on the types used within his plant Chemical reactions, factors affecting the chemical reactions, normal operating condi tions and methods of purifications must be included. Flow diagrams for each method are good training aids for this section. A safety device section must give the operator a working knowledge of the devices that are used on furnaces, generators, dissociators and their related equipment for safe operation. Emphasis of this section must be placed on: the nature of the device, its use, its limitation and its specific locations. Fuel safety shut-off valves, fire checks, tem perature limit switches, pressure limit switches, purge timer, COj systems, color coding, safety flame indicators and masks are some of the devices to be included in this section. A section on analyzing, controlling and measuring gases must give the operator an understanding of the importance of each device to the safe operation of a furnace. Emphasis must be placed on gas analyzers, -gas-analysis controllers and measuring de vices, such as temperature, pressure and flowindicators. Operators must have a working knowledge and a skill to operate the measur ing and controlling devices so that data meaningful to the proper operation of the furnace can be obtained and evaluated. For the operator, the most important sec tion gives him the correct step-by-step pro cedure of starting (lighting), firing and securing each furnace or furnace system for norma! on-the-job conditions. A statement explaining each step is necessary to give the operator a better understanding and a greater appreciation of the procedure for safe opera tion. An emergency procedures section must give the operator a step-by-step procedure for each furnace and its related equipment so that he can act safely in handling known types of emergency situations, such as power failure, heating gas supply failure, protective furnace gas failure for furnace temperatures above~tt0O F and below 1400 F. Again, for the operator to understand and appreciate the procedure, each step must be explained completely. The final section must give the operator an opportunity to use the knowledge gained in the program to analyze an actual operat ing situation as well as an emergency situ ation and to develop an approach to correct the situation safely. The emphasis of this section is on solving a furnace operating problem; therefore, the 40 i method on n gi. ihe e devices tors, disnent for ion must ivice. its ocations. ks, tem*e limit is, color asks are ' in this ing and ator an >f each furnace, lalyxcrs, ing dend flow vorking neasuru data of the d. int sectp proig and em for dement ivethe > opt-- must cedure ipment known power :ective atures n, for edate lained irator ained >erat- situirrect K-ing , the Industrial Safety operator must be able to obtain the facts of the situation, isolate the trouble, evaluate the possible solutions, decide on a specific solu tion and activate the solution. This section is the pay-off of the program. Summary.--A training program must be tailored to meet the peculiar characteristics and needs of the individual plant Since damages are proportional to the size of the furnaces, a training program may be considered more important for a large plant than for a small plant No furnace regard less of size should be taken for granted. Success of a training program depends on the sincere participation of all people directly associated with furnace operation. An effective training program must pro vide the operator with sound knowledge in the proper operation of a furnace that will enable him First to recognize the presence of a haz ardous condition, and Second, to initiate the necessary corrective measures to eliminate the condition to assure safe furnace operation. A training program that successfully ful fills the above considerations is a practical answer to the problem of safe operation of industrial furnaces. PLANNING SAFETY INTO"AUTOMATION By THOMAS E. SEAVEY Master Mechanic, Pontiac Motor Div., General Motors Corp., Pontiac, Mi>h In the planning, designing and building of automated equipment for industry, safety has assumed equal importance with the life of equipment, cost, productive capacity and similar requirements, as seen from the buy er's viewpoint. Since the purchaser of new equipment is vitally concerned with safety, the automation manufacturer also has be come concerned. The ultimate user of this equipment is interested from a humane and economic standpoint. Safety is no longer a by-product, but a major objective of manufacturers. It is not good business to injure your employes when, through a concerto), conscientious ef fort, these accidents could be minimized or eliminated. This is aside from the economic dotiarsand-cents approach, in light of the rising insurance and compensation costs. The costs of an accident are not measured only in tangible black and white figures, but in hid den costs, suffering and sorrow. It is now far safer to be at your job working than to be at home. Statistics show the home accident rate is many times greater than the industrial accident rate. A goodly portion of this success can be ascribed to planning and forethought to prevent acci dents before they can happen. Equipment has undergone an evolution to meet the needs of industry. Technical ad vances have been necessary to keep costs down and manufactured products within the reach of the consumer. Inherent in this evo lution have been problems of control, lubri cation, materials and safety. The complexity of this equipment normally makes safety not only more necessary but also more difficult to attain. In the days .of the simple drill press, an off and on switch was more than adequate from an electrical standpoint, with guarding at a minimum. In corporating this drill press into an automated line multiplies the hazards manyfold. In planning or design, no one set of rules can apply to all situations that could occur ifi tfre^tiesign of a complex, special-purpose piece of automation or automated equipment. Some rules will have to be violated in the interests of other considerations. Still the hazard should not be allowed to exist, and a new approach might have to be instituted to cover the particular application. General There are safety considerations that can not be readily classified as strictly mechani cal or electrical. These factors can be ex amined as a general recommendation. 41 1958 National Safety Congress A definite need has always existed for Inspection gates should be provided on some signal to indicate that a piece of auto some types of automation. Certain types of matic equipment is about to be started. Due parts many times must be removed after a to the obstructed view automated equipment critical operation to determine whether the is difficult to properly dear visually before parts are being machined within limits. Pro starting. visions should be made for properly inter A suitable audible signal should be in locked gates that allow a part to be skidded stalled in a timed circuit, compelling the or moved without back-wrenching lifting. operator to sound the signal before the ma Swinging or rotating-type leaders, or un chine will operate. Some manufacturers now loaders, are frequently serious safety haz incorporate these devices in their equipment ards. These loaders normally work very In the operation of automated equipment, air is not desirable from a safety standpoint Air is difficult to control, compressible, easily contaminated and expensive. quickly and the cams, trip levers and control switches create a large number of pinch points. This situation is compounded, if the mechanism is operated by air. This type of equipment is virtually impossible to guard, It is the control and compressibility that particularly in protecting the repair or setup causes air to be inherently unsafe. A piece man. of air-operated equipment may be shut down electrically and still be potentially dangerous because its air motive force is still under compression. -- --~------- In the general machine setup, hydraulic lines, conduit and air lines should be kept dear of the floor to eliminate stumbling but high enough to prevent hitting one's head on During sudden stoppages, when possibly a part is wedged in the transfer mechanism, unless the air system is bled, the part or transfer mechanism can do great damage them. Pipes along the floor, or just above the floor, make too convenient a place to stand of lean. A worker can easily slip off of these pipes and injure himsdf. when released. This damage could easily in Machines should be fitted with sensible volve the person or persons releasing the guards that are a 'forethought' not an `after stoppage. thought.' Some guards, attached to a ma Air operation varies with control due to moisture, drops in line pressure and subse quent erratic action of air. There are in stances where hydraulic equipment is not applicable, and air must be used, but air is normally not as desirable. In the design stages, shear and pinch points in automated equipment are one of the most fertile fields for safety accomplish chine create a greater hazard than the one being guarded against Guards should be' arranged so they can be easily replaced after tool change or repair, or they will not be used to advantage. A guard difficult to re place should not be used. Guards of ex panded metal that allow visual checking of a machine operation without removal are widely and successfully used. ment If machines could be designed more Mechanical tcide open, it would eliminate places where people can be trapped and a serious injury result There are a large number of safety con siderations that fall into the mechanical category, even though the mechanical and Some machines are so designed on the electrical divisions are often tied closely to rear of their. borizontaL~wing units that a gether. person could be caught between the return ing head^or slide and the supporting base unit The majority of automated machines and automated equipment between machines is not designed or built of a construction sub Bridge supports used to maintain upper stantial enough to withstand the stress im mechanical units, such as transfer bars and posed by mass production. hopper feeding units through which the part Bracing, casting cross sections, and screw is transferred, are normally designed so close sizes are many times too light to retain then- to the minimum clearance that a serious original alignment and accuracy. Conse `Pinch poinf is created. Attention to these quently, the twisting and moving of the factors during planning stages would elimi equipment causes accelerated wear and re nate many hazards. duced safety. 42 vided on tjf.. \of 1 i /a :ther the ilts. Proly inter: skidded ifdng. or unety hazirk very 1 control >f pinch d, if the type of j guard, or setup ydraulic be kept 'ling but head on t above ilace to slip off sensible i `after- a mathe one raid be* id after not be of i ring of ral are 7 conhardcal al and ely to- es and ties is a subss un screw l their 5onseif the id re- ' S Industrial Safety When weight is not a prime consideration, heavier construction is almost always advis able to preclude the possibility of permanent distortion, when the unusual occurs, such as jams, wrecks, broken parts or cutters and sudden stoppages. While equipment is still on the drawing board, the shop maintenance man frequently becomes the forgotten man. Objectives that are normally considered too few times in clude the factor of accessibility from the repair standpoint This applies even to ac cessibility for minor adjustments which must be made relatively often. Machines have been designed, built and put into service, requiring a small man to make repairs and adjustments. Such cramped working space can only lessen safety. Cylinders, fittings, and lubrication facilities are placed in `available' space rather than in a planned location. Some cylinders have beenso hidden as to require a major tear-down to remove them for such maintenance as pack ing replacement Some pieces of equipment appear to have been assembled around the milling and drill ing heads, making them inaccessible except from atop the machine. Working' from atop a machine is a great safety hazard, because coolant and lubrication cause unsure footing. A large portion of industrial accidents are from falls. Machines built along these lines are nor mally hazardous even for a jobsetter to change and set tools. Machines that must be climbed on to change or adjust tools or fix tures are not uncommon. Built-in walks or stiles on machines of this nature do much to reduce this hazard. Walks or steps of smooth metal are almost as poor as none at alL Materials on the market of the expanded metal type are excellent for the fabrication of stiles or walks. These materials retain their skid resistance even after-long use. The walks are not made hazardous with oil, water or other materials which cause surfaces to be slippery. Hydraulic equipment on automation or automated equipment should be run on mini mum pressures or only enough pressure to overcome operating resistances in normal operation. Operating equipment at abnor mally high pressures causes undue strain to the structure of the equipment, and in sud den stoppages could multiply the damage and subsequent hazards. All hydraulic equipment should be banded or permanently marked for proper operating pressures and settings. This procedure many times in addition to its safety benefits aids in trouble-shooting, because it indicates con ditions of abnormality that point toward possible maintenance problems. In addition to identifying pressures, it is wise to have indicated on the control valves, the direction of morion of the element controlled when the valve is manually operated in a particular direction. Many times solenoid-controlled valves must be moved manually for some reason of set up, checking after a repair is made, or to release someone caught in the machine. To know which direction the transfer bar will operate when the valve is manually pushed in one direction or the other is valu able. It could mean saving an arm, leg, or a-lift Regarding lubrication, a central lubrication system on a machine or piece of automation is almost a "must." The day of the indi vidual fitting or oil cup has long since passed. Although central lubrication has been a long step forward toward safer maintenance of equipment, there have been other hazards that have accompanied its use. The control of lubrication systems of the various types sometimes causes the use of too much lubri cant, which finds its way to the floor and creates its own hazard. All ways and other surfaces involved in `expended* lubrication should be provided with drain troughs channeled into a tank or system through which the surplus lubricant can be controlled. Many plants make use of this expended lubricant in the reclaiming process, in which quantities of cutting oils are made. Provisions should be made to pre vent this material from creating an addi tional hazard. All filling facilities on central systems, hy draulic systems and grease fittings should be arranged, depending on the application, to be out of the danger areas of an operating ma chine. Almost all of the lubrication of equip ment is accomplished while it is in operation. Overhead automation with lubrication fa cilities, and even air line lubricators, should be serviced from the floor level rather than have workers use ladders or climb upon the equipment 1958 National Safety Congress There are air-line lubrication systems in be arranged to be available from virtually use that can be filled automatically from a every* spot on the machine and from either central tank at floor level, keeping die level side. in the lubricators overhead at a working level without the hazardous necessity of climbing up to them. A widely-used application of this type of stop, particularly on long extended machines, is the safety cord. All of the machine's Washers built as a part of an automated functions and its related equipment should line are cause for a possible accident if the be stopped, using this safety stop. inspection or access doors have been removed while the equipment is potentially operative. Should the rest of the line cycle cause the washer to operate with these doors open, serious injury could result. Recessed start buttons on equipment are important This stems from the number of accidents that occur when a person's body comes in contact with an exposed start but ton while the machine is bring repaired or Access or inspection doors which, if left tools changed. This is especially true if the open, could cause injury' should have the lockout rule is violated. steam valves, pumps and other apparatus tied Since in many machines hydraulic power into a safety circuit controlled by limits on is used to activate the various functions of these doors. If a door were open, even if the machine, before transfer hydraulic pres the rest of the line cycled, the washers sure can be applied, all panel switches must would be inoperative--a situation true of be on. This would cause one of the most much of the new automatedequipmeat. ' potentially dangerous elements of the ma A section will appear harmless because of chine to remain inoperative until the rest of a condition elsewhere on the line when it is the machine is made ready to cycle. much like a `loaded gun' waiting to be triggered. In fixture design the use of controlled air blow-offs to dean locating pads is a safety' feature. Here, there is no necessity for the operator to reach into the machine with risk to himself to dean the locators. Properly placed and controlled, these derices are an advantage. Electrical Some machines are arranged so, if one section is shut down, the transfer through this section could operate, because it gains its pressure from a hydraulic unit connected to a still-active adjacent section. Locking out one transfer section does not assure safety. Through an economy effort, much equip ment is made with tingle solenoid spring return control valves. These economies are soon lost through the potential accidents pos Electrical automation safety leaves much sible in their use. to be improved. Although there is some ef A positively placed valve spool in a two fort toward standardization, safety appar coil valve is far superior because of the pos ently is not always a prime objective. sibility on a single coil valve of the spool Many plants have a general safety rule that a machine must have the master discon nect switch locked in the off position before creeping or becoming mislocated and causing subsequent jamming, erratic cycle. Double coil valves should be used wherever possible. a machine is to be worked on by' mainte In equipment operated pneumatically, the nance people or jobsetters. Although impor trapped air compressed against a sudden tant from a safety standpoint, this rule is stoppage is as dangerous as a coiled spring. difficult to 'enforce, particularly if the dis Electrically, a solenoid controlled dump valve connect switch is inconveniently located, as should be arranged to dump all air pressure on an devated platform or at one end of a to the machine when the stop, or emergency long machine. stop button is used. It is advisable to have this disconnect on the floor levd and normally as dose to the midpoint of the machine as possible. A rule convenient to obey is more readily enforced than one requiring extra effort Many machines are built without emer gency' safety' stops, or the stops are not readily accessible. Emergency stops should This accomplishes the same thing as shut ting off the hydraulic system in a hydraulic ally controlled roadiine; the source of the moving force is removed; and in the case of the air operation, the back pressure is dumped. Automatic washers, ovens and blow-off section should be arranged to become inoper- 44 1 virtually rw' |her is type of machines, machine's ait should pment are lumber of on's bodystart butpaired or rue if the ilie power notions of tulic presches must the most the ma ke rest of o, if <me r through : it gains connected iddngout : safety. :ch equipid spring miies are ler 'ps- in a two f the posthe spool d causing . Double * possible, cally, the i sudden id spring, imp valve pressure mergency : as shutydraulice of die e case of 5sure is blow-off e inoper Industrial Safety ative when the covers or access doors are removed for inspection or repair. These safetys would cause all pumps, hot water and steam facilities to be shut off until the doors and similar units were re placed. At this time the machine could be recycled and placed in automatic cycle. Important in automatic equipment is find ing what is wrong when its does not cycle as it should. Many accidents that occur on auto mation are during this period, when a repair man must subject himself to certain hazard ous situations. Many times a machine must be left in the "as occurred" conditions, so a repairman can correct a machine fault after discovering the cause of the irregularity. Often, if a machine fails to cycle and is shut down, an electrician cannot determine what is wrong or what piece of equipment failed. Because the power must berfeftron, it presents certain hazards conducive to acci dents. Placement of limit switches in areas easily reached without subjecting the repair man to serious hazard is advisable. Remote controlled limit switches are ad vantageous for the preceding reason and be cause applications requiring a coolant nor mally move the switch out of the coolant area. Limit switches shorted by- coolant are potentially dangerous. A machine of automatic nature should be wired to be failure-safe. If a switch fails, the machine will not become a hazard. An example is in the feed of a milling head. It should be so designed, if a rapid traverse limit switch fails, that the machine would be in fine feed. This eliminates the possibility of a machine going into the work in rapid advance. The dement of fluidity is inherent in the preliminary design and layout of the com ponents in an automated production line. For instance, experience supporting this informa tion has shown that the engine cylinder block line design could be hdped by lessons learned in previous automated block line building: there were existing lines where debugging had made considerable progress. But the en gine camshaft was on virgin ground, and the design had to be taken from the air. In spite of this difference, both lines were alike in that they bad to be custom-tailored to the Boor plan and the work piece, and did not lend themselves to the stipulation of rigid safety specifications, other than those appli cable to standard installations. It was not un til the preliminary design had left the draft ing board that it could be attacked from the safety angle. A team composed of process engineering, plant layout; plant engineering, production supervision, and the equipment builder's engi neers began the real work of constructive criticism and suggestion. An important part of that work was the detection and removal of potential safety hazards. This scrutiny continued through the build ing and the initial tryout on the builder's floor, and through the activating on the tactory floor. The safety department then was called in to inspect before and after. This scrutiny has never ceased. There were no rules. There were only problems on safety that had to be solved, and solved before they turned into traps. OFF-THE-JQB SAFETY--WHY? HOW? BENEFITS? (A PANEL DISCUSSION) (Co-sponsored by Petroleum Section, National Safety Council and American Society of Safety Engineers.) Presiding: Lee F. Dougan, Senior Safety Engineer, Sinclair Oil and Gas Company, Tulsa, Oklahoma. Discussion Leader--Thos. J. Berk, Safety Consultant, Metropolitan Life Insurance Co., New York City. Participants: George A. La Husen, Gen eral Safety Supervisor, Crown-Zellerbach Corporation, Portland, Oregon; C. A. Miller, Chief Safety Engineer, The Texas Co., Houston, Texas; D. E. Mumford, Director of Safety, The New York Central System, 1958 Xational Safety Congress New York Gty; J. S. Queener, Manager, Safety and Fire Protection Div., E. I. Du Pont de Nemours and Co., Inc., Wilmington, Delaware. Dougan: We are here to leant the funda mentals of off-the-job safety or to enlarge our present knowledge. Off-the-job safety is achieving long-deserved recognition. There will be three phases in today's discussion: (1) Why? (2) How? (3) Benefits. Ques tions from the audience will be answered by anyone on the pane! who would like to answer, and the audience will be asked questions, too. Berk: Mr. Queener will begin by telling us why we are emphasizing off-the-job safety. Queener: We have had an off-the-job committee for several years, but have had difficult}- in getting industry interested. Only about-forty corapanies-are participating ac tively. Off-the-job safety can lower fre quency rates by 30 to 40 per cent. Anyone should want it, apparently, but we have been having trouble selling our gold brick. Maybe it's too good. There are probably several reasons for the poor interest in off-the-job safety: man agement is not aware of the problem, people think that off-the-job safety is an invasion of privacy, they think that there is too much record keeping now, some unions are against it, and some safety people, frankly, are not selling it. The reporting form has now been sim plified. It is only one page and it is to be submitted quarterly, not monthly. Berk: Do you know what happens to our employees the other 16 hours of the day? La Husen: The story of Roy Campanella is probably the best-publidzed off-the-job accident in recent years. His accident, though, is no more tragic than that of the 19-year old in our plant who lost a leg in an off-thejob accident. He had a good college career ahead of him. Then there was a man killed off the job--an employee of ours. He left a 32-year-old widow and six children under ten. Three hundred and thirty-nine of our employees lost 6,000 man-days and $70,000 in wages. Berk: Do you include the. entire familyon a 24-hour basis? Miller: Yes. You cannot separate the two if you want to reach vour objective. Question from floor: A cleaning woman in our office (Port of New York Authority) asked me, "Why is the company so inter ested in our activities when we're away from the job?" Mumford: In labor relations now we hear the word "paternalism" quite frequently. Well, what's wrong with paternalism? It costs a great deal to train employees now adays. An employee should be grateful for an employer who takes such an interest in his welfare that it begins to look like pater nalism. Even if Roy Campanella had had this tragic accident occur to someone else in his family, it would have affected his ability to turn in a good job, too. Question from floor: At General Electric we have had many employees hurt bv power lawnmowers. It seems to me that manu facturers should advertise how to operate these lawnmowers safely. Why doesn't the National Safety Council encourage these manufacturers and also manufacturers in the do-it-yourself field to advertise for safety? These manufacturers spend millions to advertise merchandise for sale, and nothing to advertise for safety. Queener: The power lawnmower is cer tainly the most dangerous piece of machin ery around the home. One of our employees, wearing safety shoes, had the flesh taken off his foot behind the toe cap. But why pick cm the power lawnmower companies, why not ask distillers, for instance, to en courage their customers to drive safely? Berk: The question was directed to all products. Let us go on to the next ques tion--what are the sources of off-the-job accident expenses? Queener: The company has to payjfor relief personnel, they have to train sub stitute employees, equipment is damaged and the product is spoiled by these green workers, additional workloads are placed on supervision, the injured employees, when they first come back to work are not up to their previous standards, accident and health insurance payments are increased, off-the-job injuries account for 10 to 20 per cent of disability wages paid, group life insurance payments are increased, hospital and surgical insurance payments are in creased. Besides all these, we might point 46 irarate the 'bj* je. ng woman Vuthority) so intere're away >w we hear frequently, alism? It yees now:ful for an est in his ike pater- had had teone else :ected his I Electric bv power at manu) operate Jesn't the ge these :urers in rise for I millions ale, and r is cermachinnplovees, h jsn But .Aiy mpanies, ^ to enfely? d to all ict ques:-the-job pay for in subged and green aced on when not up Mt and ceased, 20 per up life hospital ire int point Industrial Safety out the crowded condition of our hospitals these days. Question from floor: We distribute hunt ing safety literature--does anyone else here do this? What I'd like to know is--how far do you go? We had a hunting safety cam paign but there were these three men who got into a rowboat, started to cross a river, saw a deer trying to swim to the opposite side, and feeling sorry for the creature, lassoed it by the antlers and tried to help it into the boat. The boat capsized and alt three men drowned. As I said, we had a hunting safety campaign, but none of us thought of mentioning the hazards of lasso ing a deer in the middle of a river. On the whole, though, our hunting safety cam paign has been successful. No one has been shot, and for that matter our whole offthe-job safety program has been a success --we have lost no toes--Se--power lawnmowers. Queener: We can't possibly hope to cover every hazard, but we try to inculcate a safe attitude. Question from floor: A comment from the panel disturbs me. Should we continue to conceal the names of manufacturers of dangerous equipment? Queener: Being from a conservative com pany, I tried to give a conservative answer. For example, we manufacture dynamite and we couldn't deny, even if we wanted to, that dynamite can be dangerous when improperly used. The founder of our company was confident that he could handle it properly, because he built his home just a short dis tance from the original powder mill. People buy these rotary power mowers because they are cheaper that the retl type. Berk: We will now try some "how" questions. What is the most important offthe-job activity in the Texas Company? Miller: We started with a first-aid pro gram. We train and retrain our people every year and we have been doing this for the past 25 years. We have a chart that shows when first aid is up, accidents are down. This chart is such a striking demon stration of the effectiveness of first-aid training that it is used by the American Red Cross. We get the entire family interested. Berk: Have any of you used a gimmick? Reply from floor: We had six or seven fatalities from traffic in one year. We now- have a "highway safety audit" We watch how people are driving to and from work. We take the license numbers of poor drivers and have a little off-the-job safety talk with them. We have improved driving attitudes. Floor: We have a family night twice a year. We get speakers on electrical hazards, fire hazards, bicycle hazards, swimming hazards, and especially electrical hazards at Christmas time. We find this very inex pensive--about $50 for one night Floor: We're in a small town of about 9,000 population. Our safety department started a company-community safety com mittee. It has four divisions--home, school, traffic, and industrial. It b getting good publicity. Floor: We had took from the men's home workshops brought in and safetychecked. We emphasized proper buoyancy equipment for fishing. We had the usual gun safety training for the hunting season, too. Floor: My company likes a continuing program, such as posters and mailed pamph lets. We had a company attorney who was on a big case. He had a skiing accident, and was laid up for a long time. The company suffered a tremendous loss because he was not able to defend the company in the litiga tion at the time. With hb permbsion, we used him as an example and found it quite effective. Floor: Our off-the-job safety program b tied in with the on-the-job. We have had one man concentrating on bonding hazards for over a year. We extend that to off-thejob to the extent o'f making home instruc tions. We have lost men to home electro cutions. In one sad case, the survivors pointed to the Underwriters' Laboratories label on a two-conductor cord. They asked us, "What can we do?" Why can't Under writers' Laboratories' approval be removed from all two-conductor cords? Mumford: You must understand the pur pose of the Underwriters' Laboratories' label. That two-wire cord was adequate for its purpose, but a home drill needs a threewire cord. Underwriters' Laboratories' tests only for the quality of the product for the purpose for which it was designed. Floor: I would like to remind the audi ence that we are on the "how" phase. How \ 1 3-; 3 .-.?vj*+j;* A?. !r1 i 1958 National Safety Congress do you convince management--what are the Mumford: Many years ago we had off- mechanics? the-job interest in the National Safety Queener: In a multi-plant company such Council, then it died, and we revived it as ours, we get safety men in various plants again. Ten years ago no one would have interested. We started with a statistical come to this meeting. Even now, we are form--a one-half sheet mimeographed form. handicapped by a lade of information. 1 After they realized what their problem was, urge you to lose no opportunity to add to the initiative came from the field. We did our fund of information on off-the-job not have to sell management, they asked us, safety. To get this movement started, we "What are you doing this year to reduce have had to force our way into other safety frequency?" Our answer was off-the-job meetings. safety. Queener: About the new form--write to Question from floor: What can the com Harry Johnson at the National Safety Coun pany do to foster off-the-job safety? cil for the form and information on about Miller: Tell employees of the hazards. how to use it. For example^ the electrical hazards story. Berk: What are the benefits of an off- Encourage community activities. In one the-job safety program? community the Jaycees had a bike rodeo. La Husen: The greatest benefit is in They put reflective tape on the bicycles, in better attitude among the employees. The spected them, and told the kids how to cor long-range benefit is this--our employees' rect,hazardous riding habits. The women children will some day be employees them of the Sor-Opdmists showed safety films to selves. It is to our advantage to have them the kids. come to us with the proper safety attitude Question from floor: How do you find learned at home. out the nature ol the injury on the form? Berk: What are the benefits you have Queener: We have studiously avoided in received from off-the-job programs other f vasion or privacy. We do not put the em than those it brings to the employee? ployee on the spot We think this has been Miller: Our ratio was eight to one be a wise policy, because we have had no union fore. Now we have better union relations. complaints in five years of off-the-job pro The attitude of the employees is improv gram activities. ing. When they learn that the company is S Floor: Do you send survey results to spending money on safety, their attitude im employees' homes? proves. Queener: No, but we get off-the-job Mumford: I saw labor at work at last safety information to the home through year's Congress. Those men are looking for magazines and other mailed materials. Berk: Does anyone in the audience have a form to survey off-the-job injuries? Floor: The foreman uses our form. It gives the name, how the man was hurt, and how many days he was off. But we found that some places with good on-the-job rec ords had bad off-the-job records. Floor: Our form has a one-line descrip tion of, the injury. Miller: Our form is a modified sick bene fit form. I analyze it and make up the re port. answers. At the President's Conference on Occupational Safety in Washington, Victor Reuther made a statement, "Safety is not a matter of codes or compulsions, but a matter of people working together." Berk: What happens to on-the-job safety when attention is given to off-the-job safety? Queener: We had reached a plateau, so in 1953 we adopted a comprehensive offthe-job safety statistical form. We broke through, and we are convinced that off-thejob safety' did it Another advantage is that off-the-job safety gives the supervisor s Berk: How do you spread off-the-job a non-contrcversial matter to take up with safetv? workers. 48 ow, -we are irmation. I r to add to ofi-the-job started, we Jther safety n--write to ifety Q>an ti on about of an off- nefit Is in >yees. The employees' yees themhave them 1y attitude you have ams other y-ee? o one be: relations, is improvocnpany is :titude imrk ist wiring tor erence on mi, Victor :ty is not ns. but a r* ob safety iff-the-iob lateau, so isive offVe broke t off-thetntage is upervisor up with By ROBERT H. FERGUSON Asst Dir., Industrial Relations, Republic Steel Corp., Cleveland, Ohio This engineering meeting has been called because of the widespread interest in this important subject and so that we might dis cuss the basic fundamentals of the problem. Recreational Boating Safety has grown so rapidly that many of us interested in the field were not even conscious of the problems which have developed. When I indicate that the people taking part in and using boats will increase 15 per cent in 1958 and approxi mately 25 per cent in 1959 and that one American in every twenty-five is jjow a boaf owner, it is just a little difficukto re alize the volume of this traffic in recreational waters. These boats are used by Americans in all walks of life. The fisherman, the yachtsman, the water skier, are only a few to be men tioned. The problem is so great that ship ping lanes and channels where the fisherman "wets his line" are often the scene of tragedy when the smaller craft gets involved with the freighter or the passenger boat Tins same statement applies to fresh water as well as salt water and the outboard motor enthusiast while in great numbers is cer tainly not outdone by the sailing cratt and bboard-type recreational vessel. Most of the persons here this morning realize that we have a problem b recrea tional waters. This is the first of a series of sessions to be held by the National Safety Council on the subject, and may I predict that unless drastic action is taken to engbeer, educate, setup and enforce safety rules, we will be faced with a problem approachbg the one we are now strugglbg with on the vast highways of this country. I might add that for every two boats sold, there is one trailer. The boatbg problem and the spendbg b relation to it has reached a retail level of more than $2,000,000,000 b 1957. One of the major, sound credit organizations of this country has set up a separate credit branch to aid b the financing of the purchase of recreational boating equipment What has been done concerning water safety for boats? The United States Coast Guard under the direction of Admiral A. C. Richmond, who is with us this morning, has long advocated strict safety rules on the waters. These precautions are bdicated not to limit the use of the pleasure craft but to get the bdividual "know how" and con fidence b his boat to eliminate tragedy. We are bdeed -fortunate to have the splendid leadership of the Coast Guard personnel b this work. The Congress which has just closed passed the Bonner BilL This is Pub lic Law 85-911 and certainly is a start ip the right direction to aid all of us who love the water. In addition, the United States Coast Guard has proposed "Standards, Rules and Regula tions" in an effort to further the educational and engineering work to aid safety. 49 1958 National Safety Congress THE SAFETY ACTIVITIES GOVERNING RECREATIONAL BOATING SAFETY DEVELOPED UNDER THE DIRECTION OF THE UNITED STATES COAST GUARD By VICE ADMIRAL ALFRED C. RICHMOND Commandant, U.S. Coast Guard, Washington, D.C. Safety on our recreational waterways is the result of common sense, courtesy, and education. Whether a motorboat becomes a pleasure or a menace to life and property depends on the manner In which it is main tained and operated. The Coast Guard, through its facilities and those of the Auxiliary, endeavors to assist boat owners and operators by recommending safe practices for the operation of motorboats- We re-emphasize to the nation's boat ing public that we are all working toward the same objective--safety. Only with the help of all concerned can we hope to spread the gospel of self-reguladoc and common sense, and bring to a halt the growing record of needless death and destruction now attendant on the rapidly in creasing family sport of motorboating. We do not govern safety. Common sense, courtesy, and education cannot be governed. However, it must be admitted that safety in pleasure boating can be improved by a proper blending of law enforcement and education, and that both are required tools in any ef fective safety kit. The Coast Guard conducts many activities in enforcement and education to promote recreational boating safety. These functions and responsibilities provide that the Coast Guard shall enforce or assist in the enforce ment of all applicable Federal laws on the high seas and waters subject to the juris diction of the United States; shall administer laws and promulgate and enforce regulations for the -fcromotion of safety of life and property on the high seas and on waters sub ject to the jurisdiction of the United States covering all matters not specifically delegated by law to some other executive department; and shall provide aids to maritime navigation and rescue facilities for the promotion of safety on and over the high seas and waters subject to the jurisdiction of the United States. Promoting Safety As the governmental agency directly con cerned with promoting marine safety, the Coast Guard appreciates the contributions other organizations have made in this field. It is evident that individual educational pro grams hare been pursued vigorously and have been expanded each year to accommo date a greater number of the boating public. However, it is also apparent we have readied only a segment of this growing fraternity. The need to develop a more wide-spread educational program is most pressing. In tensifying emsting programs will be a posi tive contribution. However, coordination of our efforts is a greater need. The Coast Guard furnishes training films and various publications, such as Motorboats, containing information on equipment requirements and regulations; the Motorboat Safety pamphlet; Aids to Navigation booklet and others. We plan to produce a completely new publication on recreational boating safety this January. Boat shows are other excellent means for stimulating safe boating education. Every* effort is made to participate, with exhibits manned by Coast Guard and Coast Guard Auxiliary members available to answer in quiries and distribute Coast Guard publi cations. To further spread the word of safe boating, "National Safe Boating Week," was proclaimed this year by the President The aid given by various boating associations was greatly appreciated and helped in making this new project a successful one. Recognizing the important problems in volved in promoting boating safety, the Secretary of the Treasury sponsored the first National Small Boat Safety Conference in Washington, D. C, December 11-12, 1957. Representatives of 36 industry and boating organizations, boating publications and gov ernment agencies attended the Conference which resulted in 19 recommendations for 50 ly conty, the butlons s field al proly and annopublic cached nity. spread g. Ina posi tion of g films \Iotoripment Iiotorigation due- ati I ns for Every xhibits Guard rer inpubli>f safe was t .The ns was naking ns iny. the td the erence . 1957. oating ! goverence is for Industrial Safety the promotion of small boat safety. The National Safety Council was an active par ticipant in this Conference, with three repre sentatives attending. In the Bonner Report on Recreational Boating Safety, comment was made on the "jack of comprehensive knowledge of the extent of fatalities and accidents in the rec reational boating fields" and that "accurate and comprehensive statistics regarding boat ing accidents are almost non-existent" The report stated that the desired statistics must be "accurate," "be agreed upon" and "meet with the approval of all groups concerned with boating safety." With the enactment of the Federal Boat ing Act of 1958, needed statistics now can be obtained on a nation-wide basis. This Act, in amending the Motorboat Act of 1940, pro vides that in the case of collision, accident, or other-casualty- involving a-motorboat, the operator thereof, if the collision, accident or other casualty results in death or injury to any person, or damage to property in excess of $100, shall file an accident report The Coast Guard is authorized and di rected to compile, analyze and publish infor mation obtained from such accident reports, together with such findings concerning the causes of such accidents and recommenda tions for their prevention. There are pro visions for the coordination of the accident reporting and statistical programs with states that have adopted uniform systems. Law Enforcement The willingness of boatmen to comply with the law has been made clear to us in our daily contact with the boating public. The Coast Guard has found that the number of violations drops off sharply as the public is made aware of the requirements of federal laws for equipment and for safe operating practices. . Our major efforts have normally centered at and near well-established boating areas, where our facilities may be located. How ever, heretofore tmnavigable waters have been improved or new waterways created. These circumstances, together with the in dustry's development of boats and trailers of improved mobility, have resulted in the creation of new boating centers far from the beaten path. The Coast Guard recognized the need to service these areas. In addition to its regular boarding program, mobile boarding teams were organized in recent years. Travelling from one body of water to another, stopping at each but a few days, they were able to stimulate interest in boating regulations and safe practices. The program was well re ceived and is a most effective means of carrying out our law enforcement responsi bilities and of providing safety educational material to those outlying areas. Basic laws affecting recreational boating are the new Federal Boating Art of 1958, the Motorboat Art of 1940, and the Rules of the Road (or "Pilot Rules" as they are more commonly known.) The Federal Boating Art of 1958 provides for the numbering of certain motorboats and the mandatory reporting of certain ac cidents. It also provides for the concurrent enforcement by federal and state govern ments on the navigable waters of the United States. The Motorboat Act of 1940 places boats in various classes, establishes minimum re quirements for safety and lifesaving equip ment, and, as currently amended, specifies civil penalties or fines for reckless or negli gent operation. The Pilot Rules set forth various rules for the piloting of boats and vessels to pre vent collisions. These federal laws and regulations are en forced by the Coast Guard throughout the navigable waters of the United States, its territories and possessions. Facilities, Services The Coast Guard is responsible for pro viding aids* to navigation and rescue facilities on waters subject to the jurisdiction of the United States. These aids include buoys, lighthouses, light ships, radio beacon stations and Loran stations. In the fiscal year ending June 30, 1958, the Coast Guard maintained some 39,992 of these aids. Accidents will happen, and in that unhappy event the Coast Guard stands ready to use all of its services, facilities and manpower to search for and rescue survivors. Coast Guard rescue facilities are located through out the waters of the United States, its ter ritories and possessions. During the fiscal year 1958 the summary of rescue statistics shows about 24,000 assistance cases handled by the Coast Guard, and 2450 lives saved or persons rescued. 51 1958 National Safety Congress Coast Guard Auxiliary The Coast Guard has dace 1939 spon sored a voluntary, non-military organization to promote safety in the maintenance, oper ation and navigation of small boats. This affiliate is the Coast Guard Auxiliary. It numbers more than 15,800 men and women and functions in 500 communities throughout the continental United States, Alaska, and Hawaii It is most actively engaged in two ex panding public service programs. During the past year 50,000 persons enrolled in the Auxiliary's three different free public in struction courses- At the same time 68,000 courtesy motorboat examinations of small ciait were made at the request of the owners. Boats meeting the requirements of the law and additional safety standards of the Aux iliary are awarded a decal for the current year. The- record indicates a 50 per cent increase in each of these activities for the first six months of this year. In addition, the members patrolled 300 regattas and an swered more than 2,200 calls for assistance. The Auxiliary* is a most valued adjunct in the Coast Guard program to arouse the interest of the ever-growing number of new and prospective boatmen in the maritime safety program, and to foster a wider dis semination of boating safety practices among small boat operators. Promulgating Regulations Proper blending of law, regulation and education is essential to the achievement of a maximum safety program. The Federal Boating Act of 1958, the Motorboat Act of 1940, and the laws setting forth the Rules of the Road provide for the establishment of additional regulations by the Secretary ot the Department under which the Coast Guard is operating. The Merchant Marine Council of the Coast Guard is the deliberative body which, after public hearing required by the Administra tive Procedure Act, recommends rules and regulations or changes to be prescribed. This process insures that the public will have every consideration and that such laws or regulations will promote safety. I annually have appointed a Motorboat and Yacht Advisory Panel to the Merchant Ma rine Council, consisting of representatives oi national reputation from industry and boat ing organizations, to advise me and the Council on boating safety matters. The Coast Guard has consistently followed a policy of non-interference in matters of construction standards for small pleasure motorboats. We find boats designed by naval architects or built by reputable builders have scantlings adequate for the purpose. There are exceptions. We have had requests for scantlings from builders, indicating a need for guidance in construction standards. We have in the past and will continue in the future to support industry-sponsored efforts, such as the American Boat and Yacht Council, in de veloping snch standards. LEGISLATIVE ASPECTS UNDER CONSIDERATION TO PROMOTE SAFETY OF THOSE OPERATING SMALL BOATS By MRS. GEORGE WELLES, JR. Governor's Boating Safety Committee, Duluth, Minn- It might be a good idea in starting to have the record absolutely dear as to my position on this panel. 1. I am jest an average boatman operating on inland or state waters. 2. Though I belong to and work with some safety organizations and boating 52 organizations, such as National Safety Goundl, St. Louis County Safety Council, American Red Cross (a chair man for water safety), a member of onr Minnesota Committee on Boat and Water Safety mid U. S. Coast Guard Auxiliary, I do not today represent offi- Industrial Safety dally any of these organizations nor will these remarks of mine necessarily represent the thinking of these groups. 3. I am a fisherman and I am a hunter. 4. I am both a "stinkpotter" and a sailor. 5. All together, our family (my hus band and myself and seven children) can count seven boats of all types and sizes. 6. I am not a water skier or skin diver, but my sons are. 7. As a family, we have found both great pleasure and great annoyance com ing from boating and boaters. We have strict family rules and regulations and will welcome and abide by sound state laws, because we believe in the need, to ~.....' increase the pleasure for those using our public waters. 8. Lastly, I have read and studied the testimony in the 1600 published pages of the Bonner Committee hearings throughout the country, which can be fairly said to represent the thinking of the majority of boatmen in the U. S. I am familiar with the Bonner Commit tee report and the bill itself--Federal Boating Act 1958 or Public Law 85-911. It is dear that the very rapid rise in the popularity oi boating as a family recreation and its abuses has brought about this great interest and demand for some sensible safe boating legislation, both on a federal level and on a state level. The figures put out by the industry itself as estimates of the extent of recreational boating today are astounding. 1. $1,912,000,000 retail `level for boats, motors, equipment, docking, storage, etc. 2. Nearly $400,000,000 for new boats and motors alone. 3. 35,000,000 persons using our water ways. 4. 7,071,000 recreational craft on all waters--nearly trebled in 10 years. But, there are several other factors beyond the obvious over-crowding and increasing hazards that have done much to arouse the states' interest in better safe boating legis lation. It seems to me that the earliest step forward in this direction was the two Water Safety Afloat Conferences five years ago, sponsored by OBC, with the American Red Cross as a cooperating organization. At the second one hdd at Fox Lake, Illinois, four year ago, the delegates who came from 17 states were given OBC's first proposed model boating act and the influence of this was soon seen in several states. Two years later, OBC presented its second model boating act more up-to-date and streamlined, and more states fell into line. The next great influence on state legisla tive trends was of course the Bonner Bill (now the Federal Boating Act) which H. I. Richmond has already covered Looking at this from a state's view, we find this is in fact a "states rights" bill and as such was written with the close cooperation of the Coast Guard and the Council of States Gov ernments. The result is that it tends to give the states wide latitude while promoting uniformity. In effect, it makes possible the return of all waters of a state for numbering purposes including federal waters. There is, of course, a set of standards set up which a state must meet if it is to be allowed to have jurisdiction to number motor boats on all waters. These include: 1. Coordination of state numbering with a national uniform numbering system including uniformity of location and display of numbers. 2. Renewal at least every three years. 3. Pocket size certificate of number. 4. Notice of transfer of ownership. 5. Reporting of accidents systems. 6. 90 day reciprocity on numbered out of state boats. Another provision which has great appeal to the states is that which makes state law enforceable on the navigable waters of the U. S., as well as on other waters within the states' jurisdiction. Federal law applies-here also. Other parts of the act have to do with ad ministration and enforcement There are no special safety provisions. However, the Fed eral Motorboat Act of 1940 contains mamsafety requirements (though it has been generally agreed this could be brought up to date). When this bill passed Congress final ly, we in Minnesota felt that it was definitely in our best interests to accept these standards and incorporate them into our own proposed legislation. 53 1958 National Safety Congress The next big step forward was still an chose to handle this. Some might set other suggested model "State Boat Act" up a new state agency--others might sent to all the states by the Council of State divide the responsibility among ex Governments. The purpose of this new model isting state agencies. was to assist the states in securing state legislation that would be complementary to the federal legislation. This was set up also with assistance from the Coast Guard. Briefly, the suggested state act contains these essential provirions: Thus, at this point, the states are con fronted with a growing demand for sound legislation and the question of how best to proceed. Do we adopt the federal number- ing system, do we repeal our present boat laws, if there are any, and start all over or 1. That the numbering of all (no JO amend existing Ian's? Shall we use the sug L.P. exemption) inboard and out gested model act word for word or adapt board boats will be uniform and con it to our own? form with federal regulations and those standards I mentioned will be met In my humble opinion. I'd say take your state waters back and accept the federal numbering system and for the sake of uni 2. It prorides for safety equipment such formity use the suggested state boat act as as' life preservers, lights, ventilating closely as possible. Look at what a blessing systems, whistles and fire extin a uniform automobile code throughout the guishers to meet C. G. requirements country would be and it is plain that in the on federal waters. This means natu years to come we shall see the wisdom of rally that there wifi be no confusion passing uniform boat laws today. in requirements taking jour boat from state to federal waters. As you can also see, with complete uniformity it wifi not be necessary to worry about whether you are on federal waters or state--thus neatly sidestep ping the problem of definition of "federal waters." 3. Also for the sake of uniformity this For -the benefit of those of you who have never gone through the labor pains of giving birth to proposed legislation, let me say that from my own personal experience in my state of Minnesota, I'd rather give birth to twins again than a bill. From now on, I am going to speak specifically about what we in Minnesota are doing, as I am not Fred Litton, the well informed legislative coordi suggested state act provides that the nator from OBC who knows what all the state law wifi govern throughout the states are doing. Sorry he couldn't be here territory of a state but will permit a locality having an unusual local prob lem to apply to the appropriate state agency for special rules and regula tions to handle that situation. 4. There are additional requirements in today, but his help to us has been invaluable. Our committee was fortunate in being called together as an official "Water and Boat Safety Committee of the State of Minnesota" and our primary' task was the writing of proposed boat safety legislation. cluded in the state act not covered by the federal law and which have become of great importance recently' --that is, water siding, boat races, tournaments, etc This somewhat official capacity had a ten dency to eliminate the writing of dozens of "seretebair bills that have a. tendency, to spring up. This reminds me of one law in the state of Washington I came across as 5. Also included and of interest to the a fine example of what I'm talking about. states is the section on civil liability. In the law it actually says "There shall be The owner is liable only when a boat no squirrelling or burning doughnuts." is used with his express or implied consent (such as being used by any member of the immediate family). Back to Minnesota. Our battles (I mean meetings) were held at the state Capitol and, at first glance, the committee appeared to 6. The proposed state act uses the term be made up mainly of non-boaters indig "appropriate state agency" in con nantly demanding operators' licenses, limit nection with administration. This was ing speed, limiting distances, limiting horse because it was felt there would be power, limiting boat size, limiting age of some variations in the way' a state operators, throw out the water skiers and I H 54 O' jStt ight mong ex- are con:or sound w best to numbersent boat I over or the sugor adapt afce your ; federal : of unl it act as blessing bout the it in the sdom of ho have f giving say that in my birth to n, I am ;t we in t Fred coordiall ' if be; j titrable. being er and ate of as the slation. a tenens of icy to faur in ` oss as about all be mean 1 and, ed to indig* Bmitlorsefe of ; and Industrial Safety let local regulations prevail, and one man who claimed the federal government was stealing the state house. We boatmen op posed all these as some of these demands actually could cause unsafe conditions or were restrictive to boating as a recreation. I am reminded also of a letter received by Pop. Boating Magazine from a reader on the subject on this type of legislation who ended with "The legislators should listen to practical boatsmen down by the water in stead of a lot of windbags in the state house." He probably does have a point there, in that the good boatsman certainly must be well represented in planning legislation on boat safety. Well, when the smoke died down, there were representatives also from the industry, boatmen and enforcement groups. A sub committee was named eventually to actually draft a bill and progress was smoother. After 13 months, the full committee has just approved the proposed bilL We followed OBCs model act closely. We are still making changes and will in corporate some of the Council of State Gov ernment's "State Boat Act" just received. We plan to repeal, not amend Here, brieflv, are a few highlights of our bill: I. We have left out the 10 L.P. exemp tion set up in the Bonner BilL We feel it is essential to number all if we are really to have a good system of identification. Also, we have in cluded a stipulation that the system must be set up in a central bureau so information on owner identifica tion wifi be available immediately (and not a week later). Our equipment requirements follow Coast Guard regulations for federal waters. Also, even fishermen in small boats at night most display a light--or the hunter going out be fore dawn to his blind (We don't expect to have everyone love us, but we stuck to our safety ideals.) Our registration wilt be handled through the Conservation Department with the Com missioner empowered to set up additional rules and regulations for the purposes of carrying out the Act--such as, inspection of boats for hire, etc. Enforcement in our case goes to the sheriffs. Also inspection of boats for hire. Those of us who wished concurrent enforcement with all peace officers in the state lost out here, regretfully. We accepted the standards in the federal bill on numbering, but did not set up the actual scale of fees. However, we have specified 7 classifications of boats for this purpose and fees will be on a graduated scale. Funds will be in a dedicated fund and not the general revenue and it is likely that 50 per cent will go to the sheriffs for enforcement, 30 per cent to go for ad ministration and 20 per cent for public ac cess. You can't blame the sheriffs too much for wanting the entire enforcement when the slice is 50 per cent We also must consider more public access to the less used lakes to relieve the congestion existing on many others. We lost out to the group who want local regulations. This was due to a district courtruling in Minnesota to the effect this was legal. The Supreme Court is reviewing this now and there may be a reversal. We are still hopeful to knock out local regulations unless carried out by special dispensation from the Commissioner of Conservation. There are other Items, too, but this is enough --it's not perfect--there will always have to be compromises and we will lose some of these provisions in committee, but we will be carrying out the provirions for uni formity. Alright, so you've written a good bill-- "there's many a slip" says the old bromide and how true--between writing it and get ting it passed there's a long hard road to travel. Let's face it--you have opposition. It may line up like this: 1. Some resort owners--(usually 2nd raters). 2. Some hunters, fishermen and so- called sportsmen. (Good ones rarely object) " 3. The general "aginner" who knows his "rights" and "this is a free coun try" and "no one is going to tell me what to do," etc. 4. The legislator, with4infiuence, who has personal reasons for voting No and beware of the old excuse "My constituents would never go for this." Answer: Just go and sell his constituents. Now please don't think I am just gen erally running down legislators. That is 55 St -MM ISj fl hM wm 1958 National Safety Congress not true, as I have worked on boat safety Before I conclude, we in Minnesota would legislation before with a wonderful group like to salute some of the other states who of them who tackled the situation earnestly are doing a fine job of pioneering in modern and worked long and hard to get some good boating safety legislation. Just to pick out legislation two years ago. Our bill was de a handful: Arizona, California, Louisiana, feated, however, and as hindsight is always Michigan--(A leader in this field for many better than foresight, we on die outside years--now building better marinas. Mich learned a lot about what defeated our other igan also has set up a new committee to bill. We were naive enough to think that study such important matters as duplicate a sound bill ran through on its own merits. taxation of watercraft and marine fuels). How wrong we were. Even though we had New York--(Some fine legislation but did used OBCs model boating act, we just include some highly controversial restric hadn't learned about opposition. tions, vetoed by the governor), Oregon, Right here a word about interim commit Rhode Island--(Excellent job), and Wiscon tees. Some hearings in these committees sin. have been most fruitful in eliminating mis However, three states do have the con understanding, but not in my experience. troversial operator's license and three states The interim committee I met with already do have age limitations. Many still have had made up their minds and there was no speed, distance, horsepower limitation. We changing them. We were unfair to hunters, have opposed all these for the time being as fishermen, they generally insinuated. We being unenforceable or too restrictive OBC were unrealistic and didn't know what we has now a printed complete digest of all were talking about Most of them have since states laws which may be had upon request. changed their minds, but the damage was It is very helpful. done. Our earlier bill was defeated by three votes and was defeated by what we call the four intangibles, or you might say the "four Horsemen of the Legislature." 1. Ignorance. Too little was known about boat safety and what actually was in our bill so that when in troduced late in the session there was little time for study. Therefore, our legislators had to rely on hearsay too often. Now, to those of you who are doing a fine job in this field--congratulations! To those of you just starting out--remem ber the value of a state appointed official study committee Twenty-two states now have To the eager beavers--beware of severe restrictions at this time Work for uniformity of numbering sys tem, operation, equipment, etc 2. Misinformation. As an example 50 Consider water pollution, harbor facilities telegrams were received by 50 legis and public access (possibly' in separate bilb). lators when our bill came to a vote Be prepared to get into politics. recommending NO as the bill was Be willing to get out and sell boat safety. "restrictive to the industry." This ' Education in this field is badly needed. was proven false information. 3. Rumor--deliberately spread, usually. We owe a debt of gratitude to those who have already done so much in the field of 4. Selfishness. The legislator who was education--USCG in training Amriliarists,' a resort owner and was afraid he'd U. S. Power Squadron and the Auxiliary have to put on lights and life pre for Public Instruction Courses--OBC and servers on his boats and some legis the industry itself, American Red Cross for lators who voted against to get even again moving ahead, and National Safety with another legislator. Council. There is a tremendous job ahead It doesn't take many of these to lick our of us, if we are to have safe and happy many hard working and conscientious law boating in the years ahead. makers who are doing their best Our fault lay in not spending enough time on selling and getting support We have the advantage this year of the official status, an even greater demand for boating legislation and But remember---a task without a vision is drudgery', A vision without a task is a dream. But a vision with a task is victory. greater public acceptance. We can do it' 56 of wild to j*0 n modern pick out -ouisiana, for many s.^ Michmittee to duplicate e fuels), i but did restricOregon, Wiscon- the conee states ill have oil We being as erOBC t of all request ga fine rememoffidal s sow severe icilities bills). vision Industrial Safety THE PRACTICAL APPLICATION OF SMALL CRAFT REGULATIONS THROUGH SERVICES OF LOCAL SAFETY COUNCIL By PAUL J. HOOVER Vice-President, The Halle Bros. Co., Cleveland, Ohio Many problems relating to boating today are similar to those experienced in motoring 40 years ago. At that time roads were in adequate; proper driver training was almost unheard of; and regulations were only in the discussion stage. Fortunately, the Coast Guard, Coast Guard Auxiliary, Power Squadron, Red Cross, and other groups have offered to many boat oper ators the opportunity to learn safe operation of their craft. Without this training, oar boat accident and fatality rate would have climbed rapidly in the past decade, as it did in the twenties with the spectacular growth of automobile sales. Boat accident statistics are difficult to com pile, but a recent Outboard Boating Clnb of America study showed, boating is maintain ing its outstanding record as one of the safest of all outdoor sports, in spite of the tremendous growth it has enjoyed. Although the number of outboards in use increased from 2,643,000 in 1949 to 4,740,000 in 1956, serious boating accidents have decreased-- 1,243 in 1949; 1,237 in 1956. "The single most important cause of boat ing accidents is 'operator negligence'--failure to exercise common sense and courtesy afloat. Some 31.7 per cent of the accidents covered in the report fall into this category (over loading, standing, sharp turns at high speed.) Capsizing was the second most important cause, accounting for 2&8 per cent of the reported mishaps. And such factors as swamping by wave, the wake of another boat, windstorm, or rain squall accounted for an additional 15.5 per cent of the accidents." We constantly read of or witness the care lessness of the new boat operator, who not only endangers his life but those about him. Some 35-million people use a boat once or more annually, and there are more than 7million boats owned in the United States. It is estimated this figure will double in the next 10 years. What can we, as safety people, do to keep abreast of this growth of boat operation? After a rash of boating accidents in Lake Erie a few years ago, the Greater Cleveland Safety Council decided to take action. As Vice President for Public Safety (and a boat owner), I was asked to organize a boat and water safety program. We of the safety council felt our organi zation was well suited to act as the co ordinating body because: 1. Through our thousands of volunteer workers, we could obtain public support of any boat safety program. 2. We have the means of distributing liter ature and posters on boat safety through our many divisions covering industrial plants, schools, commercial companies, and private homes. 3. Our close relationship with the press, radio and television provides good publicity coverage. 4. Our constant work with the police de partments and public officials in the various municipalities gives us good liaison for quick action at die local level 5. We have the funds and trained staff to handle the many details in connection with an energetic boat and water safety program. A meeting was called of representatives of all agencies interested in boating and water safety. These organizations included the United States Coast Guard, Greater Cleve land Boating Association, Cleveland Power Squadron, U. S. Coast Guard Auxiliary, American Red Cross, Cleveland Chamber of Commerce, U. S. Weather Bureau, and the Ohio State Waterways Safety Commission. This first meeting was not very successful Each of the agencies felt it had a welldeveloped and effective program and could see no necessity to coordinate its activities. However, they all admitted that not enough boat operators were exposed to their training 57 ; / ' Bill yP^M vSI Mi 1958 National Safety Congress and educational materials. They recognized that need for some form of safe boating regulations was urgent and required quick action. Finally, after almost three years and many meetings, agreement was reached on the principle of coordination of the eight organ izations. A separate division in the safety council was formed for boating and water safety. Walter Liesegang, commander of the Greater Cleveland Boating Association, was named vice president for this division. Mr. Liesegang and the group he represents --yacht clubs--had been working for some time on boating regulations for the waters adjacent to Cleveland. It is true that the Coast Guard has the authority to enforce federal regulations, and it does a wonderful job, particularly in regard to inspections for required safety equipment. However, there are minor infractions which are difficult to prosecute because of the cost and delays usu ally found in federal court cases. The first thing needed was a city ordinance regulating boat operation. The new Boating & Water Safety Division was instrumental in passage of such an ordinance. The enforcement problem was not so easy. There were no funds in the city treasury available for police patrol boats. A solution was found when Capt. Peterson, operations officer of the Ninth Coast Guard District, offered the use of their patrol boats for local enforcement Chief Frank Story of the Cleveland Police Department was glad to co operate and assigned 12 officers on a rotating basis to ride in the Coast Guard boats. Coast Guard personnel on the boats are advisors and when a violator is spotted, he is questioned by Coast Guard representatives and police officers. If equipment violations are discovered, the boat operator may be cited for that infraction. If a local regu lation has been disregarded, the police officer may issue a summons for that violation. It wa? realized that wholesale arrests would be unfair, as most boat operators were unfamiliar with the new regulations. Manv thousand copies of the regulations were dis tributed by Mr. Liesegang and his committee to yacht dubs, boat ramps, dealers, and on the water, before enforcement became active. These new regulations received wide pub licity. Thousands of small boat owners immediatdy applied for their certificates of operation and were almost unanimous in their acceptance of the regulations. When the first two arrests were made for reckless boat operation, much pubfidty was given to the cases; the $30 maximum fine assessed each of the boat operators not only gave them a good lesson in boat safety but undoubtedly had a sobering effect on many other careless and inconsiderate boat oper ators. Members of the safety council's Boating and Water Safety Division -meet monthly' and discuss matters relating to water safety. "National Safe Boating Week" was wdl organzied by this group. Publidty pictures were taken of the committee members with the mayor of Geveland, when he signed the Gty of Cleveland "Safe Boating Week" proclamation. Green-cross flags imprinted with "Safe Boating'1 were distributed and flown at all yacht dubs and other boating docks during this week. Inddentallv, with the rise in popularity of water skiing and skin diving, many aeddents have resulted. The Boating and Water Safety Committee invited representatives of the water-ski and skin-diving dubs to meet with it to discuss mutual problems. The first meet ing was bdd in July, and before next sum mer it is expected many of these problems will be worked out It is our feeling that until state and national safety education and enforcement can catch up to the rapidly growing needs in water safetyjdforts, theJocal -safety organi zations must take immediate action. Most communities have the tools with which to work, but as in building a house, each skilled workman must coordinate his job with the others to accomplish the end results. 58 as W m /flisamunittee s, and on ate active, ride pubfners im5cates of imous in made for icity was num fine not only tfety but on many at oper- Boating monthly r safety, well orpictures with tncd the Week" ^printed ted and boating irity of xidents Sr \ of J et with t meett sumoblems e and tement teds in rgani- Most ich to skilled `Ji the Industrial Safety PROBLEMS OF ADMINISTERING MULTI-PLANT SAFETY PROGRAMS D. T. MOULD, Safety Director, General Motors Corp., Detroit EARL H. STOCKDALE, Accident Prevention Div, Golf OH Corp., Pittsburgh, Pa. C. H. HOOPES, Supvr., Safety & Health Services, Continental Can Co., Inc, Chicago W. C. MAHLSTEDT, Safety Eng, Continental Baking Co, Rye, N. Y. L. R. MORRISON, Safety Mgr, A. C. F. Industries, Inc, New York City. J. E. NICHOLS, Dir. of Safety, Reynolds Metals Co, Richmond, Va. D. A. PATRICIAN, Staff Administrator, Safety & Accident Prevention, Radio Corp. of America, Camden, N. J. In this session 114 persons attended. Forty- manager or the person in charge of the eight of these represent 1,400 plants and operation. _________ 1,600,000 employees. Fifteen department heads or foremen, pins eight insurance com pany representatives, were present Questions and summarized answers follow: It is costly, wasteful and dangerous when the experience of a company is not shared with all locations. Prompt exchange of information is essential in maintaining quality Q. How many employees should be required and effectiveness of multi-plant safety pro to have a full-time safety man? A.1 grams. Opinions ranged from 1,000 to 2,500. A majority of those present indicated they Q. Should the safety director have the au presented written accident prevention pro thority to stop or change an operation? grams to their plants. A. Only in an extreme emergency. Such responsibility must be that of the fore man or supervisor in day to day oper ations. Q. Does the safety department also handle fire protection? A. About one-third of those attending indicated it did. Plant management people must be involved in safety meetings, if the program is to be effective. Best results come when the safety office is included in planning plant layout, operations. Standards should be drawn up for purchas ing. Safety consultation should be sought in Q. Does the safety department also handle design and before action is taken on specific insurance? A. Only about 10 in attend plant changes. ance so indicated. Attention of the safety director should be Q. Does the safety department have a bud directed first to problem plants. It is of defi get of its own? A. More than 50 per nite help, when he visits plants periodically. cent attending indicated it does. The size of the company determines fre Q. Is the safety department budget ab quency of his visits."' '* sorbed by others? A. About 20 per cent Several ideas were given regarding awards. attending indicated it is. Most of the panelists indicated recognition The majority of those attending were of the opinion that for greater effectiveness, of good performance was essential to the maintenance of interest in the program. safety should be the responsibility of the When a local plant decides to do less than manufacturing VP and not personnel or in the company requires for safety, it is best to dustrial relations. Best results come when provide line management with the facts and the safety man reports to a line and not a have them take the necessary action to cor staff man. rect the situation. In locations where up to 150 are employed, Most multi-plant safety directors are in the safety representative should be the plant volved only in the investigation of accidents 59 1958 National Safety Congress with serious results. Local plants normally investigate cases and report satisfactorily. Reason for home office participation is to have facts firsthand for answering top man agement questions. Major function of the headquarters safety office is to maintain management interest This is done by collecting data, publishing reports of results, suggesting line manage ment action. REPORTS AND REPORTING PROCEDURES By D. T. MOULD Safety Director, General Motors Corporation, Detroit D. T. Mould described the program devel oped during his administration of General Motors' safely program. He stressed their use of ASA Z.16 code in measuring experi ence. From information subnutted by each plant, monthly reports are prepared and distributed, showing the position of each plant. This posi tion is obtained by adding the position in re lation to frequency to the position in relation to severity. Man-hours worked are used in case of ties, the top spot going to the plant having the greatest exposure. Attention up the management line is given to the bottom 20 plants and the top 20 plants. Home office safety assistance is given, as de manded, and when the plant record indicates need. Integrity is maintained through adherence to standards. Promptness of reporting is es sential to the success of the program. THE SAFETY ENGINEER'S MAJOR PROBLEMS By MYRON L. MILLER Supervisor of Safety, Westinghouse Electric Corp., East Pittsburgh, Pa. In an effort to find the safety engineer's major problems, I sent out 170 questionnaires to engineers all over the United States. The response was most gratifying. I received back 137 replies, which represents an 81 per cent return. The No. 1 problem with the most of you is not a feeling of inadequacy as to your ability, your training, or your skill to deal with the engineering phases of your job. Rather it* appears to be an inability to reach and influence people. One of my good friends in our profession summed it up very simply by writing, "My No. 1 problem can be stated by one word--people." Before looking at the summary. I would like to consider one important aspect of the questionnaire. As you may recall it gave opportunity for you to list your own No. 1 problem before evaluating the 13 suggested sample problems. Less than five engineers indicated they had a problem of equal or greater importance. It was interesting to note that each of these problems dealt with some phase of educa tion and training. There was onejnpblem statement however, which seemed to place the emphasis a little differently. Here it is: "To train supervisors in the art of con trolling worker safety performance." We are indebted to our good friend, H. W. Heinrich, for this statement I consider Mr. Heinrich one of the deans of safety engi neering. He is an author and safety engineer of national repute. He has given active leadership to our society for many years, and though retired from one company, is still busy in the field of accident prevention, with 60 Industrial Safety the* Uniform Boiler and Pressure Vessel Laws Society Inc. of New York. Mr. Heinrich refers to the ability to con trol worker safety performance as an art. This includes not only having a basic knowl edge of the fundamentals on safety, but deals more specifically with the science of motivating or influencing human behavior. Let's examine for a few moments this problem. We must agree that he has struck at the very core of one of our basic prob lems--that of understanding and bring able to control human behavior. Safety engineers accept quite generally the findings of the statistician--the majority of accidents result from human failure rather than from material failure. We are fully aware of the importance of safe working conditions and believe that effective safety programs must be premised on good control of work surroundings. However, after we have put our houses in order, there is no assurance that accidents will stop. In fact, the job is only begun. Our big task is to motivate safe workmanship. Before a foreman or supervisor can in struct a workman in a safe work practice, he himself, must be fully familiar with the safe procedure. To do this requires some form of job safety analysis, to establish both the protective requirements for the job and the specific precautions to be followed. Once the front line supervisor has deter mined the safe practices necessary to do the job, he must know how to teach this in formation to others. This requires a special skill known best to the training experts. I feel sure our professor friends from the col leges and universities can be of assistance here. Mr. Heinrich's problem implies a skill be yond that of knowing and imparting infor mation. It implies an ability to convince or motivate action. Mr. Heinrich calls it an art. We will touch briefly on motivation when we discuss this subject later in our study. In answering the questionnaire, many of you sent in problems which I have compiled into a digest There were almost 50 prob lems which I have grouped under seven categories as follows: 1. Self development 2. Professional status 3. Education and training 4. Skills and procedures 5. Promotion--selling safety 6. Attitude 7. Communication I regret that time will not permit a dis cussion of all of your problems at this time. We will touch on some of them as they re late to your major problem selections. I asked in my questionnaire letter for a numerical evaluation of 13 selected problems. I asked you to arrange them in the order of importance to you. Your replies have been summarized. Rather than attempt to deal with your selections individually, I chose to arrange them in their order of importance by taking the top 25 per cent of the total of the 1st, 2nd, and 3rd choices. Using this method of selection, the problem having recrived the largest number of choices was considered the No. 1 problem, etc Here is the result: 1. To motivate supervisors to carry out * their safety responsibilities. 2. To interest top management in acci dent prevention. 3. To establish good safety attitudes among workmen. 4. To set up an effective safety organi zation. 5. To find college courses to meet the needs of the safety engineer. 6. To secure trained safety engineers. 7. To train workmen on job safety. . 8. To analyze and evaluate my own safety program. 9. To establish realistic accident costs. 10. To make a job safety analysis. 11. To use and evaluate significant sta tistics. I. Motivate supervisors--Ninety-one safe ty engineers placed "motivating supervisors to carry out thdr safety responsibilities" in the top 25 per cent of their problems. Only 10 said.it was no problem. We are competing for a portion of the supervisor's time. For example, we know the front line supervisor has responsibilities al most too numerous to mention--production, quality control, work schedules, time and payroll, tooling, budget control, industrial relations, planning an efficient operation and 61 1958 National Safety Congress a multitude of others, to include accident prevention. Because the front line supervisor is so important in controlling accidents, it is im perative that he discharge his safety re sponsibilities. Supervisors are human beings. They do not want accidents. They cooperate willingly and some cooperate enthusiastically with the safety program without particular motivation. In general, however, they re flect the emphasis of top management. Motivation may be accomplished in vari ous ways, but in my way of thinking there are three considerations which will get good results. You may have a better plan. I pre fer this one. 1. The front line supervisor's responsi bility for accident prevention must be clearly defined by his manager. 2. The front line supervisor must be trained to carry out his responsibility. 3. The front line supervisor must be re quired to make a regular accounting to his manager in the discharge of his responsibility. This may sound rather blunt, but it works. A few years ago one manager in our plant passed down instructions that each job in his department was to be studied and ana lysed by the immediate supervisor. The haz ards were to be listed. The safety equipment was to be noted. The safe work practices were to be established. All workmen in the department were to be briefed in accordance with this analysis. All new men were to be instructed before they started cm the job. The job safety cards which were developed from die studies, were to be used monthly as the basis to talk to each man in the de partment. A record of these talks was re quired to be turned over to the general fore man monthly. At the end of the quarter, the reports were passed on to the superin tendent who reviewed them and sent them to the manager's office. Each time a workman was disabled by accident, the foreman was to place a complete report on the manager's desk before the end of that shift. This program resulted in a very marked improveemnt in the attitude of the foreman toward his safety responsibility. He was fulty aware that he was responsible for the safety of the men working under him, and his boss wanted to be kept advised how things were progressing safety-wise. You may have all kinds of interesting gim micks and safety training courses, but if you want to get results, it is necessary to have top management make crystal clear its safety requirements of the line supervisor. 2. Top management interest--While 76 safety engineers rated this problem in the upper 25 per cent in importance, there were 23 engineers who stated they had no prob lem to keep top management interested. If time permitted, it would be very helpful to have these 23 tell us the methods they use to maintain top management's interest. I was surprised at the number who indi cated this to be their Xo. 1 problem. I will agree that top management needs to be kept informed. I will agree safety engineers must compete for a rightful share of top manage ment's attention and consideration. I will agree that we do not always get what we ask for,-and sometimes it appears we get neither "appreciation'' nor "appropriation." I will not agree, however, that they are dis interested. I hesitate to make an assumption, for fear oi misinterpreting the intention of your an swers. 2 wish it were possible to have all you who consider this to be your Xo. 1 prob lem to state vour point of view. I wish time permitted us to sit down with those who do not consider it a problem and exchange thoughts. May I venture a guess 'that some of the difficulty is not a lack of top management's interest but rather a lack of effective com munication between us and top management. Fundamentally I feel top management is in terested in accident prevention because acci dents not only represent human suffering, but are profit detractors. I feel we as safety engineers can improve on our means of com munication and our methods to stimulate more active top management interest. I&aliring the position of our top manage ment people; we can hardly expect them to do the job they are paying supervisors and safety* engineers to do. Fortunate is the supervisor or safety engineer who has top management's active interest to the extent that they participate personally in the acci dent prevention program. Top management is held responsible by the stockholders to operate a successful busi ness. The measure of top management's suc cess is shown in the profit statement, return 62 sting gimbu?"'wou >* kxe ' its safety sr. While 76 an in the here were no probrested. If helpful to they use rest. who indim. I will 0 be kept cers roust > tnanage1 I will what we s we get priation." f are dis- for fear your anhave all x 1 probvish time : who do exchange r* 'he ge J's ive comagement. ait is inuse acciuffering. is safety of comitimulate managethem to >ors and : is the has top : extent he acci- sible by :ul busiat`s suc; return Industrial Safety on invested capital, growth and expansion of the business, public acceptance, a smooth operating and progressive organization, good employee and good community relations and a number of other measurements. As safety engineers we must compete for the attention and financial backing of our programs with problems of marketing, pro duction, quality control, engineering develop ment, advertising, customer relations, budget and finance and a host of others. If we are to break through this competition barrier to secure a deserved share of attention, we need to learn to talk the language top management understands. Are we exhausting every possible avenue to interpret our function as one of control ling a definite profit detractor? Have we been successful in telling top management that our job deals with the quality control oi the human factor in the business? Have we got across to top management, when we speak of accident prevention, we really mean preventing the incident which results in de laying a shipment, losing a customer, break ing a machine tool and damaging a product: or have we been satisfied just to tell the story* of the man who was struck by a flying particle and lost two days' work? Are we guilty of under-selling our product? Do we provide top management a quarterly statement showing the dollar and cents losses in compensation, medical, and hospital ex penses? Do we place before him the other money losses which accompany these inci dents? Have we ever tried to interpret our lost-time reports in terras of profit detrac tors? Have we pointed out to top manage ment the results of our accident prevention program in terras of units of product saved and profit made? Have we made any effort to dramatize customer relations, employee tension and ad verse public opinion which accompanies poor safety performance? I am sure we will gain the attention of top management just as soon as we start evaluating our accident prevention program and our performance in terms of profit add ers and profit detractors. In saying this, I do not intend to infer that the human aspects of accidents are unimpor tant and of no consequence to top manage ment. In fact I have found this to be quite the contrary. All top management men are human beings. It makes no difference whether they work side by side with a man in the shop or whether they are separated by an office door. They are concerned and dis tressed when a fellow human bong is in volved in a serious accident If the only losses of accidents were ex pressed in human suffering, I am sure our top management would support our safety programs: however, why do we depend en tirely on the humanistic approach? Why do we not try using some of the language which top management is concerned with every day? Why not express your program in terms of profit adders, and cover all as pects of the physical gains which accrue from a good well-engineered accident pre vention program. 3. Establish worker safety attitudes--At titudes have a great influence on the actions of people. I liketo-think of an attitude as that state of mind which determines how a person will react to a given situation. This is probably an over simplification of the defi nition: however, it will serve my purpose. A good safety attitude is like a safety valve in a boiler. It acts as a silent watchman to control a man's actions. We are told that attitudes are affected by education and training, physical or mental conditions, religion, political beliefs, books, friends and associates, home, work experi ences,--in fact every exposure to one's en vironment While well established wrong at titudes are difficult to correct, they can be changed through proper persuasive methods. Good safety attitudes must be cultivated. The foreman plays an important role in shaping employee attitudes. Most people are receptive to suggestions supported by sound reasoning. Most workmen will do as they are expected when they respect the foreman. Most workmen are influenced favorably by good example. _ If the foreman expects people to conform to company policies and company regula tions, he must let it be known by word and action what he wants. For example, if he wants his people to wear eye protection, he must first tell them what he wants, give them sound reasons why, demonstrate his convic tions by wearing eye protection personally, and permit no exceptions either in himself, other management personnel, or other em ployees. He must be persistent and consistent, but patient. 63 1958 National Safety Congress What are some of the ways a foreman can use to build good attitudes? Unfortunately one of the best ways to teach a safety les son is through experience. Those who have lost eyes are convinced that goggles must be worn. Those who have lost fingers will tell you to use punch press guards. Those who have lost a loved one in an automobile acci dent will tell you not to speed. One of the most enthusiastic safety engi neers it has been my privilege to work with was a fellow who lost his brother in a shop accident. He seemed to have a personal stake in accident prevention. To him it was a part of his way of lift He practiced the golden rule. He believed he was his brother's keeper. A foreman cannot let his people learn to be safety-minded through personal experi ence. Education of this type is costly and painful, seasoned with blood and tears. A foreman can tell a story: how well do I remember a young fellow studying for a musical career at CJ.T. He had outstand ing talent as a violin player. The summer of his junior year he took a job as a press operator in one of our valley industries. His career was ended when be cut off two fingers on his left hand. There is the financial appeal. Workmen's compensation will not pay the bills. A crip pled man is dead weight on his family and society. No normal red-blooded man wants to be a charge on society. He is financially better off to be working. Safe practices will help keep him on the job. A foreman can do a selling job. Sales are made by convincing people that the benefits of working safely' are many. The losses of having an accident are great. When a super visor associates man's basic wants with the security of safety, he has a sound motivator and attitude builder. If he can thoroughly convince a workman that -safe workmanship will give him the things he wants and unsafe workmanship will destroy, or take away his security and wreck his future plans, he has one of the strongest motivators known. Most of us will agree that attitude plays a very important part in our program and it behooves us as safety engineers to make sure that every one concerned with safety develops a healthy attitude toward accident prevention. This imposes an obligation on us, that we must never belittle or minimize any effort, big or small, which contributes to building sound safety attitudes. Accident prevention is serious business. 4. Effective safety organisation--There are various ways to organize people to carry out a safety program. It would be difficult to get agreement on an ideal arrangement to suit every* situation. Some of you get good re sults with a staff type organization, others prefer a more direct approach. Others use a modified line and staff organization. Many things influence organization--peo ple, product, geography, plant construction and facilities, size of company, services rendered, company policies and other things. Each safety engineer must determine the organization structure best suited to hi< particular industry. The arrangement with which I am most familiar and__which has proved successful 'for us at the plant level, has the safety or ganization reporting to the industrial rela tions manager and performing a staff ad visory sen-ice for the line organization. The line organization, from the manager to the front line supervisor is responsible for acci dent prevention and the safety of the people. The foreman is the key man in this or ganization. He is responsible for carrying out the safety policies and has the solid backing of line management. He may secure aid to set up his program or to solve any of his safety problems by- calling upon the staff safety' organization--the supervisor of safety, the safety' engineer, or the safety inspector. Also, the foreman may consult with his line superior on money expenditures and other management consideration. He may appoint workmen to act as safety observers. This gives a three angle approach to the jobline management, staff service, employee help and cooperation. In this type organization the manager fixes the responsibility for safety in his line personnel. The supervisor of safety' meets periodically* with the manager to develop safety policies and to give consideration to general problems. The manager passes this information along to his line people. The safety engineer who reports to the safety supervisor, sits in on all regular meetings of the manager's staff and acts as a consult ant in matters of accident prevention. The safety inspector attends the safety observer meetings where the foreman acts as the i Industrial Safety h contributes d^r 'jxidcnt chairman. The program however is built around the foreman as the key man. ---There are ; to carry out I have found this type of safety organiza tion to be very effective in getting results in our type of industry. As stated before how lifficult to get ever, the safety organization is dependent unent to suit upon many different factors. You must study get good re vour own industry to decide the type best cation, others . Others use ization. ilzation--peoconstruction suited to your needs. 5. Safety engineering courses--What are the college courses available to safety engi- I neers to meet their needs? Thirty engineers considered this a major problem. my, services other things, etertnine the uited to hi< Clyde Rich oi our Northern Ohio chapter writes, "I personally believe that college courses must be established to fit the prac tical needs of industrial safety engineers." i I am most id successful He goes on to say that if we can meet these needs adequately, most of our present prob lems will be solved. ie safety oriustrial rela- a staff adnization. The nager to the ible for acdif the people. i in this orfor carrying as the solid e may secure solve any of po: ^ staff wi .safety, ty inspector, with his line s and other may appoint ervers. This Homer K. Lambie, member of our national executive committee asks that we define the functions of safety engineering, as a requi site to determine the college course needs. Joe C Stennett. also of our national exec utive committee proposes several questions. "How much need is there for college trained safety engineers? Should safety engineering be taught as a separate course? To what extent can safety be integrated into college engineering courses?" John V. Grimaldi, former chairman of our committee on cooperation with engineering societies and a present member of our na tional executive committee asks this ques tion, "What exactly does safety engineering work include and how should a safety engi neer go about his job?" to the job-- j These are excellent questions. Our com mployee help mittee on cooperation with engineering col leges know some of the answers. Also many he manager :y in his line safety meets to develop of our colleges and universities have given attention to the problem. Perhaps our friends from the universities here today will give consideration to some of these questions. sideration to If time permits in our discussion period, I - passes this feel sure our able past national president, people. The A.S.S.1L, \V. N. Cox, Jr, professor of > the safety safety and industrial engineering. School of lar meetings Industrial Engineering, Georgia Institute of as a consult- Technology, Atlanta, Ga, has engaged in ention. The research into the academic needs of the ety observer safety engineer and can offer some enlighten acts as the ment from the university point of view. Many engineering colleges offer a subject or two in industrial safety. Some colleges have expanded the curriculum to offer more extensive industrial accident prevention train ing. If you are interested in the colleges which offer safety courses, this information is available from our committee on coopera tion with engineering colleges. 6. Secure trained safety engineers--John F. Juli, our past national president, writes in substance, "If we could get trained safety engineers well grounded in college courses to meet their needs, the other problems cited in your questionnaire would be pretty well taken care of." The problem of finding the trained safety engineer rests with the industrial relations manager, the manager of accident preven tion services or the staff management repre sentative in charge of plant safety. Where does he turn ? - A common practice is to up-grade within the organization. The one selected may or may not have had formal technical train ing, but usually he is well grounded in manu facturing procedures and job practices. If there is a college in the area that offers night school courses in accident prevention and re lated subjects, he will be enrolled. He will be scheduled to attend safety conferences and conventions. He will seek-out the local chapter, American Society of Safety Engi neers and attend its meetings. Eventually he will seek membership. He will make con tact with the local safety council or the Na tional Safety Council and enroll in the baric * and advanced courses in accident prevention. He will avail himself of the Safety Council services. The manager may choose to hire a recent graduate in I.E, M.E, E.E, and bring him into the organization for a year's orientatipntraining. If he has chosen to elect a course in industrial safety while in school, this fact will be to his advantage. The problem of securing trained safety engineers will be acute until such time as colleges and the safety engineering profes sion come up with a course of study which meets the needs and skills of the safety engi neer. 7. Train workmen in fob safety--Before workmen can be trained in job safety, two things basically must be known, (A) What 65 195S Xaiional Safety Congress \ to teach, (B) How to teach. It is up to us shop language, when used as a teaching aid r as safety engineers to assure ourselves that to train the workmen in safe work practices. \ the first requisite is covered. We can look Time does not permit me to discuss the to our training specialists to furnish us with details of teaching. This is a task for the the method of teaching. In this area our training expert As implied by Mr. Hein professional men from the colleges and uni rich, it is one of the most important jobs. versities can be of help. The art of teaching should be mastered bv The knowledge of what to teach comes evety supervisor and instructor. It is one of N through experience and analysis. This im the most important, yet probably one of the B plies some sort of job safety study. This study can be as comprehensive and detailed as your accident experience justifies. If you most neglected sciences. How many super- | visors leave to chance or to other workmen B the important task of training his employees. B have complete records of all accidents, you We could well afford to spend an entire ses can easily pin-point the areas to emphasize. sion on this important subject. In simple, a job safety study or job safety analysis means first, a detailed review of the elemental operations of each job, arranged in proper sequence; second, a tabulation of the safe work practices for each operation with the protective devices to be used and the protective clothing to be worn. The results of my meager endeavor to pin-point some of your problems lead me to these conclusions: 1. Your overwhelming response indi cates the need for a more exhaustive study into the safety engineer's ma jor problems. As stated before, this study can be as de tailed as your experience justifies. You may differ with me, but I believe the job study should be made by the foreman and reviewed by the safety' engineer, with the minimum of alterations and refinements. Of course, it should be complete. It is important that the supervisor making use of this information should understand it well. It should be translated to simple 2. Problem solutions should be sought from the combined experience of so ciety members and university people. 3. Future conference programs should be devoted to specific problem solu tions. 4. A digest of the problems with prob lem solutions will provide the basis for improvements in our safety engi neering courses. A SAFETY ENGINEER'S MAJOR PROBLEMS The following is a classified list of problems sent in by 135 safety engineers to supplement those proposed in the questionnaire. While some were cited by two or more engineers, there were no specific problems which stood out as general problems. The classification, however, may be considered indicative of some general needs. Self Development: To develop an effective speaking ability. To organize my time most advantageously. To get along with people. To stimulate sifetr engineers to take an active part in developing technical papers in the field of accident prevention. To motivate initiative and aggressiveness in safety personnel. To secure college degree in safety engineering. To learn a foreign language to convey safety in foreign operations. Profession*! Stains: .. To establish professional recognition of safety engineers. To influence state registration of safety engineers. To define the function of safety engineering. Toadefine the job of the safety engineer. To place safety engineering properly in the plant organization structure. Education and Training: To train supervisors in the art of influencing worker safe-performance. To establish safe work habits. To provide basic education in both management and employees safety responsibility. To edneate shop men in specific subjects, as Workmen's Compensation. To approach the subject of accident prevention from the psychological point of view. To set up a fire protection training meeting: To integrate safety into M.S.. C.E., E.E.. Chem.. Physics and related college courses. To establish the requirements for a science degree in safety engineering, To integrate safety in M.S.. C.E., E.E.. Chem., Physics and related college courses. To provide at least one semester subject in safety engineering to all graduate engineers. 66 i tep-Wng aid M Jictices. > discuss the task for the V Mr. Heinportant jobs, mastered by It is one of y one of the many superler workmen is employees, in entire ses- endeavor to s lead me to sponse indie exhaustive gineer's ma- d be sought rience of so:rsity people, rams should roblem solu- ; with probie the basis safety engi- io jposcd vobi.__ i which genenl needs. i the field of Industrial Safety Siillt nnj Proainrtt: To develop week procedures which *re free of accident hazards. To improve my accident inrestigatioa procedure. To find a test to screen out potential accident repeaters. To find a uniform measuring slide to properly evaluate safety performance. To tarnish the Supervisor with "tools'* to carryout bis safety responsibilities. To set up a preventive maintenance program. Promotion--Mothmion--Sotting Snfetj: To develop new incentives, contests, and gimmicks. To stimulate top Management to take an active roll in Accident Prevention. To get top Management to impress front line Supervisors with the importance of Accident Prevention. To derate Safety to equal status with Production. To convince the Engineering Profession of the need for Special Engineering Training in the field of Accident Prevention. To devdop a taring system to measure a Foreman's Safety Performance and incorporate it into the sal ary and bonus plan. To get others to take an active part in Accident Prevention. To influence Design Engineers to integrate Safety into operations and equipment. AaitnJt: To develop a spirit of cooperation, rather than antagonism, when one employee tries to correct another. To stimulate an interest in non-paid Safety Meetings. To sdl employees on the use of protective equipment. To get workmen to report promptly for treatment of minor injuries. To maintain good labor Relations. To prevent panic in severe accidents or near disasters. Commnniemion: . ............. - To get better communication on accidents as they happen and the preventive measures taken. To establish good communications up and down the line. To coordinate the safety effort in 49 plant locations. SAFETY EDUCATION BY INTEGRATION OR SPECIALIZATION By G. I. CAMBRE Associate Professor, Mechanical Engineering, Louisiana State University Baton Rouge, La. Let us begin this discussion by progress ing from a study previously made on the subject of safety education by studying the report of the National Conference on Safety Education by Colleges and Universities (Now 1950), by the National Commission on Education of the National Education Assodation in which.it states: "In conse quence the whole emphasis of the National Commission on Safety Education and other groups is upon the key word safety: Upon prevention of damage and death rather than upon alleviation after damage and death have come." (From the foreword of above report) Dr. Raymond Walters, president of the University of Cincinnati, and conference chairman said in part: "The National Conference on Safety Edu cation by Colleges and Universities was held to enable representatives of such insti tutions to explore plans for more effective contributions to safety, in working and leisure activities of our people. The wide spread expression of need for such a nation wide conference came from leaders in higher education as well as from outstand ing representatives of government, business, labor, industry and school systems. "As a working basis for the conference, the ultimate goals of Safety Education by Colleges and Universities were interpreted thus: (a) to educate those within their sphere of influence to an' understanding that safety is an integral part of intellegent living and working; (b) to develop special ists and leaders in certain specific phases of safety education and accident prevention and (c) to establish and maintain a safe campus environment for students, faculty 67 1958 National Safety Congress and staff, and to encourage their habitual use of safe practices. "In the three day meeting at the Uni versity of Maryland, the planning com mittee concluded that the conference should concern itself primarily with the following areas of college and university work: liberal arts education, teacher education, engineering education, agricultural educa tion, university extension and services, and college and community living." The panel speakers at the conference observed that the colleges and universities have not sufficiently emphasized safety, and that a large part of the knowledge of safe practices possessed by their graduates has been acquired after they left collge. The panel speakers expressed the belief that our institutions of higher education should attempt to give a better safety background to all their students and should strive to indoctrinate them in the ideals of safety, and that textbook publishers should be informed of the need to incorporate specific areas of safety relating to the subject matter in their texts. In discussing the relative merits of safety education by integration or specialization, let me state here that in order to develop specialists and leaders in certain phases of safety education and accident prevention as set forth as one of the goals of the National Commission on Education of the National Education Association, this must be done by special courses. I don't think anyone will argue that point. However, where safety by integration is taught, the specialist-to-be will have been indoctrinated in safety before he begins his specialization and too, this indoctrination may possibly have motivated him to specialize in safety. I feel however, that the other goal set by the National Commission of Education "to educate those within their sphere of influ ence to an understanding that safety is an integral part of intelligent living and work ing" is the facet that needs discussion at this time. Many institutions are on record as teach ing safety by integration. In far too many cases this is a statement and not a fact. This is so probably because of the difficulty of making teaching safety by integration a fact. The motivation to integrate appropriate safety principles and fundamentals comes only after one has at least developed a limited awareness and understanding of accident prevention possibilities, and far too often those who are in position to teach safety by integration in his discipline are too untrained to even visualize the facets of safety and accident prevention other than that which is only too obvious. Perhaps we should at this point define safety, which involves much more than just accident prevention. "Safety means more than accident prevention--it means, also, conservation of all that goes into making life worthwhile; health, opportunity' and the material resources upon which life itself depends. Safety is the opposite of waste." What is needed in order that safety taught by integration may be effective? 1. That engineering text books be so written as to make the student analyze the need for safety considerations in each and every phase of every' subject in his engineer ing curricula. 2. That some problems at the end of each chapter include one or more that specifically requires the student to consider the safety aspect of the subject. 3. That the humanistic and social studies required of the student also include the study of safety as applicable to that particular subject. 4. That the college or university authori ties be sold on the need for safety being taught to all students and that academic deans make it known to all parties con cerned that safety must be taught as appli cable for each subject. 5. That all existing faculty be introduced formally to the need for teaching safety by- an organized institute or seminar. 6. That each newly employed faculty member be indoctrinated in the need for teaching safety' as appropriate for his specialty as soon as he is employed. 7. That annual regional seminars be held on teaching safety by integration and heads of colleges and universities be annually In vited to send participants to these conferences. 8. That a one day conference be held annually for college heads on the same subject since they are the ones whose 68 Industrial Safety e ^oropriate ic; | comes dt.eloped a standing of j > and far too tion to teach discipline are te the facets on other than point define ore than just means more means, also, into making wtunity and rii life itself if waste." that safety ftective? ooks be so analyze the in each and is engineer end of each specifically the safety cial studies include the e ^that ty authoritfety being : academic uties cont as appli- [ interest and cooperation are necessary for the program to be successful. Let us now consider teaching safety by specialization. This can be done by separate safety courses in the various curricula. If i we are to be guided by the planning com mittee of the National Conference on Safety Education by Colleges and Universities, this would include liberal arts education, teacher education, engineering, and agriculture education. For some of these disciplines this would include health and physical education, while in others it would include safety engineer ing in its many phases. In order to make these courses effective, there is a need for a well prepared outline such as is prepared by the American Society of Safety Engineers in "Industrial^ Safety for Engineering Students." This outline is complete as to appropriate notes from which to teach as well as the sources from which this information has been obtained, chapter by chapter, and can be easily followed by anyone who is given the responsibility for teaching such a course. In studying these references the teacher can become very proficient in the subject in a short period of time: Of course there remains the problem of fitting the separate course into a crowded curriculum--but the purpose of education is to prepare one for his role of service to our society in his chosen field and if he does not learn while he is a learner, to use his acquired knowledge safely and thereby efficiently he may become a casualty himself before he can put his other acquired knowledge into practice or will misapply his other knowledge through his lack of knowledge of safety fundamentals. Therefore whatever time is required to teach him these fundamentals will be worth while since it will tend to assure proper usage of this overall education. College and university authorities would probably fit a special course in each dis cipline if the various industries were to realize the need fx every graduate they hire having learned these fundamentals be fore being trained and assigned to their respective positions in industry, rather than learn these fundamentals piece-meal through the tough road of experience and demand that fundamentals of safety be taught in colleges and universities. Since the writer has been teaching such a course for the past ten years at the senior level, it is my firm conviction that in each discipline a special course should be offered and in addition to the special courses an attempt be made to put into practice those suggestions above relative to teaching safety by integration, and that in every case the employment of safety instruction by speciali zation be accomplished first, since it is a direct approach and can assure positive re sults. Then relentlessly work toward the teaching of safety by integration to complete the requirements of the best possible safety education in college and universities. introduced ing safety inar. d faculty need for for his i s be held uid heads rually in to these be held he same s whose REMOVING A BLIND SPOT IN ENGINEERING EDUCATION By THOMAS H. ROCKWELL Assistant Professor, Industrial Engineering Department, The Ohio State University As a result of this new missile era and the need for technological supremacy, higher education in this country has been placed under g'eater scrutiny. Many indictments have beet, leveled against present engineer ing education. Some insist on more mathe matics--others decry the lack of humanities and the engineer's shortcomings in oral and written communication. However justified these charges may be, those of us concerned with safety engineer ing believe that many engineering graduates are deficient on another score which we might call the responsibility for the safe guarding of human life. In effect, this de ficiency reflects itself in an unawareness of safety considerations in engineering func tions. It is this lack of safety consciousness 1958 National Safety Congress that I term a "blind spot" in engineering education. Fortunately, this blind spot is not a permanent disability ot the student Its treat ment, which requires the efforts of both educators and practicing safety engineers, consists of an adaptation to sound safety philosophy and the illumination of safety engineering principles. I would like to direct my comments to safety for engineers in general, not safety tor safety engineers. I'm convinced that safety engineers cannot be made in the classroom, but rather must be forged from actual experience in the fidd. Thus, I'm referring to the chemical, mechanical, elec trical, civil, and industrial engineering stu dent who will indirectly be concerned with safety in his work. Let me describe this blind spotbv dis cussing some of its characteristics which I have observed in both my own under graduate training and industrial experience, and have noted in fifth year engineering students. There is a prevailing attitude which is antecedent to these characteristics. I'm afraid most engineering students can not be considered humanitarian oriented. In fact, their training has emphasized efficient and economic design and has instilled a rugged individualistic aspect in their think ing that is reflected in such convictions as: (1) it is primarily up to the operator to protect himself from accidents; (2) acci dents happen to those who take chances; 13) safety in design is obvious to any engineer; (4) sate design is often un warranted because it is too expensive. This attitude is manifested on the part of the student by his 1. failure to incorporate safe features into engineering design, such as not providing the operator with adequate control of his equipment, safety interIgcks, guards or protective equipment; Z design of man-machine systems which necessitate risk-taking on the part of the operator; 3. ignorance of the storehouse of sound and safe engineering practice found in the state and American Standards Association codes; 4. lack of human engineering considera tions which result in designs which fail to make use of data on the operator's capabilities and body dimensions; 5. underestimation of the true conse quences of accidents, dollar-wise; 5. failure to relate the effect of environ mental conditions on operator safety; 7. inability to anticipate the safety impli cations of a design. These represent some of the more out standing characteristics of this "blind spot" Doubtless others could be added and the ones above expounded upon. Those who have worked with the neophyte engineer may certainly recognize some of these characteristics. The important aspect of this to my mind is that they are the product of the engineer's orientation in college. The solution to this problem lies in making the engineering stu dent aware of the fact that safety is his responsibility and is just as important as other criteria of good engineering practice, such as economy, service life, efficiency, output and so forth. Too seldom is the engineering graduate reminded that his professional stature im plies a service to mankind, an obligation not just to raise the standard of living, but to enable people to enjoy it. In considering the reorientation of the student engineer for the purpose of creating a safety' awareness, 1 think we should dis tinguish between what is required and how it is to be achieved. Some aspects of safety belong properly in a thorough integration in all engineering courses, particularly in laboratory' courses; other safety material can be best incorporated in the framework of specific courses in safety engineering. On one hand, safety' consciousness -can be developed by bringing it into considera tion in several phases of engineering train ing, such as machine design courses, elec trical engineering labs, eta This will be successful only with whole-hearted support of engineering faculty members, however. On the other hand, it is desirable to acquaint the student with principles of human engineering, control of industrial hygiene hazards, and other material which is difficult to introduce outside of specialized courses. It is not my purpose to attempt to resolve the question of integration versus Industrial Safety ta; J the in1 iodv rue conse-wise; ) environ in' safety; fety impli- more out'lind spot" i and the hose who t engineer of these my mind engineer's m to this eiing stu:ty is his ortant as practice, efficiency. | I I I I I I graduate iture im- ibligation ring, but ic a said dis and how >f safety tegradon darly in material tmework sering. less can nsiderag trains, elecwill be support wever. able to >les of dustrial which cialized snpt to versus % r I- specialization of safety material in engineer ing curricula. My own experience has been that many safety requirements in engineering can only be properly developed within the framework of a unified course. Some of these require ments would be a knowledge of workmen's compensation laws, a realization of the costs of accidents, an understanding of what safety codes are available, how they can be obtained and their general content, prin ciples of guard design, an understanding of the mechanism behind accidents and the complex interaction of environment and behavior in accident causation, and basic information on occupational diseases and industrial hygiene hazards. For example; in this atomic age our engineers will be work ing more and more with radioactive ma terials and must have a minimum knowledge of the measurement and control of ionizing radiation. These are Just a few of the knowledge requirements which ideally the graduate engineer should possess. However, we must realize that some compromise is needed between what the engineer should know and what we can realistically expect him to know in light or curriculum restraints. Engineering curricula is becoming more and more crowded. The trend towards greater specialization coupled with a countermove to include more humanities has resulted in compression, reduction and re-alignment of traditional course material. Each course in curriculum reorganization must be clearly justified. We must accept the fact that safety engineering education per se is not universally accepted today by engineering educators, nor is it found in recommended curriculum suggested by The American Society for Engineering Educa tion. Unless such groups as the American Society of Safety Engineers or the National Safety Council can exert more influence on university faculty members, I fear that when curriculum pruning begins, courses in safety will be among the first to go. This will mean that if safety is to be a part of the engineer's training, it must be more than something the engineer can "pick up on the side." Industry, which ultimately sets the re quirements for engineering training, must voice its demand for safety engineering education and acquaint such groups as the American Society for Engineering Educa tion. In light of the general squeeze on hours devoted to education in safety it be comes more and more important that safety educators make effective use of their allotted time. The case study approach described below may be one method of removing the safety blind spot One last point in this regard concerns the general atmosphere in which safety is to be introduced to the student It is not sufficient to expound upon the "do's and don'ts" of safety engineering design. A "thou shalt not" approach is doomed to failure. A positive position is necessary, especially when one recognizes the typical resistance to safety exhibited by our present day engineering student Moreover, it ihould be emphasized that safety Is not just the simple construction of guards. Acci dents are extremely complex phenomena and require intensified effort for their elimina tion. I shall never forget the demoralizing blow in one of my classes when a guest safety engineer from industry blithely an nounced that the primary attributes of a safety engineer are "a winning personality and common sense." I would like to make a few comments on the methods of safety instruction for two reasons. First, the basic problem I have found in safety education for engineers is motivation. Although motivation is a con tinual problem in education, it is perhaps more acute in safety because of the previ ously mentioned student preconceptions that must be overcome.. In this case the method of instruction will greatly influence the student's reception to the course. Second, in considering methods we can see how the practicing safety engineer and educator can effectively "team up" for safety. Where posable, an emphasis on safety in all facets of engineering education is of a prime importance; However, the difficulties in safety by inte gration and the complexity of the accident problem require us to consider methods of instruction in a unified safety engineering course. Here we can take several basic approaches. The teacher can lecture and demonstrate safety principles, or have the student solve safety problems. All are necessary to an extent 195S National Safety Congress One procedure that I've adopted which has had gratifying results is the use of the case study approach. By this mechanism < especially in the form of group action), it is possible to generate interest on the part of the student, allow him the fullest extent of his ingenuity, and thus increase the effectiveness of instruction. Moreover, in the case study method, the student is dealing with reality where there are several possible solutions to the problem, depending upon the dollars available for its accomplisliment Many aspects of the engineer's role in accident prevention cannot be taught by pro fessorial proclamations since generalizations must be made at the expense of consciseness. Rather than lecture on the "do's and don'ts" of plant layout and its effect on safe operation, it is usually far more effective if a specific problem is given to the student involving an accident precipitated by poor plant layout considerations. In the case study approach, I usually have a team of engineers tackle an accident situation or a potential one. The team spends an hour reporting and justifying their results to the class, which takes the part of management and labor. The class, I might add, may or may not be safetyinclined and often will ask penetrating questions of those presenting the case. In each case attention is given to cost corriderations, legal positions in light of workmen's compensation laws, soundness of engineering design, relation to existing codes, industrial hygiene hazards (where appropriate), implementation of proposed solutions, etc. In many instances the case is used to introduce subsequent lecture ma terial. Also, the case study team is often expected to present material which man agement would not be expected to know. For example, in discussing a control system for radioactive material, a short discussion on the methods of detection of ionizing radiation would be required. By far the most difficult task for the instructor in using this method of teaching is finding realistic and appropriate case study material. Hypothetical accident situa tions lack the realism of actual cases and hence fail to achieve one of the primary aims of the case study method, namely, the generation of student interest This is where practicing safety engineers can help. To date I've received some fine support from many local industries in supplying cases from their files. These are then usually reworded to avoid any reference to the supporting company and edited to insure maximum discussion value. Controversial issues, such as chargeable costs of an acci dent, are not dodged--;in fact, they are often inserted to force the safety team to take a position. At present nine cases are used each quarter, each one emphasizing a differ ent facet of safety'--such as the legal posi tion of accident victim claimants, cost con siderations, equipment guard design, use of radioactive materials, etc Unfortunately, good industrial cases are difficult to find, especially those involving actual engineering design. However, I'm sure that with a little investigation most safety engineers can recall past cases which typify the land of problems an engineer would meet in his work. I'm convinced that a case study text, on the role of safety engineering in accident prevention sponsored by the American Society of Safety Engi neers would be a real contribution to safety education. We can't make safety engineers out of all our graduating engineers, but we can make them all safety conscious. The primary task is to sufficiently impress upon our students the need for safety considera tions in their engineering wort Then we can rely on the student's engineering capa bilities and his personal moral code to insure his designing safety into the job. We must make the most of the few hours allotted to safety in the engineer's education. The case study approach possesses many favorable advantages over traditional lecture methods. It considers safety problems in a total framework including engineering, financial, legal and moral implications. Most important, the realism of the cases does much to overcome the lack of interest typi cally demonstrated by engineering students. This is a joint task for the practicing safety engineer and the educator. The engineer can provide the basic problems needed for the cases. With this help the educator can turn out safety-oriented engi neers who, by designing safety into the job, can substantially lessen the burden on those charged with the responsibility for safety. 72 ic ' 'wort A > are then ;ference to i to insure ntroversial if an acar are often to take a are used g a differ* legal posi- cost con* gn, use of cases are involving .'ever, I'm vtion roost ises which t engineer -inced that of safety sponsored :ety Engti to safety rs out of it we can lus. The jress upon conc'dera% )we ring Jspae to insure We roust allotted to L sses many nal lecture oblems in igineering. ons. Most ases doe* erest typi' students. practicing tor. The problems . help the nted engi- into the burden on bility for Industrial Safety OXYGEN--RESUSCITATION, WHEN, WHY AND HOW By RALPH E. De FOREST, MJ>. Secretary, Council on Medical Physics, American Medical Association The when, why, and how of resuscitation and oxygen use involves a consideration of basic physiological principles and their thera peutic implications. Without attempting to go into detail, these principles and implica tions will be outlined and briefly explained. How much oxygen is used by a normal adult seated comfortably in a chair? The answer is 300 cc per minute. And in so doing, this adult must inhale around 7,000 cc oi air during the oue-minute time interval. Since .20 per cent of this air is oxygen (Le., 1,400 cc), it is readily apparent that the greater portion of the oxygen inhaled is also exhaled (Le^ 1,100 cc) and is not consumed.1 Whereas inhalation provides the important function of bringing oxygen into the lungs, it must be kept in mind that exhalation pro vides the equally important function of ridding the body of excess amounts of car bon dioxide. During normal respiration, breathing will saturate the blood with oxygen to the extent of 973 per cent to 98 per cent of its oxygen carrying capacity. If the normal adult were now to breathe air consisting of 40 per cent oxygen and 60 per cent nitrogen, the oxygen concentration per 100 cc of arterial blood is increased by 0.9 cc. This increase per 100 cc of blood oc curs as follows: An increase of 03 cc oxygen carried by the hemoglobin (thereby saturating the hemoglobin); and an increase of 0.4 cc oxygen dissolved in plasma. On the other hand, if this adult were next ~to breathe air consisting of oxygen only, the increase of 0.4 cc oxygen already obtained in plasma is augmented by an additional 0.7 cc to give a total of 1.1 cc However, no in crease in oxygen bound to the hemoglobin can be expected because the hemoglobin was already saturated by breathing the air con sisting of 40 per cent oxygen. Thus, in a normal person the total oxygen concentra tion of arterial blood can be increased by little over 2 cc per 100 cc of blood.* Thus, it can readily be appreciated that a normal, adequately breathing person can ob tain only negligible benefits from breathing air composed of oxygen concentrations greater than ordinarily present. Any person capable of normal breathing can obtain the necessary oxygen to meet body needs simply by increasing the rate and depth of respira tion. The respiratory mechanism is capable of a wide range of accommodation. For instance, a person walking at a rate of four miles an hour will breathe 26,000 cc of air per minute and will extract from this amount 1,200 cc of oxygen.1 This rep resents a 400 per cent increase in oxygen consumption when compared to the resting adult mentioned above. Obviously, if the victim of an emergency situation can be in duced to breathe deeply and rapidly, an abundant supply of oxygen is provided. The various manual as well as mouthto-znouth methods of artificial respiration provide pulmonary ventilation with ordinary air, and they can be most effective in sus taining life and providing an adequate bloodoxygen saturation without additional oxygen in the inhaled air. However, when it is dif ficult to maintain adequate blood-oxygen saturation for some other reason, the addi tion of oxygen to the air inhaled has a real and significant therapeutic value. Although obviously not essential in an emergency situation, it is highly desirable that oxygen which is administered over long periods of time be humidified before being administered. Failure of a person to receive an ade quate supply of oxygen for any reason at all is called hypoxia. As a rule, emergency situations one will encounter result from conditions discussed in some detail in the sec tions immediately following. These condi tions are:1 1. Inadequate oxygenation of blood in the lungs. 2. Inadequate transport of oxygen by the blood. 3. Inadequate tissue oxygenation. 73 1958 National Safety Congress Inadequate oxygenation of blood in the lungs can be caused by a number of condi tions. 1. Deficiency of Oxygen in the Atmos phere. This condition most often results in a confined atmosphere when any gas dis places the oxygen of ordinary air. For in stance; in mines certain gases--such as methane (fire damp) or nitrogen and car bon dioxide (black damp)--can displace the oxygen and thereby lower the oxygen con centration. In such situations, the gases which have displaced the oxygen do not necessarily by their presence produce direct harmful ef fects upon the human body. They simply act by reducing the oxygen tension (con centration) in the confined atmosphere of a particular location.4 Readjusting the oxygen concentration of the air which the victim breathes is consequently most urgent and es sential. Obviously, this can most easily be accomplished by moving the victim into the air of a less contaminated environment, or by die administration of oxygen by nasal catheter or oro-nasal mask. A deficiency of oxygen in the atmosphere is also a characteristic of high altitudes. Al though the percentage of oxygen in the air remains constant as one ascends, the absolute amount of component gases which comprise a unit volume of air is decreased because the air pressure at such heights is less, and all gases have expanded. Thus, there are fewer molecules of oxygen available in each breath. Signs and symptoms due to atmospheric oxygen deficiency may begin to appear in healthy individuals at an altitude of 10,000 feet above sea level. These symptoms are characterized initially by feelings of ex hilaration and hilarity accompanied by some increase in the rate of respiration. Generally speaking, an altitude oi 23,000 feet rep resents the limit to which unacclimatized men cap ascend without the aid of an arti ficial source of oxygen. When reaching an altitude of 40,000 feet, a human being cannot maintain life even if breathing from an artificial source of pure oxygen. For this reason, airplanes flying at such heights are equipped with pressurized cabins. 2. Inefficiency of Respiratory Activity. Shallow breathing, as can be caused by a painful chest injury, may result in a marked lowering of both tissue and blood-oxygen levels and in dyspnea (belabored breathing). In such cases, the administration of oxygen by nasal catheter or oro-nasal mask is in deed helpful. Adding carbon dioxide to the oxygen also has been advocated; this may be especially hdpful if the victim's rapid, shal low breathing has caused him to exhale ex cessively large amounts of carbon dioxide. However, a word of caution is in order! One cannot be sure that this situation has in deed occurred. Therefore, it seems far wiser to relieve the victim's pain with the ad ministration of suitable drugs and splinting, and to encourage the victim to breathe more slowly and deeply. Complete and partial apnea can also be listed under this heading. Either complete or partial apnea is most often encountered in drowning, electrocution, stroke, or poisoning by drugs or certain chemicals (methyl chlor ide, benzol, etc.). Obviously, administration of artificial respiration by either the mouthto-mouth or back-pressure arm-lift method should be begun immediately. When available, an apparatus which pro vides pulmonary ventilation (Lc^ breathes for the patient) can be used. Most of these apparatus, known as resusdtators, employ a face mask through which is provided air consisting of nearly pure oxygen. In addi tion, they facilitate removing carbon dioxide from the victim. An abundance of carbon dioxide develops in the tissues of any individual who is not breathing because no carbon dioxide is ex pelled through the lungs. Thus, it is readily apparent that in cases of asphyxia (i.e^ an inadequate supply of tissue oxygen and over abundance of carbon dioxide) no additional carbon dioxide is needed to stimulate respira tion. A victim of asphyxiation who has re covered sufficiently to maintain some degree of unaided respiration should be encouraged to greater breathing efforts. If the victim is comatose (unconscious) or nearly so, arti ficial respiration can be used if no resusdtator is available. The administration of oxygen by nasal catheter can also be of great help in this instance. Victims of a stroke or an acute respiratory paralysis may also suffer from severely de pressed respiration. Once again, oxygen ad- 74 i i marked H pt al ./). : oxygen sk is inte to the s may be id, shalhale ex dioxide, ier! One has inar wiser the ad;plnting. lie more also be iplete or tered in oisonmg yl chloristration mouthmethod ich probreathes of these employ ided air in addi- ievelops > is not : is exreadily (i.t, an id overditional respira- ras re degree mraged ictim is o, artixsusdion of be of 1 liratory ely dejen ad- Industrial Safety ministration by nasal catheter is desirable if the victim is breathing. If breathing is ex tremely shallow or nonexistent, artificial res piration should be applied. 3. Obstruction of Airways. Obstruction of the airways can be caused either by fordgn bodies which become lodged or by such con ditions as laryngeal spasm, displacement of the tongue, or acute bronchiole spasm. Dis placement of the tongue is as a rule found in victims who are either unconscious, semi conscious, or paralyzed; acute bronchiole spasm is usually found in asthmatic subjects. These situations call for speedy relief of the condition causing the obstruction. Oxygen by nasal catheter is usually in dicated. Another condition which can block free passage of air to alveolar respiratory epi thelium is pulmonary edema (fluid in al veoli). The edema may be secondary to acute; severe coronary occlusion, congestive heart failure, traumatic shock, or may be due to chemical poisoning such as occurs following inhalation of sulphides. In an emergency situation with no professional medical help immediately available, it is usually difficult to determine if pulmonary edema or coronary occlusion is actually pres ent. However, the presence of severe shock can more readily be determined. At any rate, the administration of oxygen in these in stances is indicated and desirable. The re sultant increase in oxygen concentration in the lungs enhances the diffusion of oxygen through edema fluid and on into the arterial blood. Inadequate transport of oxygen by the blood exists in subjects with coronary oc clusion, congestive heart failure, traumatic shock (so-called peripheral circulatory col lapse), hemorrhage, or carbon monoxide poisoning. A study of two groups of patients re vealed a number of pertinent facts.* One group suffered from coronary occlusion ac companied by pulmonary edema and shock, and the other group from coronary' occlusion not accompanied by pulmonary edema or shock. It was found that the blood-oxygen saturation level of the first group had dropped to 80.8 per cent (normal = 97J5 per cent to 98 per cent). When these patients were ventilated with air composed of 40 per cent oxygen, around 42 cc oxygen were added to each 100 cc of arterial blood; breathing nearly pure oxygen added around 5.5 cc oxygen to each 100 cc of arterial blood. However, the investigation also revealed that the blood-oxygen saturation level of the second group had dropped to only 94.1 per cent Here it was found that administration of air composed of 40 per cent oxygen added only 1.6 cc oxygen per 100 cc of arterial blood; administration of nearly pure oxygen added 2.9 cc oxygen per 100 cc of arterial blood. The authors concluded that the adminis tration of oxygen in patients with coronary occlusion not accompanied by pulmonary edema and shock is probably not needed, but that it helps to relieve dyspnea and adds to the oxygen dissolved in tissue fluids. They further concluded that the administration of nearly pure oxygen was desirable in all cases of coronary occlusion accompanied by shock and pulmonary edema. Some authors* feel more strongly on the point of relieving such deleterious effects as tissue anoxia (lack of oxygen). They feel that high oxygen concentrations are espe cially useful in such conditions as surgical shock; severe myocardial infarction, or cere bral infarction--all of which are character ized by severe localized tissue anoxia. Here, such high oxygen concentrations are applied for the primary purpose of increasing the amount of oxygen dissolved in plasma. (As stated previously, the hemoglobin is readily saturated by breathing low oxygen concen trations.) Hemorrhage. The foremost problem in hemorrhage is, of course; to stop the bleed ing and to restore the volume of blood by transfusion of whole blood or plasma. Sup plemental oxygen is of help to a limited ex tent, since normal breathing provides suffi cient oxygen to supply the decreased amount of hemoglobin remaining in the blood stream after hemorrhage. However, of greater im portance is the increase of dissolved oxygen which will occur in plasma. Since hem orrhage is frequently accompanied by shock and subsequent pulmonary edema, oxygen therapy is desirable, particularly' if volun tary respiration is depressed. Carbon Monoxide Poisoning. Hemoglobin shows an affinity for carbon monoride which is approximately 300 times stronger than its 75 ;l 1958 National Safety Congress affinity for oxygen. It is therefore of utmost importance that the hemoglobin-carbon mon oxide combination be broken as quickly as possible. A high percentage of oxygen should be received by the lungs, for it is possible to displace the carbon monoxide by oxygen provided the tension of oxygen is high and the tension of the carbon monoxide is low. The administration of carbon dioxideoxygen gas mixtures has been recommended.' Such mixtures contain 90 per cent to 95 per cent .oxygen and 5 per cent to 10 per cent carbon dioxide, and they are administered by means of a face mask. It is believed that carbon dioxide aids in releasing the carbon monoxide from the hemoglobin mole cule. At any rate, if such a gas mixture is not available in an emergency, oxygen should--and can--be safely and appropriately used. = The amount of carbon dioxide a victim of carbon monoxide poisoning should receive might well be left to the discretion of the attending physician, for the physician can carefully watch the subject to insure that harmful levels of carbon dioxide do not ac cumulate within, the subject. The victim of carbon monoxide poisoning presents a severe problem in an emergency situation. He will undoubtedly hyperventi late due to his inordinate hunger for oxygen, unless too comatose and depressed to do so. Furthermore, while hyperventilating, he may "blow off" excessive amounts of carbon dioxide--thereby leaving his respiratory cen ters insufficiently stimulated. These reasons clearly show the victim of carbon monoxide poisoning to be a case for the hospital where careful attention can be given to his carbon dioxide balance and other needs. In cyanide poisoning there is no interfer ence with the carriage of oxygen by the blood. However, the tissue-enzyme mechan isms which are responsible for normal tissue respiration are poisoned. Such chemicals as methylene blue, amyl nitrite, sodium nitrite, or thiosulfates are used to counteract the ef fect of the cyanide. In poisoning of this type, adequate oxygen ation of arterial blood can usually be ob tained by encouragement of deeper breathing. Administration of supplemental oxygen is desirable, particularly if the victim is de pressed or in shock. The primary treatment, however, is directed toward the removal of cyanide from the tissues. The long taught back-pressure arm-lift method and the newly promoted mouth-tomouth method of artificial respiration can both be effective. The back-pressure arm-lift method has a disadvantage in that both of the rescuer's hands are occupied in applying pressure to the lack and lifting the arms, thereby mak ing it difficult for the operator to keep the airway open. It is, however, a "push-pull" method which provides active phases of both inspiration and expiration. The mouth-to-mouth technique provides a positive form of insufflation of air from the rescuer into the victim. The rescuer provides around 10,000 cc of expired air per minute which contains 18 per cent (i-t, 1,800 cc) of oxygen and thereby can maintain adequate blood-oxygen saturation in the victim.' An other advantage of this method is the fact tha* the: rescuer's hands are used to hold up the jaw and thereby maintain a patent air way. Yet, this technique also has certain disad vantages. These are primarily in the esthetic area; i.e., some persons may be reluctant to come into such intimate contact with per sons apparently dead or for some other rea son. During the course of administering this technique, it is also possible to blow a quan tity* of air into the victim's stomach, and this air must be expelled by pressure on the abdomen. Unfortunately, the expelled air may carry with it some of the stomach's gastric contents; and the resultant disagree able situation may make it difficult for some rescuers to perform this method of artificial respiration. A number of resuscitators which provide 100 per cent oxygen through an oro-nasal mask are available in the United States. These resuscitators provide artificial respira tion by one of two methods: (1) Alternating positive and negative pres sures are applied through the mask to the mouth. The positive side of the cycle in hales for the victim by blowing oxygen into the Itmgs, and the negative side of the cycle assists in exhaling. (2) Intermittent positive pressure is used to provide inhalation. Exhalation in this case is accomplished by recoil of the thoracic cage. Resuscitators operating by either 76 emov^l of ) : aim-lift mouth-toation can hod has a rescuer's ressure to reby mak keep the push-pull" *s of both irovides a from the r provides er minute 00 cc) of adequate lim.' An; the fact o hold up atent air- iin disade esthetic reluctant with per- ither reaering this v a quan.a ^ died air stomach's disagreefor some artificial t provide oro-nasal 1 States. I respira- tivepresk to the ryde in"gen into the cycle : is used in this thoracic y either Industrial Safety method can also be used to supply a flow of nearly pure oxygen for inhalation by the subject who is able to breathe without out side assistance. Three basic types of devices are available for emergency use. The first device is the rubber or plastic oro-nasal face mask which fits over the mouth and nose--such as the BLB mask. Openings are located on either side of the mask. Outside air entering through these openings is mixed within the mask with oxygen from its source. In addition, these holes allow a part of the victim's expired air to escape. The mask is connected either to a rebreathing bag and to the oxygen source or to the rebreathing bag which in turn is connected to the source of oxygen. Devices of this type have advantages as well as disadvantages. One major advantage is that high oxygen concentrations can be administered; disadvantages, on the other hand, may include rebreathing accumulations of carbon dioxide and the resistance to flow of air within the mask. Oxygen can be administered in concentra tions ranging from 40 per cent to 100 per cent, and the masks are especially useful in providing oxygen concentrations ranging from 70 per cent to 100 per cent. It should be noted at this point, however, that high concentrations of oxygen in the inspired air can only be achieved if high oxygen flow rates to the mask are employed. Rebreathing of carbon dioxide accumula tions occurs as follows: When the victim on whom the mask is applied exhales, part of the breath flows into the rebreathing bag and remains there. When the victim again inhales the contents of the bag, the carbon dioxide just exhaled will once more be in haled. This process will then repeat itself. In this way, it is possible for the victim to breathe air containing accumulated carbon dioxide concentrations of 2 per cent or more. As a result, these high carbon dioxide con centrations may increase respiratory rates around 40 per cent to 50 per cent and thereby increase the victim's dyspnea. This is par ticularly objectionable in cardio-respiratory patients. High oxygen flow-rates (eight to ten liters per minute) must be used to keep carbon dioxide "washed out" of the bag. Resistance to gas flow encountered within the mask is usually not a great problem during exhalation. However, in cases of ob structive apnea, the victim already suffers from' severely belabored breathing, and the additional burden posed by the mask is ob jectionable. It is the resistance encountered during inspiration which is most often of consider able concern. During inspiration the victim is required to suck air from the rebreath ing bag and through the orifices in the mask. In some cases these orifices consist of sponge rubber disks; in other cases they are simple perforations. The resulting negative pressure within the mask is of little signif icance during quiet breathing. However, the negative pressure becomes a serious problem in subjects who are suffer ing from dyspnea or whose respiration is markedly increased. In these cases a nega tive pressure of 1 to 2 cc water column -, during inspiration exerts a suction force on the respiratory epithelium; and breathing against a negative pressure has been shown in the laboratory to be cause for edema of the lungs* Therefore, resistance to inspiration should at all times be avoided, especially in subjects suffering from obstructive dyspnea, heart failure, or in any patient in whom a ten dency toward edema of the lungs might de velop. All of these statements support the contention that low flows of oxygen should not be used with this type of face mask. The second device is another face mask, the so-called "meter mask," which does not allow the subject to rebreathe any part of the exhaled air. When the subject exhales, the breath escapes through a valve to the outside, and consequently the concentration of carbon dioxide in the subject's breath--while using this mask--does not rise above 0.2 per cent even with oxygen flow-rates as low as two liters per minute.* Air consisting of 95 per cent oxygen can be supplied with flowrates of right liters of oxygen per minute. Air consisting of approximately 40 per cent oxygen can be supplied at flow-rates of two to three liters per minute. In a non-dyspneic adult, a flow-rate of four liters of oxygen per minute can provide a supply of air consisting of 50 per cent oxygen. However, in the dyspnric subject higher flow-rates must be used in order to supply an equivalent percentage of oxygen in the inspired air. In order to obtain higher 77 1938 Xational Safety Congress oxygen concentrations in inspired air by the mask method, oxygen flow-rates in the order of 10 to 12 liters per minute must be sup plied. For these reasons it is well that such de vices have a gauge indicating the rate of flow to meet the patient's needs. Or the device must deliver maximum oxygen flowrates at all times. In this way the operator can be certain that adequate concentrations of oxygen are provided. Tank capacity should be at least 300 liters or greater ("D" tank) in order to provide at least half an hour's continuous supply of oxygen. The third device, the nasal catheter, is in serted into the naso-pharynx and is one of the easiest and most efficient means of ad ministering oxygen.3 For instance, with an oxygen flow-rate of six liters per minute and adequate breathing, concentrations of .40 per cent to 45 per cent oxygen can be obtained in the inspired air. However, care must be exercised in plac ing the catheter properly. If the catheter reaches too far into the pharynx, the victim may be gagged or air may be forced into the stomach. If, on the other hand, the catheter does not reach far enough, the proper concentrations of oxygen may not be obtained. One method of estimating the proper distance of insertion is to measure from the tip of the nose to the front of the ear and then to add one quarter inch. This length is then inserted and the catheter is taped to the face. This method of administering oxygen is particularly useful tor several reasons. There is no mask to restrict the tree exchange of air by the subject, and consequently there is little or no interference with elimination of carbon dioxide. The attending person does not have to pay attention to a mask and is free to attend to the patient's other needs. Furthermore, the catheter can readily be in serted into the non-breathing victim. This frees thg rescuer to administer artificial res piration by either the mouth-to-mouth or back-pressure arm-lift method. And since asphyxia and apnea are indications for using either of these methods, the administration of added oxygen will have a useful purpose. Conclusions--Whenever impaired oxygena tion is either suspected or can subsequently be expected, attention must primarily be di rected at maintaining adequate respiration, a sufficiently large supply of oxygen, and the elimination of carbon dioxide. In an emer gency, the oxygen of ordinary air can always be relied upon. Attention must primarily be given to maintaining adequate pulmonary ventilation. This can be achieved by urging the victim to greater breathing efforts, by manual or mouth-to-mouth artificial respira tion, or by use of a resusdtator as. indicated by the victim's breathing status. Air ranging in oxygen concentration from 40 per cent to 50 per cent can readily' be applied, inhaled, and maintained by nasal catheter. Apparatus utilizing the mask and rebreathing bag can provide safe inhalation of higher oxygen concentrations, provided the mask is properly placed and high oxygen flow-rates are maintained. REFERENCES 1. Karpovich. P. V.: Physiology of Muscular Ac tivity. 4th edition. Philadelphia and loadoa, V?. B. Saunders Company. 19)3. p. 114. 2. Borden. C W.; Ebert. R. V.; and Wilson. R. H.; Anoxia in Myocardial Infarctioa and Indication! for Oxygen Therapy. J.A.M.A. 148:1370-1371 (Apr. 19) 19J2. 3. A.M.A. Fundamentals of Anesthesia. 3rd edi tion. Philadelphia and London. W. B. Saunder! Com pany. 1954. p. 10. 4. Best. C. H.. and Taylor. N. B.: The Physio logical Basis of Medical Practice. 4th edition, Balti more, The Williams & Wilkins Company. 1945. 5. Coates. . O.. Jr.: Brinkman. G. L.; Dumke. P. R.; and Green, E. W.t Oxygen Therapy, Post graduate Medicine 24:60-66 (July) 1958. 6. Barach, A. I_: Physiologic Therapy in Respira tory Diseases. 2nd edition. Philadelphia. London. Montreal. J. B. Lippincott Company, 1948. --- - 7. Elam. J. O.: Greene. D. G.; Brown, E. S.: and Clements. I. A.: Oxygen and Carbon D'oxidc Exchange and Energy Cost of Expired Air Resuscita tion, J.A.M.A. 167:328-334 (May 17) 1958. 7g louth or ad. i:e or' wing istration purpose. txygenaequently y be diration, a and tiie n emeri always larily be hnonary urging orts, by respirandicated Mi from idily be y nasal isk and halation Tovided oxygen mlv Aci. W. B. ibon -R. die' * tt : | 3rd edi cts Coat- Pbrjioo, Bilti4}. Dumke. T. Post- RcspinLondoo. E. S.: D'oxidc ejusota- Industrial Safety TYPICAL EMERGENCIES CONFRONTING THE NURSE WORKING ALONE By HAPPY B. BRUDER, R. N. Saks Fifth Avenue, Chicago, III. Within us all there is a great deal of pride, plus much loyalty to the company we serve, so I must tell you that although our Chicago store (Saks Fifth Avenue) only employs an average of 600 people, we can boast of being the largest chain of fine specialty shops in the country. First of all, please remember--any estab lishment that opens its doors to the public is responsible for what happens to those who enter these portals. ' Fonexample, I recall the wife of a prom inent citizen harbored in the powder room, one flight up a lovely winding stair case-- not merely intoxicated, just plain drunk-- with her several friends. A known alcoholic, she has been put in her car by a police offi cer, who also knows her and wants to pro tect the family. But it's a lovely day and they all come to the store to shop--shop they cannot--disturb they can. It is your duty to straighten them up and get them down these stairs and off your property before they injure themselves and their reputations. Another woman tries on a $63 hat with a hornet in it. Hornets sting--and this one did! There was an obese lady, who wears a size 44 and insists on trying on a size 40. The saleslady', in pulling up this garment-- not without difficulty--lets her hand slip and she literally socks the customer in the nose. When 1 saw this woman, I thought Marciano couldn't have packed a better punch. Then there's the customer who is zipped in the dress--skin and all. Sometimes I think these salespeople are in competition with the skin men. They have removed so many warts and moles. There are the fitting pins in toes of women wearing toe-less shoes--and the corset stay that breaks (metal). It digs and cuts and scratches. And all these people bleed, you know. Some of the scenes are as good as Shock Theatre. A plate glass mirror covers an entire wall in a fitting room. It falls and strikes a small child. A customer falls out of her car in your parking lot--and there are those who fall just getting in--or stumble on your sidewalk in front of your property. The epileptic--the drunk--the truly ill have accidents near your store, and well-meaning employees bring them in and send for you --because you're such a nice nurse! I won der? You see the 75-year-old woman who falls two steps and fractures a hip. They just fall and you wonder, as you have a mental picture of your accident experience for the year. Why didn't they use the elevator pro vided for their convenience? Then we have the over zealous beautician who trims the ear lobe as well as the hair. And there's the customer who feels that time has been unkind to her, and she will improve on nature, forgetting she has any sensitivities. She suffers an acute reaction to the dye she has chosen for her new bair. Burns sometimes come from permanent wave solutions. These people you must con vince they will not develop cancer of the skin tomorrow. Customers' children play in busy revolving doors. Indignant parents are completely ob livious to them until they are injured. Now, a few things that happen to our own personnel--like the woman who deliber ately walks into a parked truck in the alleywhile talking and visiting with her friends. The laceration in her head requires four sutures. A porter walks out the back door to be thrown back into the building by the impact of a truck passing through the alley. A watchman, performing his duty, argues with an employee who insists on taking a package out of his door without proper au thorization. He suffers a ceretai accident A stock girl has a spontaneous abortion in a washroom. You sit her on a hard gar- 79 1958 National Safety Congress bage can, and hope they will hurry with the ambulance. And I recall the trickster who alleges she fell off a ladder and is having a nasal hemorrhage. She arrives in your office with the assistance of four people, who should be in their departments selling. This one has copious amounts of white tissue, stained bril liantly red, against her face. You look, and you must tell her--you may be old, but not a fool. The stain on the tissue is merthiolate. This one had just been refused a four-week vacation. Eighteen men in one department are stricken one afternoon with acute gastric up sets and diarrhea. This is a real emer gency. It will cripple a busy department dur ing a most important sale. All these men had eaten their lunch be hind the scenes, a time saver to accommodate the crowds. Those who had eaten the tuna fish and egg salad, the food you might sus pect, were well. Those who had failed to wash their hands were ill. I must tell you, these were shoe salesmen. We had a hysterical woman who would sit on the floor instead of her chair. She sews. She spent four months in the hospital, with the services of the best in medicine, orthopedics and psychiatry', and took good care of my accident experience for that year. Not three weeks ago, I was handed a subpoena to appear in court The same woman tried it this time on the C.T.A. And finally there was the elevator opera tor who had a "vision" and ran her car, loaded w-ith patrons, well above the safety level. And so it goes--each day a little different --interesting to say the least, but every day a new challenge Certainly I see the fellow with the acute abdomen that ends up as an acute appendix, the fellow with the kidney stones, and the acute gall bladder-'and the usual cardiac emergencies. I must deride quickly which to call first--the doctor, the clergy, the fam ily, or. the fire department. You call one or the other, and sometimes all. and things seem to work out. EMERGENCY IN THE PLANT--NURSING ASPECTS By ANNA J. THRASHER, R. N. Chief Nurse, Hawthorne Works, Western Electric Co., Chicago, III. Hgw should we as nurses prepare for emergencies in industry? I will discuss this from the viewpoint of the individual nurse, not limiting It to a oneor a multiple-nurse unit. The needs are es sentially the same. If the doctor is on call or on the premises we will prepare for his attendance. Upon assuming a new position, acquaint yourself, as soon as possible, with the phys ical aspects of the plant. On your tour, determine not only the type of accidents that may occur but the accessibility of the in jured to the medical department Designate a place for the stretcher or stretchers; see that the aisles are wide enough to accommodate them or find out which aisles are. Who does or will maintain the stretchers? Are there trained cot crews to bring the injured to the nurses' station; will they recognize the need to call the nurse or the doctor to the scene? Is this a factory with enough floors to warrant an elevator? If so, institute a signal sytem to be used for emergency purposes and see that the stretcher fits into the elevator. -If- tlie doctor is^itot on the premises at all times, confer with the doctor on call as to his preference in medications and treat ments of acute conditions so that you will have the necessary supplies in readiness. Contact and negotiate with a nearby am bulance service so that there will be no waiting period for confirmation of respon sibility at the time of need. Do the same for a car or cab service; and the local Fire Department. Discuss with the hospital of your attending doctor the possible admission needs. List all of these emergency services 80 1io^*kduU iaf ihe ! Ko.fi/ta], medicine, ook good that year, handed a "he same r.A. or operaher car, ie safety different very day the acute ippendix, and the cardiac lv which the famII one or ngs seem iCTS } he nurse loors to a signal purposes nto the nises at : call as d treattoa will ess. by am- be no responte same al Fire rital of mission services Industrial Safety with addresses and phone numbers in a very conspicuous place. Include the phone num bers of the local parish priest and police. Having arranged for all of these com munity facilities, enumerate the essential details and refer to your procedure outline when the first occasion arises. Until you have followed through on a repeated num ber it is so easy to omit one step. Make up a hospital admission form for entering all of the vital statistics that are readily available from your medical de partment records and that will be required by our hospitals. Also, provide a space for ''tentative" diagnosis and medications that have been given. You can understand how important this is for the seriously ill pa tient Prepare a form letter for hospital admis sion, of company responsibility cases also. Designate to whom the reports and bills will be sent This leaves only the identifica tion of the employee to add at that time. Include in your procedure the notification oi relatives. If it is at all possible either by extension or plug-in phone, try to allow the patient to speak to his family. No mat ter how you try to soften the shock, it is difficult for the family to accept the fact that you have sent a husband or a father to the hospital. Have a designated person or group to do the notifying in case you are unable to con tact relatives by phone. This preliminary planning is so helpful in expediting the care of the acutely ill employee. Attempt to arrange the medical unit to accommodate a seriously ill patient in some degree of privacy and quiet; a room sep arated if at all possible from the normal activity. Have your side rails attached to the bed so that you will not have to leave the patient to fetch them. Designate one cupboard, shelf or unit for emergency equipment Establish a routine for checking this regularly. When you and the doctor have decided on its contents list them, do not rely on your memory. Include here such articles as tourniquet, stimulants, syringes, blood pressure cuff and stetho scope, poison tray, airway, narcotics (if per mitted in your situation), orange juice, glu cose, eye wash, sterile dressings and small suture tray. You might be duplicating equipment and supplies used elsewhere in your situation but this is not wasted effort or supplies. Test your oxygen tank and equipment at least once a week. Keep a log on the amount in the tank; if you maintain an ambulance v>n the premises include this in your weekly inventory. Inspect the tubing and masks for leaks at the same time. Strap a padded tongue blade on the wall next to the bed or in a familiar spot where it can be easily reached. With all of this in readiness you are pre pared for your first emergency. Now, the specific nursing measures that we can employ until the doctor arrives: In acute absorption from toxic fumes, re move the employee from the work environ ment immediately; notify the doctor; ad minister oxygen; if- extremely- weak, give some form of sugar by mouth e-g., Karo Syrup with dilute lemon juice. In heat exhaustions put the patient at complete bed rest; give salt and sugar by mouth; if the patient can retain it, notify the doctor, and prepare the emergency tray for I.V. administration on order. In cardiovascular accidents, start the oxy gen if the patient is dyspneic and try to reassure him; attempt to keep interested on lookers away; check the blood pressure and pulse, consult the medical history, have something concrete to report to the doctor. In acute G.I. upsets where there is a food complaint or history of food contamination, induce vomiting using an emetic such as warm soda and water. In acute gall -bladders give nothing by mouth; apply heat to the epigastric region and have your hypnotic ready. Your acute G.U. emergencies are usually kidney stones; here again we are limited to using local heat and having an hypnotic ready. Antiphylactic Shock--If you are adminis tering flu vaccine or other prophylactic se rums, it will be under the direction of the doctor. At the time you set up the program determine specific allergies which would make the vaccine contra-indicated; do not give it to those having these allergies. Also obtain the drug of the doctor's choice for injection, in case of sensitivity. Have ready, not only the vial of medication, but instru- 81 1958 National Safety Congress meats for cut down in case of complete amounts of eye solution; when you are tired collapse. It would be well to keep these of holding the lids apart and have used up packs on the table where you are dispensing one bottle of solution start on the second the vaccine. one. You cannot flush too much. Patch Drug Reactions--list all known sensitivi firmly and transport to the doctor. ties in the medical history'; Sag the record Thermal bums of the eye--are almost al in an obvious place; attempt to have the ways due to ultra-violet and the patient will record available at the time of the treatment If, as sometimes happens, the patient doesn't admit to an allergy until after administration of a drug, use an antihistamine immediately, even before any untoward reaction occurs. not notice the symptoms for about 6 hours. By this time the cornea has begun to peek Do not flush these. Patch firmly. Thermal bums of the eye are almost bilateral. To facilitate locomotion you might want to use Here some serious health counseling is in dark glasses insteal and send to ophthalmolo dicated. gist. Acute Central Nervous System Emergen cies--In any loss of consciousness, your first concern is to protect the patient If he b having a convulsion or seizure, use the padded tongue blade; loosen his clothing; pull up the side rails; if he responds verbally reassure him; give him some mild sedation e.g., phenobarbital and let him rest Do not allow him to return to work the same day. See that he b accompanied home, if not hos pitalized. Advise him to consult hb doctor before returning to work. This will re emphasize the importance of adhering to hb doctor's program of treatment Acutely Disturbed Employees--Have an established policy in writing, for the handling of the acutely disturbed. Have assigned per sonnel to help restrain until the doctor has ordered indicated disposition. Insulin Shock -- If possible, give orange juice by mouth and prepare vour I.V. glu cose; here again clearly flagged medical rec ords will help in detection. However, also encourage personal identification. In the rare diabetic coma, prepare the insulin and use the same precautions that you would for all loss of consciousness. In acute low back strain--If the employee has just dropped to the floor having incurred a severe acute back pain following lifting of a heavy object and you are called to the scene of the accident: Try- to.,move the patient without putting any more strain on the back muscles. If you transfer him to a cot keep the knees flexed. If you are. transferring the patient from -the cot to a bed, support him on either side under the arms, thereby avoiding the use of the back muscles. When in bed again, elevate the knees. In hemorrhage of wounds--Apply pressure with compression dressing. If you are unable to control with this method apply tourniquet. In severe bleeding from the nose -- Keep the patient in sitting position until active bleeding has stopped. Advise patient to breathe through mouth. Press both nostrils together for 5 to 6 minutes. If bleeding does not stop pack a small amount of gauze back into nostril, leaving end so that it can be removed. For internal bleeding--Complete bed rest. Do not sedate. Reassure the patient, give nothing by mouth. In severe chemical bunts--Wash with co In severe traumatic lacerations -- Apply a pious amounts of lukewarm water and apply -sterile protective dressing and a firm com a sterile dry dressing and firm bandage. pression bandage until operating room fa In thermal bums--Apply a sterile dry cilities are available. dressing and firm bandage. Force fluids; treat for shock if indicated. Avoid de bridement or ointments until patient is under the care of a doctor. In fractures and amputations--Our main concern b protection. Apply a sterile pro tective dressing, a firm bandage and immo bilize by splinting. Avoid flat splinting. In serious mechanical eye injuries--If the cornea b lacerated or there b a penetrating wound patch firmly and transport to the Attempt to splint in position of function. Bandage securely. Do not allow any mo tion of the injured area, thus avoiding addi ophthalmologist tional damage to soft tissues. In chemical bums of the eye--As in chem Acute head injuries--Apply a compression ical bums to the body flush with copious bandage to control bleeding. Do not remove 82 u are tired ce ; ) up the --cond ch. Patch almost alJatient will it 6 hours, an to peel . Thermal iteral. To ant to use hthalmolo- : employee ig incurred ing lifting lied to the >ut putting uscles. I{ the knees he patient i on either oiding the bed again, iy pressure are unable tourniquet. se -- Keep util active par ''t to th . irils eding does rauze back it can be : bed rest, dent, give -- Apply a firm cornroom fa- Our main :eri!e pro ud immosplinting. function, any mo ling addi- mpression ot remove Industrial Safety any protruding foreign bodies. Watch closely and record such vital signs as bleeding from the ears or nose, conscious on admission, loss of consciousness, period of unconscious ness ; contraction of pupils, alteration in pulse, respirations, and so forth. Normally, keep the head elevated to prevent congestion. However, if the patient has trouble breath ing you can't maintain this. Do not sedate. This may mask the symptoms. Non-Occupational--Appendicitis: History --Nothing by mouth; contact personal physician if your doctor has ordered hospitalization. Transportation to hos pital. Ruptured Ulcer: History--Nothing by mouth. Treat as any shock patient. Do not sedate. Treat for shock. Obstetrical: Determine specific policy of management relative to length of time that pregnant employee may work. If there is no limitation on this you will have to be prepared for a delivery. In . miscarriages if employee has been brought to you on stretcher do not transfer to a bed for examination. If there is any vaginal bleeding no not at tempt to remove any visible clots. Use perineal pads with pressure and strap legs together. Then do all you can to expedite her removal to the hospital of her choice. Again I would like to repeat that it is so important to instill confidence in the em ployee, not only in our technical skill but more important possibly in our sincere in terest in him as an individual. IS TRAINING FOR SAFETY DIFFERENT FROM OTHER TRAINING? By RALPH M. HARTMANN Mgr., Training and Development, Quaker Oats Co., Chicago, I1L In addition to my duties as manager of training and development for the Quaker Oats Company, I am responsible for the functioning of accident prevention effort throughout the Quaker organization. We do not find this inconsistent, nor is safety just an "added duty," because we consider that safety is one of several factors that must be built into our operation. A training man is not simply a training man for quality or production or even saiety. Training must reach into every phase of our working life. It will serve no purpose to train a supervisor merely in job instruction methods and neglect to train him in basic principles of management. Similarly, it is unwise to teach employees production methods without also coaching them in the safeguards that will assure con tinuity of operation. The more we have studied the problem of accident prevention at the Quaker Oats Company*, the more we feel that success in safety is the product of an environment which emphasizes individual responsibility-- exercised at all times and at all levels. It follows then that safety training should be so directed as to assist all people in the organization in discharging their safety re sponsibility, Le., to get as many people as possible to perform the work assigned 'to them in the right way. Now back to the question--Is Training for Safety Different From Other Training? Today there is no universal agreement among professional training people as to the best methods, materials, etc. to be em ployed To meet'"every training"need=-then surely there can be no general agreement among training people on this particular subject My personal opinion is that training (as such) for safety is not different from other training. However, in the approach to safety training, that b in preparing for and conducting of safety training, obviously some different considerations must be kept in mind, than were you, for example, pre paring for and conducting, training to make people more quality or cost conscious. 83 K: r^>: j 1958 National Safety Congress Let me suggest we handle our discussion of this subject in somewhat tins manner. First, let's review a few of the considera tions we should keep in mind when we are preparing to do a safety training job. Then next let's examine and discuss a number of specific questions on the subject of Safety Training. This entire procedure may help you individually to explore this subject as it applies to your immediate circumstances, so that you may find your own answer to the question--Is Training 'for Safety Different From Other Training? Let's take a look at some of the special problems or considerations we should keep in mind when preparing for safety training work. 1. The modern conception of accident prevention seems to identify it as a major executive problem. If so. it then follows that management must be responsible for the formulation of broad, all-inclusive safety policies and provide an organizational struc ture which will make possible and encourage an effective safety endeavor. As safety men, do we do the informing, educating, and training of our executives, so that they have an appreciation of their safety responsibility and the safety job they must do? This means special training for executives is necessary. 2. Another concept, generally accepted, and to which we subscribe, is that the direct responsibility for safety is in the line super visors. More and more, management is realizing the dominant position occupied in industry by supervisors and foremen. How ever, before safety training can be effective with the foremen, this concept must be known and accepted by foremen and super visors alike. 3. And another point on which there is considerable agreement--is that safety--to a large degree, is pretty much a matter of attitude--a state of mind--on the part of an individual. An important phase of the training job is to instill safety consciousness into the individual workman. How many training and safety men consciously consider this factor when preparing for and con ducting safety training? 4. In most instances, the mental resistance of the trainee to the subject of safety is greater than the normal resistance to pro duction or quality training--the people to be trained are very often not in a receptive frame of mind. More than in any other areas of training we encounter the attitude that "safety is sissy stuff'--"I don't have the time," and so on, which professional safety men know all too well. We must study and know our trainees. 5. Another factor--which has much to do with the receptiveness of individuals to safety training--is the concept that safety is primarily a matter of converting faulty physical conditions. Regardless of all the seemingly convincing data that has been published, industry still devotes a very sub stantial part of its accident prevention effort to physical conditions. We need to over come this concept. Steady improvement of physical conditions is a must, but while doing this we must guard against creating an impression this is the whole answer to our safety problem." 6. In many concerns, training for safety is still handled on a somewhat amateur basis. * Professional training in industry has made great strides in recent years, but much of it has been concentrated on Production, Management Techniques, etc. 1 have also noticed that in some companies where group training is conducted for safety that the same amount of time, attention, and expense is usually not given to the preparation of training materials for safety as is done preparing for other types of training. 7. One additional thought--In our safety training work have we been emphasizing too much the penalities, suffering, etc., that could occur if we do not perform our job correctly and safely? Would it be helpful-- would our people be more receptive to safety training if it stressed more the ad vantages--to working safely? 8. And now, probably the most important single factorJthat must be considered when planning safety training activities has to do with participation. Probably the most effective technique known that can be util ized to gain cooperation and acceptance by fellow-workers in your accident prevention work is to provide for their participation. Participation helps to bring about a mutual desire for operators, supervisors, and execu tives to work closely together by creating the "conditions" necessary for cooperation to occur. How often we proceed to build training activities without thinking to in- 84  receptive an ther e v ..Tide lon't have ofessional We must uch to do [duals to at safetv ag faulty t all the has beat very sub ion effort to overvement >ut while creating nsner to r saiety amateur istry has 'Ut much xluction, sve also re group that the expense ation of is done rs, ] ring too c., that our job elpful-- live to the ad- portant d when has to e most be util* ince by vention ipation. mutual execureating eration > build to in Industrial Safety volve the people to be trained, and then we wonder why the training is not accepted enthusiastically 1 Now let's examine and discuss briefly a few specific questions on the subject of safety training. 1. Should training for safety be included with other job training? Does stressing safety confuse job sequence while training? Since safety can only be achieved as the job is being done, and is an inherent part of the job, then surely safety training should be a part of job training. This should be the responsibility of the individual's im mediate supervision. I see no reason why stressing safety, as it relates to job operation, should in any way make less effective the job instruction. However, I see no particular reason why the safety aspects of the job should be emphasized any more than the quality, quan tity, and other phases of the total job opera tion. As regards safety training to create a good safe working attitude in a new em ployee, more than the safety training pro vided in connection with on-the-job training must be done. Probably the best time to start this type of training is immediately after a man has been lured. An effective safety indoctrination program utilizing vari ous visual aids, and first aid and fire equip ment, covering a variety of subjects would be helpful. Such a program objective should create in the mind of the new employee a sense of belonging to a group of people, who are interested in their safety, as well as that of fellow workers. 2. Another question--Should training for safety be handled by the supervisor or by the safety man? We have touched upon this point. Since the supervisor is the man who tells the worker what to do, and normally he mil do a much better job of following through on his personal instructions than on instruc tions given^to his workers by a third party, surely then, the supervisor should provide job safety training on an individual basis. On the other hand, certain safety training activities may be better handled on a group basis, such as fire fighting--life saving techtuques--proper lifting methods, etc. Train ing of employees in such subjects by the safety man, or other well qualified people^ is usually welcomed by supervisory personnel. 3. Someone asked, "How about handling safety training for particularly hazardous jobs as opposed to normal routine?" My reaction is that as long as the regu lar supervisor supervises and directs the worker on this particular operation, then the supervisor should give the on-the-job safety training. 4. Another question--Can we motivate for safety at the same time we train for production ? Surely we can and must Safety per formance is a factor considered in our annual job performance appraisal of all supervisory and management people: This is considered on the same basis as quality --meeting of production schedules and costs. This helps to motivate supervision. Proper safety orientation training--effective job training and provision for participation in group and departmental safety activities will all be needed to provide-necessary safety motivation to workers. The supervisor who understands certain simple concepts regarding learning wilt save himself untold aggravations and insure more pleasant relations in giving instructions and supervision to his employees. If he under stands the fundamental principles of learn ing, he will use his energy best in giving instructions. Learning is a process of forming habits --This requires a series of actions or experi ences on the part of the one who is learning. Many things may be done or caused to influence the rapidity with which habits are formed, but it is fundamental that the learner must take part in the process physi cally and mentally. As many of the senses as possible should--be--effeetively supple mented by an appeal to thinking for the most rapid habit-forming. Learning re quires participation on the part of the learner as well as repetition until the habit of following a sequence of actions is de veloped. Certainly if supervision is to provide job safety training then all supervisors should be trained in the techniques of Job Instructor Training. The question before safety and training people today seems to be--"How can we 85 1958 National Safety Congress most effectively deliver the goods?" Industry demands from all of its functions* depart ments and services, a good return for every dollar expended, including the costs for safety training. It is not a question of doing something in order to get something done for the record. It is a question of doing a needed job, when it is needed and doing it well. The success of safety training depends upon the changes that are taking place with in the individuals working in the plant. Our success is measured in terms of frequency and severity. It is measured in terms of those in the plant, who as a result of safety training, habitually fotlow safe practices. It is time we got our safety training into step with the Age of Automation. As this, I believe, can best be done by not thinking of safety training as being different from other training. Training for safety can be accomplished most completely and efficiently when integrated into an over-all well or ganized continuous training program. IS SAFETY TRAINING DIFFERENT FOR MANAGEMENT? By M. C. NL POLLARD Director of Safety, National Gypsum Co., Buffalo! N. Y. When a company believes in the impor tance of accident prevention, it establishes a policy and interprets it for application by line management people. There should be understanding of the fundamentals of acci dent prevention even more at this level be cause these persons must be able to give answers to questions raised by plant mana gers. Like a first-aid instructor, they must know more than just procedures outlined in the textbook. The instructor must have ad vanced training, learn about the skeleton, the body, the circulatory and respiratory systems before he can teach. It would seem this same thinking applies for accident pre vention. When basic principles are understood by the people having the greatest responsibility', they are better able to interpret problems, and give assistance to those reporting to them. "* lated problems. This program continued for a year and was then carried on by the vice president of manufacturing with the gen eral production managers and production managers. To properly place the importance of ac cident prevention, the first meeting of each year was devoted to safety-, and subsequent meetings opened with a review of plant accident experience for the preceding month. In each of these meetings those staff people haying responsibility for administra tion of safety-, quality-, production control, etc. supply information for discussion and may be called on to report progress, but they do attend meetings and are available to answer questions. Each production manager is called on to develop a personal program for safety- and make accident prevention No. 1 among his responsibilities. In the administrative office of our com- < They, in turn, demand the same accept pany the senior vice president of operations ance of responsibility- on the part of each held a meeting once a month with the vice plant manager. Evidence of hoyv it is fol president of manufacturing, general produc lowed can be best shown by the fact that tion managers, and production managers periodic plant operating reports must begin who have direct responsibility for plant with safety. operation. This includes activity- in the program such The agenda for each meeting followed as meetings, inspections, action on recom same pattern: safety', quality, cost and re mendations, listing of first aid cases, and 86 " * :rep*ncv teiS (of of ;_*ety actices. ning into As this, thinking nt from r can be ffidentlv well or- ued for the vice ie genduction of ac>f each sequent ' ' "''1 m* i : staff inistraxmtrol, >n and ss, but able to on to !y and ng his ccept: each s folt that begin i such xom. and Industrial Safety reportable injuries. Details of accidents are briefed and corrective action spelled out for each case. It also covers house keeping and fire protection. At the plant level, each meeting opens n-ith safety. Department heads and foremen are required to hold frequent meetings and contact people individually about safety. It is important that this level of line management also understands fundamentals. A special training course was developed. It calls for four one-hour sessions, each introduced with a sound slide-film that runs about 10 minutes, and the balance of the hour is spent in discussion. You may ask how this applies to top management training? None of it would hare-been possible without top management having been convinced that such a program is essential for good operations. Results obtained over the years in reducing the number of accidents were the reason why they believe as they do. Some may scoff, but humanitarianism-- a sincere regard for the health and safety of employees--continues to be the greatest motivation for management interest. If you were the president of a great corporation could you sleep nights, if you knew your accident experience was poor and ths' you were injuring people every day? Pernaps not enough has been said about the fact that American industry provides the best example that we are our brother's keeper. Our management deplores the occurrence of an accident and its resulting injury. No cost report is required nor expected. If a man is injured, no expense is spared for medical attention. We hurt him. We should care for him. What does the cost matter if a man loses an eye, cuts off a finger--or even meets death? Are dollars and cents important then? It is not necessary to have a continuing program for top management safety train ing. It is necessary to keep them informed of results and show them in every way pos sible that the policy they expressed is being followed- * Results come only through persistent ef fort on the part of line management When a problem arises, the production man re sponsible for the operation may seek help. Here, the safety director can be of assist ance in finding a solution. Action taken must be through the line organization, not by a staff man. If the latter were permitted to act, the strength of the management in terest would slowly dissipate. A safety man should have authority only for administration of a program. He may suggest, advise, recommend, analyze, plan, but never weaken any manager's effort through direct action. Training is best through example. Sin cerity of purpose can be best demonstrated, not forced on a person through harsh words. A pat on the back for good performance carries a lot of weight Safety men should let management know when a division, a plant, a department, a man deserves a "well done." Signature of the boss on a letter provides impetus for any program, when results merit congratulations. Training down the line comes from ex ample as well. Management must approve expenditures for safety, and some opera tions call for considerable amounts of money for this purpose. Knowledge that the company is willing to pay for it lets those down the line know the policy for safety is real and alive and sincere. Failure to get approval for such items stems not so much from lack of interest,' as it does from poorly prepared requests for appropriations.. Given the proper facts, management will provide the means for better results. Is safety training different for manage ment? Yes, because management is the trainer. Haying the desire to make a profit, and knowing that this comes only through safe, efficient operation that pro duces high quality, low cost, competitive, saleable goods, management trains in every way possible to achieve its goal. This ap proach provides jobs and secures the future of every person in the organization. This is the ultimate for safety. 87 (A Demonstration) By EARLE S. HANNAFORD, PH.D. Safety Engineer, Long Lines Department, American Telephone and Telegraph Company, New York City Assisted by: William J. Hrdlicka, Staff SupervisorPersonnel St Louis, Mo. Edmund J. Kelly, Staff Supervisor White Plains, X. Y. Sidney Robbins, Staff Supervisor-Plant Construction White Plains, X. Y. Phoebe M. Guyon, Welfare Supervisor Xew York City Lucille C. Sassmann, Staff Assistant New York City *** On-the-job training, usually described as training on the scene of action, is as old as man himself. Every single day of our lives, both on and off the job, we leant by doing. That's where the age-old axiom, "experience is the best teacher" comes from. In fact, on-the-job training is one of the major factors, and in all probability, the most vital factor in our lives. Without it we would be helpless for formal classroom or school training can never cover more than a small part of our living requirements. On the job it's sometimes difficult to be sure just what is job training by the fore man or supervisor and what is called super vision. For so much of day to day super vision on the job is really training. Actually, only, a limited part ofjob training is formallyplanned and given by the supervisor. How ever, -the same fundamental, practical guid ing rules apply for spur of the moment onthe-job training given on an as required basis. So let's cover them briefly. If we have them in mind the demonstration of on-the-job training will be more interesting as well as more meaningful. At the risk of oversimplifying the ele ments of learning. I'm going to call your attention to a few proven simple psveho- 88 logical facts upon which the on-the-job training process is based: 1. There are paths into the mind and paths out of the mind. 2. What comes out of the mind depends upon how it goes into the mind. 3. We learn best by seeing. 4. Permanence of learning comes from ac tually doing. 5. Seeing something done, followed by doing it ourselves, ensures good learning. The four step teaching-learning process for on-the-job training is founded on those principles. Here it is: Four Steps ut Job Training Step I Step II Step III Step IV Preparation Presentation Application Test The Path Into the Mind The Path Out of the Mind Briefly, here's what each step does: Step 1--Preparation-- Prepares the Learner Puts him at ease. Focuses learner's attention on a known idea which offers tie-up for a new idea. Gets him interested in learning job. Step 2--Presentation--Do the Work Operation for Him Show, tell, illustrate and explain carefully and patiently. Instruct clearly and completely, taking up one point at a time, but no more than he can master. Emphasize key points. Step 3--Application--Learner Does Work Operation Have learner try doing the job himself. Have him explain key points. Introduce safety aspects of job. Ask checking questions and correct errors. Continue until you know he knows. :graph on-the-job mind ana id depend; s from ac- Uowed by anting. S process t on those 9 Path the d Path Out eilind s: ) lown idea dea. Work carefully >g up one n he can er elf. errors. Industrial Safely Step 4--Test Have learner perform the job without help. Observe work operations carefully. If he fails, go back into step 3 and correct errors. Do step 4 again. Tell him to see you if he needs more help. Follow up work operation on the job. Taper off extra coaching and close follow up. Check periodically and retrain if indicated. This, then is the norma] job training teach ing-learning process. Step 1 in normal job training centers about the job and doing it. Keep in mind for onr later discussions the fact that safety and accident prevention are not a part of Step 1 and only-appear slightly in Step 2 which consists of showing and telling the learner how to do the job. As I have noted, accident prevention and satiety appear in the third step--the step where the learner tries out his hand at doing the yob. In Step 3, also, the supervisor checks on how the learner does the job and what he kuows through the use of questions and by correcting the learner's errors. Please note this. In actual practice Step 4 includes periodic checks on die job. These are actually part and parcel of good super vision. That's why I said it's hard to tell where job training ends and supervision as such starts. Remember the old adage--"If the learner hasn't learned, the teacher hasn't taught?" From the standpoint of safety let's make it --"If the learner hasn't learned to do the job safety, the teacher hasn't taught." Since accidents do happen to well trained people, the question arises--"Is training for safety different?" Obviously, if there is an accident retrain ing is indicated and the chances are that the original training didn't get the safety mes sage "into the mind" so it would come-"out of the mind" properly^ A short time ago I said we learn best by seeing. That leaves me no alternative but to demonstrate the job training teaching learning process for you. We will show you the teaching of the same job twice--one without' special emphasis on safety, and fol lowing that the same job with special em phasis on safety. I would like to introduce the participants or role players: William J. Hrdlicka Staff Supervisor-Personnel St Louis, Mo. Edmund J. Kelly Staff Supervisor White Plains, N. Y. Sidney Robbins Staff Supervisor-Plant Construction White Plains, N. Y. Phoebe M. Guyon Welfare Supervisor New York Gty Lucille C. Sassmann Staff Assistant New York City Actually we have two demonstrations. First well show you the job training in a man's job set up and follow it with one for women. Our first demonstration shows the job training of how to prepare a lead sleeve in cable splicing. So just imagine you are watching a construction foreman and his men. First I am going to teach the job without special emphasis on safety. The cards will indicate what step in the four step job training process is taking place. Note: Foreman and the two men do not wear safety glasses, gloves or hats during Part A of the demonstration. Foreman--How are you this morning, fel lows? Bill and Ed together--OK, Boss, OK. Foreman--Late.yesterday I was checking a couple of the sleeves we put on earlier in the day. Step 1--Preparation We could stand a little review on it and I'm going to go over the preparation of lead sleeves so we'H all be on the ball. Bill--Just a minute. Boss! I was the one who showed you how to prepare sleeves when you were just starring. Remember?-- I know that I know how to do it--so--in clude me out Foreman--Yeah, Bill, that's right, you did break me in. That's one reason why I want you to go through it along with Ed. Ed--As far as I'm concerned, I would like to go over it. You know, I haven't been 89 1958 National Safety Congress around long and can stand all the help I can get Bill--OK, I'll play along. In fact maybe I ought to do the teaching. Foreman--No, Bill, I want to do that my self. Preparing sleeves is a simple enough job but it's important that it be done right or the whole splice can turn out bad. I've got some sleeves and the tools are laid out. Here's the instructions, too. I've got them propped up so that we can all see them. Ed--Let's not go too fast. Boss. Remem ber, this is all new to me. Bill--Don't worry. Kid--Just watch me. I'm the original on this stuff. Foreman--OK, Bill. What's the first thing to do? Bill--Anyone knows you drift the sleeve first! Foreman--Sure, sure but remember Ed's new. Supposin' I just show him what the tools are we're going to use. Now here's a sleeve Ed. You know what it s for? Ed--Sure, we put it over the splice joint and wipe it in with the hot lead. I've seen that done. Foreman--Yeah, that's right These are the tools. Here's a rasp which we will use to dean the sleeve. Bill--Wait a minute. Boss, wait a minute! The first thing you do is to drift the sleeve as I said before. So why not show him the drift plug first? Foreman--Well--maybe you've got a point Bill! Here's what we call the drift plug, Ed. We have also a wire brush, a shave hook, a dresser, a cradle to hold the sleeve and some stearine. Ed--Yeah--the names fit them pretty well. 1 can pick them out all right Step 2--Lecture and Demonstration Foreman--First thing'we doTs to Sift the sleeve. ^That's to make sure it's round, be cause in cutting it off and handling, it may have gotten out of shape. See--I start the drift plug in the sleeve and then force the plug through the sleeve by holding the sleeve and striking the handle of the drift plug on the floor. Once it's started, I grasp the sleeve in both hands and thump die handle on the Boor until the plug clears the sleeve. Like this! Then I put the sleeve in the cradle. Bill--Now, Kid, the next thing to do is pick up the rasp and-- Foreman--Yeah, that's right. Bill. Be my guest while I rasp it. (Takes rasp irom Bill.) Hold the sleeve firmly in the cradle with your left hand, stroking the sleeve with the rasp, like this. The object is to get the sleeve clean for three or four inches on each end. Ed--Yeah, I see. Bill--You can turn it with your left hand while you rasp it Foreman--Hand me that shave hook, will you, Ed? That's what we use next (Ed takes off the leather guard and hands the shave book to foreman.) Ed--Here it is. What's it tor? Foreman--You use it to bevel the inside edges of the sleeve and clean them. Ed--Oh! Foreman--See; like this. I hold the sleeve rigidly m the cradle with my left hand and wipe the shave hook around the inside edge with my right hand. There--see that bevel ? Now--hand me that dresser, will you, Bill? Bill--That's not the way I taught you. Boss! Foreman--What do you mean. Bill? Bill--Why, anybody knows you should brush the sleeve before you dress it 1 Foreman--Yeah ? Bill--Yeah-- Foreman--Well--as I was saying, Ed-- you take your dresser, hold the sleeve firmly in the cradle and shape it into approximately cable size. You rotate it as you strike it so as to shape it in evenly. Seer (Strikes it.) Ed--Why did you say you do that? Foreman--To shape the sleeve down so that it is approximately the size of the cable. Then you beat it in for wiping after you get it on the splice. Ed--Oh! Foreman--You brush the sleeve smooth with a wire brush tor a two-inch space on each end. That's so it will be dean and you will get a good wiped joint. Finally, you you are going to use it. Bill--I still think you should have brushed it before you dressed it 1 Foreman--OK! Supposin' you prepare a sleeve, Bill, and tell us what you are doing and why you are doing it as you do it 90 g to do is m i my rasp from the cradle the sleeve * is to get inches on left hand hook, will ext (Ed hands the the inside the sleeve hand and side edge at bevel? z, Bill? ght you, ill? g. --i- smooth pace on and you ily, you brushed spare a : doing it Industrial Safety Bill--Sure! This is old stuff to me! Just natch my smoke, Kidt Ed--Sure, Bill, sure! Foreman--OK, Bill. Step 3--Demonstration By The Learner Bill--First, I drift it with the drift plug. Foreman--Why ? Bill--To make sure it's round--what else? Then I put it in the cradle and 1 rasp it dean at each end for three or four inches. Foreman--Yeah! OK! Bill--With the shave hook. I'm going to bevel the inside edges to dean them and make a good joint when we beat the sleeve in on the cable. .Vow--I brush the sleeve for three or four inches on each end so it will be good and dean for wiping. Ed--Yeah--Bill--but the Boss said . ..-- Bill--Sure the Boss said dress it first, but--when / do it, I brush it first! Foreman--Hmmm__ (Bill continues brushing.) Bill--Now--with this here dresser, I beat it in. Foreman--Tell Ed toby you are beating it in! Bill--To shape it to the size of the cable. This stearine will keep it good and dean, now! Foreman--Bill, do you think that it's really dean after you lave dressed it? Bill--And why not? Foreman--Well, the dresser might be dirty and then you have beaten a lot of little ridges in there, too. Could be that causes trouble. Bill--Oh, 1 don't know! Foreman--Well, if you brushed it again before you put on the stearine, you would be sure, wouldn't you ? Ed--If you waited to brush it till after dressing it -- Bill--Keep your cotton-pickin' fingers out of this. Kid This is between me and the boss! Foreman--Well, if you want to go through life brushing everything twice . . . Bill--All right--all right--you're the boss! Foreman -- Now, Bill, don't you really think it's best to brush it afterwards? Bill--Well, m try it that way and let you know. Foreman--OK, Bill, I'm going to take you at your word. Let's see you run through the whole thing now without me saying any thing. Step 4--Test Bill--OK--First, I drift it to make sure it's round. I put the sleeve in the cradle and then I rasp it dean for three or four inches on each end--like this--see! Hand me that shave hook; Kid! I'll teach you how to be a good bdper. Ed--OK, here it is. Bill--Now that I've beveled the inside edge with the shave hook. I'll brush her up. No--wait a minute--wait a minute! I'll dress it first! There--that looks about cable size. Now--111 brush it! It's got to be smooth for about two inches cm each end and-- here goes the stearine to keep it dean. How do you like them apples. Boss? Foreman--Looks good to tpe, BilL Ed--You know--I've learned a lot this morning. How about my trying it? Foreman--OK, Ed. Leader's Remarks--This completes our demonstration of on-the-job training using the four-step teaching-learning process with out special emphasis on safety. As you have observed, each of the four steps was easily recognized so, in our second demonstration of the on-the-job training teaching-learn ing process with special emphasis on safety. We will only run through Step 2 lecture and demonstration, and Step 3, demonstra tion by the learner. Steps 1 and 4 will be omitted. It's in these Steps 2 and 3 that safety should be introduced and emphasized. In fact, safety is, for the most part, introduced in Step 3. This is so the actual job opera tions, as demonstrated by the supervisor, wUl be dear and dean-cut with respect to the job sequence. Of course, since die safe way and the right way are one and the same thing, this should in no way detract from the effectiveness of introducing the greater part of the safety concepts in the succeeding step. Step 3, demonstration by the learner. For the purposes of our demonstration, remember that Step 1 has already been com pleted. 91 rm \<\ /?M i; r - t. fT i1:;! W----. 1 iwtO h .f; 1958 National Safety Congress Note: Foreman has his safety glasses and gloves on but men have gloves in back pockets and are not wearing safety glasses. Foreman--Now, Ed, Fm going to show you how to prepare die sleeve. Ed--That's fine. Boss. Foreman--By the way--where's your safety glasses, Ed? You are supposed to wear them eight hours a day on the job, you know that Ed--They're in my pocket I don't need glasses! Foreman--Yeah, but you do need eyes, so how about getting your safety glasses on. Ed--OK! (Bill glances around and quietly puts on his safety glasses also.) Foreman--There's something else missing, too. (Bill and Ed silently check over the tools.) Bill--The tools we need are all here-- what do you mean? Foreman--Yeah--except for what's in your back pocket Bill--You mean these? (Bill takes gloves out of his pocket and slaps them down on the table.) Foreman--Now, Bill, you know you should wear gloves. We do not want any cuts and infections on this job. Bill--But... Foreman--No hut's about it--both of you get 'em on and your hats, too. You wouldn't exactly enjoy sunstroke ether. Ed--The boss is right Bill. Bill--OK, OK. I notice you didn't have yours on cither--Jet Job! Foreman--The first step in preparing a sleeve is running the drift plug through it This is done to make sure that the sleeve is round. Let me have the drift plug, Ed. <f--OK,'bereshe isf end. First I put it in the cradle so I hold it securely and it won't get away from me and falL That could cause a bad aeddent Notice I rasp away from myself and rotate the sleeve slowly in the cradle. Bill--(as if talking to himself) That's right--leave it out--don't bother to tell him! Foreman--What was that. Bill? What are you grumbling about? Bill--Oh, it's OK by me if you don't tell him everything he needs to know. I'll fill him in later, anyway*. Foreman--OK, Bill--What is it now? Bill--Wei!--don't you think you ought to tell him which side of the rasp to use in stead of just showing him? Ed--I can see he's using the flat side! Foreman--Yeah, Ed--that's the side to use--the flat side. Now, with the shave hook, I wipe her around the inside edge, like this, putting a good bevel on her. That's so when we beat it into the cable it will lie up against it good. That land of deans it out, too. Be very* careful with that shave hook--the point is really sharp and it it slipped it would give a nasty wound. Ed--Yeah -- it would slice through the gloves easily. (Note: The guard is left off the shave hook and laid to one side.) Foreman--Using the dresser here, I beat the ends in to almost cable size. Bill--(in a love voice, holding up the wire brush and shaking his finger at it.) I still think... Foreman--Yeah-- I know. Bill--the wire brush. Didn't we agree to try* it the other way? (Pause) How about doing it my way, huh? That's the way I want it done on the job anyway, see? Bill--OK, Boss, OK--If you say so. Step 2--Lecture and Demonstration Foreman--See, I start it; then, holding on to the sleeve, I thump the handle on the floor until it emerges from the sleeve. Keep a good hold on the sleeve, keeping one hand under it so it won't fall when the plug clears it. If it fell, it could sure bust your toes. Now I'm going to rasp the sleeve so as to dean it three or four inches back from each Foreman--Well, I do say so. Now, I've got it dressed. I'll brush it--brushing it the safe way--away from me. Gean it about two inches at each end. Finally, 1 rub on the stearine to keep it dean. Any question, Ed? Ed--No, I've got it. Bill--Thai's what you think. Foreman--OK, Ed. Supposin' you show me how to do it, telling me as you go. ) That's tell him! tVhat are don't tell I'll fill Jgh the I i he wire I Still iie wire e other ty way, on the r it Ac : about rub on Jestion, Industrial Safety Step 3--Demonstration By The Learner Ed--OK. Fust, I drift it--like this-- Foreman--Why do you drift it? Ed--To get it round. (Bill turns away, pulls a newspaper out of his pocket and starts reading it.) Foreman--Anything special to watch out for? Ed--To keep one hand under it to hold it because it's heavy and could break up some toes. Now I put the sleeve in the cradle where 1 can keep it from getting away from me and causing an accident. Then using the flat side of the rasp, I clean the sleeve three or four inches back, like this. Foreman--Yeah, be sure to stroke it away from you. You know these rasps can take oft a big hunk of skin if you miss. Ed--Yeah, that's right, I guess. Foreman--What's next? Ed--Well, with the shave hook I bevel the inner edge. Foreman--Wait a minute; where's the guard tor the shave hook? It should always be on it when it's not in use. That hook is pointed as well as sharp and can cut you up plenty. Bill--Here it is. Foreman--You used the hook last. Bill. Why didn't you put the guard back on when you finished? Bill--I forgot--anyway I figured we'd be using it again soon. Foreman--Makes no difference. Let's get this straight. I want all guards put back as soon as you finish using the tool--and I mean always. Ed--Got it beveled now. Foreman--Why did you bevel it, Ed? Ed--So that when we beat it in, it will lie snug to the cable. Foreman -- That's right -- and remember that shave hook has a keen edge on it, so keep it under control and stroke it right so you won't cut yourself. (Bill holds up finger and inspects Band-aid on left index finger-- looks around and quickly puts hand back in glove.) Ed--Now let's see. I'm a little confused here as to whether I dress it or brush it! Bill--(looking up from his newspaper)-- I'm not! Foreman--Well--neither am I. Let's use the dresser. Ed--Oh yeah--that's right, that's right--if I brush after I dress it; it will be clean and I'll only have to do it once. Foreman--Yeah--and watch out for that wire brush. It doesn't give you a beauty treatment if you miss with it. Ed--Ok, Boss. Now finally I rub on the stearine to keep it dean. Foreman--That's OK. Bill--Yeah--that's OK, Kid. Maybe some day' you will be as good as I am. Foreman--Now let me see you run through it completely on your own, Ed. "A" The second demonstration of on-the-job training will be presented by the ladies. It portrays some of the differences between job training women and that of men. The women--"God bless them''---look at things from a different standpoint than men and often have different reactions to similar situ ations. The job teaching-learning process is the same of course. The trainer's approach to and handling of the steps must be ac commodated to the women's frame of refer ence as well as meet their tendency to per sonalize situations in a way which is seldom it ever experienced with men. The points of difference are in no way critical of women. They are perfectly natural and arise out of the different things ex perienced by women as they grow up, the' things that only they can contribute to so ciety, and of course their baric philogenetic and psychological drives. Without these feminine characteristics the human race could not have survived, for the characteristics we are discussing also give rise to that fanatical devotion to and protection of the young. So we heartily agree with the Frenchman who said: `Wive le difference!" Here are some of the female foibles which will be portrayed. Watch for them and note how they color the handling of the job training process. Women tend to personalize everything Women should never be criticized directly Women are never wrong Women like to parade Women like to verbalize 93 y?.m [I l/< 1958 National Safety Congress "B" Women ask questions even when they understand Women's minds may wander--attention is less critical Women do not have a mechanical background Of course, some of the illustrations of these may be a little overdrawn in this demonstration. That is for emphasis and to meet the needs of role playing. The girls and Mr. Kelly will demon strate the job training process in teaching how to operate a drill press. The first time we will do it without special emphasis on safety. On-the-job Training With Safety-- Is It Different? A Demonstration of On-the-job Training Job Taught--Operation of a Drill Press A. Without Special Emphasis on Safety Note: Foreman and both girls do not use safety glasses during part "A." Girls do not wear caps and do not remove jewelry'. Foreman--As I discussed yesterday. I'm going to start you gals on drill presses today. Has other of you ever operated drill presses before? Loo and Phoebe together--No, I haven't. Foreman--Well, OK, then. I'm going to go over the job with you and teach you the things to da Phoebe--I don't know whether I like drill presses or not! I was happy enough on bench assembly. Loo--So was I but the higher price rate on this job won't make me mad! Foreman--Let's not make up our mindc before we've tried the job, Phoebe. I think you will like it Phoebe--Well ... OK, if you say so. Step 1--Preparation Foretnan--Here's the spindle you will be drilling. (Holds up one) It doesn't look like much but it goes in the central part of a guided missile so it really is an important item. What you are going to do is drill a hole in one end of it A hole like this. Phoebe--This is wonderful! Just think-- little ole me working on guided missiles-- that sends me. Loo--By the way. Boss--what is the piece rate on this job, anyway ? Foreman--It's 10 per cent more than it was on your old job. Loo--That's what sends me--that extra 10 per cent Foreman--The first thing to do is to turn on the press. Here's the switch. Then you pick up one of these rods and put it in the fixture. See? You tighten the holding screw so as to hold the piece firmly in the fixture. Then you turn it over and place it fiat on the table of the drill press, like this. Next, you dab a little of this lard oil on the point of the drill with this brush. See? Phoebe--What was that? Foreman--I said, you take this little brush which is in the can here and dab some of the lard oil on the point of the drill. Phoebe--Oh! I see! Foreman--The oil will make the drill cut smoothly and evenly without heating up or binding. Now I place the fixture under the drill, holding it fiat on the table with my left hand, lining the hole up with the drilL Then I bring the drill press handle down smoothly and evenly with a steady pressure. I sort of ease up as the drill breaks through. If I don't, it might catch and the whole fixture would start whirling around. I raise the press handle to the all dear position. Finally, I loosen the screw, take the piece out of the fixture and put it in the tote box with the bole to the right. Now--any questions? Loo--What was that part about easing up? Howf're you gonna drill it if you don't have any pressure on it? Phoebe--Yes, I don't get that either. Just how are you going to drill it if you don't press on it? Foreman--Maybe it I drill a couple of pieces and you put your hand on mine as I do it, you will get the feel of it. Phoebe--This part I like! Loo to Phoebe--(As foreman is putting piece in fixture)--Phoebe, this isn't Elvis Presley, remember! It's the boss. Turn off the glamor. The only oil we need here is the lard oiL (Phoebe gives Loo a dirty took) Foreman--Break it off, girls, break it off! Now, Loo, put your hand on mine as I drill 94 > to turn ten yon it in the ig screwfixture. : fiat on !. Next, he point le brush some of drill cut S up or ider the my left IL Then moothly sort of i. If I fixture tag up? i*t have r. Just u don't iple of ie as I putting ` Elvis tm off : is the ookj it off! I drill Industrial Safety this. Notice how I ease up on the pressure as the drill goes through? Loo--Yeah, I get it! Foreman--Now, Phoebe, you try it See-- notice how I do it? Phoebe--Uh, huh. Foreman--Loo, you try it first If you have any questions. I'll help you if you need it Loo--OK. (Loo hesitates, looks at Phoebe, and makes no move towards starting.) Foreman--All right Loo, let's go. You run through the operation and tell me what you are doing and why you are doing it Loo--What? Step 3--Demonstration By The Learner Foreman--You run through the operation and tell me what you are doing and why youare doing it Loo--Oh--weU, I turn on the machine here, like this. I put the rod in this here thingamabob and turn this dingus until it's down tight Foreman--Yeah 1 That's a fixture and you turn down the screw to hold it tight Loo--Yeah, that's what I said--you turn the dingus down so as to hold it tight Next I put a little lard oil on the point of the drill with this brush. Foreman--Why? Phoebe--So it won't get "all het up," dearie! Loo--Why don't you wait until your turn before you get all het up yourseli! Foreman--Let's have Loo do this and keep vour minds on it huh? Now, Loo, why do you put lard oil on it? Loo--Well, let's see. Oh, yeah--that was so it would cut thematerial easily and the drill wouldn't stick or bind. Foreman--Yeah--and also so it won't "get all het up!" Loo--Now--I put the gadget flat under the drill and hold it with my left hand so it won't move: I bring the handle down steadily and evenly, like this. But I sort of ease up as the drill goes through. Foreman--That's good--but why' do you do it? Loo--Well--limm--Why do I do it? Foreman--So the drill won't grab and the fixture whirl around with the drill. Loo--Oh, yes, I remember, now! Then-- I unscrew it and put the piece in the tote box, like this. Foreman--Yeah--except that the hole should always be to the right. Loo--OK, if that's the way you want it. Foreman -- Were you watching that, Phoebe? Phoebe--Sure . . . watching what? Foreman--Watching the whole operation. Phoebe--Oh--yeah--I've got it. Foreman--That's fine. Loo. I think you are ready to take over but you might as well wait until after I have run through this -with Phoebe. Leader's Remarks--This completes the first demonstration of the four-step teachinglearning process without special emphasis on safety. Step IV was omitted in the interest of saving demonstration time and because it is purely repetitive. In actual job training it must be completed because it is where we make sure that what we taught "comes out of the head" correctly. In the second part of the demonstration in which special emphasis will be on safety, we are going to do only Steps 2 and 3. Steps 1 and 4 would, of course, be the same tor, as previously mentioned safety features in the work operation are introduced in Steps 2 and 3 with the majority of them being brought out in Step 3. This ensures a dear cut presentation of the job sequence in Step 2. Furthermore, when the safety items are brought out in Step 3, demonstration by the learner, retention and recall are strength ened by the learner's actually doing the op eration herself. B. With Special Emphasis On Safety Note: Foreman wears his safety glasses all through Part B. Girls do not put on their safety glasses and caps or remove their jewelry until foreman tells them to do so. Foreman--Phoebe, I'm going to show you and tell you the work operation. Phoebe--OK. I saw Loo do it I think I can do it all right if she can--but go ahead. Foreman--Wait a minute, though! You should both have caps on to keep your hair tucked up and out of the way. It might 95 /9.in m I 1958 National Safety Congress catch on a shaft and you would get injured. Also, we wear safety glasses on this job. Your eyes are mighty important to you and they can't be replaced, either. Phoebe--Oh, I don't think I want to wear a cap or glasses. Loo--Let's not get all shook-up, Phoebe. The other girls who had this job wore caps and safety glasses. We can. Foreman--That's right. Loo. Now one other thing--on this job you will have to take off all jewelry--those rings, wrist watch and bracelets. Phoebe--That does it! I just don't feel dressed without my rings and dangle brace lets. Loo--You should have brought your horse, too, Mrs. Astor! Foreman--Well, girls, the reason you.can't wear' rings;'wrist watches and bracelets is that we don't want you to lose those pretty fingers. I think you'd miss them more than giving up wearing your rings. While we're doing this, just lay them here where we can see them and then take them back later and lock them up. (The foreman hands each girl her cap and safety glasses.) (Girls step to one side and remove jewelry and put on safety caps and glasses.) Loo to Phoebe (aside)--And all this for a lousy 10 per cent Phoebe to Loo--Now who's getting shook up? Step 2--Lecture and Demonstration Foreman--Well, Phoebe; first you turn on the drill press. Here--like this. Then you pick up the piece and put it in the fixture, tightening down the thumb screw to hold it securely. Using a fixture prevents injury to your hands while drilling. Of- course,--it also holds the piece firmly and steadily which would be a little hard to do with your fingers. Then I take the fix ture and locate it under the drill. Now I dab a little of the lard oil on the drill so as... Phoebe--Yes -- that's so the drill won't heat up. Foreman--That's right Also it will make it cut easier and keep it from binding. Then I bring the handle of the drill down with an even pressure and ease up as the drill goes through. If I didn't ease up the drill might catch and the fixture would whirl around and it might hurt you. Phoebe--Uh-huh. Foreman--I raise the press handle to the all-dear position. Then I unscrew the fix ture and finally take the piece out of the fixture and put it in the tote box with the hole to the right Any questions? Phoebe--Oh no 1--I've got it Foreman--Well--now let's have you do it and I'll help yon, if necessary. You tell me what you are doing and why you are doing it Step. 3--Demonstration Phoebe--OK! First you turn on the drill press with this switch. Then you put the piece in the ... in the ... uh ... in this thing. You dab a little oil on the drill point and then you put it... Foreman--Wait a minute. Haven't you forgotten something? Phoebe--Why no--of course not--are you implying I'm a dope? Foreman--Of course not Next you've got to tighten the screw that holds the piece in the fixture: You didn't do that. Phoebe--Of course, I did. I'm no dope! Foreman--(heaving a sigh)--Well--any way--let's tighten it again, huh, and be sure to check and see that it's tight every time. Loo (to herself)--Now I wonder who sneaked in and loosened that screw! (Phoebe gives Loo a dirty look and flings her head) Foreman--Loo, I'm sure you've got this OK Why don't you take your rings and put them in your locker? (Loo picks up jewelry and goes to one side of platform) Now, Phoebe, let's try it again. (Note: In the meantime, the foreman has removed the piece from the fixture.) Phoebe--Well--I pick up the piece and put it in this block. What do you call it--the block that is? Oh, yes, it's a fixture. Then I tighten the screw so that it's in there good and tight OK? Foreman -- That's fine, Phoebe. Why, though? Phoebe--Well--that's because the fixture will hold it firmly, which I probably couldn't do with my fingers, and I might get hurt Foreman -- That's right, Phoebe. That's good- 96 sc >'* the re }uld m. He to the ' the fixit of the with the you do it u tell me are doing . the drill : put the . in this rill point en't 3-ou -are you duVc got piece in dope! ell--anyl be sure ay let )o (Phoebe tr head) got this ngs and ticks up 'atform) nan has ) and put it--the i Then n there Why. fixture couldn't hurt That's Industrial Safety Phoebe--Then I dab a little of this oil on the point of the drill so it won't bind and it will cut easier and--oh. yes--so it won't get all het up! Then I locate the fixture under the drill and bring the handle down evenly until it's about to break through and then I sort of let up on it Foreman--Yes, that's fine, but why do you do that? Phoebe--Well, if the drill caught the whole thing... Foreman--The whole what? Phoebe--. . . the whole fixture would start going around and I might get hurt Foreman--That's right; that's good. Phoebe--Then I unscrew the fixture and put the piece in the tote box. (Phoebe picks up the piece and puts the wrong end up, grabbing the part where the hole was drilled.) Foreman--Yeah, but Phoebe--you put the piece in the tote box with the hole to the left Also, you must be careful not to pick it up where the hole is because there are burrs on it and you might cut your finger. Phoebe -- I'm sure you said to put the pieces in the box with the hole to the left . . . and . . . I didn't grab it tightly. Foreman--\Sr ell -- anyway -- starting now, let's put them with the hole to the right! You know, you could get a badly infected finger from a burr cut, so be sure to pick the piece up on the clear end. (Loo returns to the drill press and stands r. arby.) Foreman--Since you're back. Loo, Now I can emphasize a couple of things to both of you. Loo--OK. Foreman--What's the first thing you do when you get oa the job each day? Phoebe--I start thinking about the coffee break. Loo--The boss means--what you should do, wiseacre. Foreman--Like what. Loo? Loo--Like taking off your jewelry and getting your safety glasses and caps on. Foreman--You're right--Those things are musts. Phoebe--I was just kidding. Foreman--OK--but remember, safety is one thing we can't kid about--it's for real. Are you sure you've got that? Loo--I have. Phoebe--lie, too. Foreman--Fine, girls. (Glances at watch) Guess it's rime for that Coffee break. Leader--That completes die demonstra tions of job training. I'm sure you were able to distinguish the differences in train ing with special emphasis on safety as well as the variations in approach and handling of the process when men and women are trained. The importance of making sure that things "go into the mind" with the needed empha sis on safety insures their "coming out of the mind" in such a way as to get the job done safely. No doubt many of you are thinking-- "Important as it is, on-the-job training with safety is not the only factor in good job performance." You are correct Motivation, that is, the "will to do," is also essential. Here's a simple statement that expresses the relationship in the form of a formula. Ability X l Aptitude and Training Motivation l Will to Do Performance i Job Results Including Safety Ability can be 100 per cent but if motiva tion is only 10 per cent their product when multiplied gives only 10 per cent perform ance. It work the other way also. However, good training with' safety includes stimulat ing and developing the will to do. The key that unlocks the door to safety on the job is complete acceptance of per sonal responsibility for safety. For super vision it means supervision with special emphasis on safety by each and every super visor. And, as we have seen, that calls for on-the-job training with safety stressed. For each and every worker it means accepting and fulfilling their individual safety respon sibility at all times. There is only one way to get safety and that is on the job while the job is being done. You can't get safety after the job is completed any more than you can save money after you have spent it 97 /? /^i 1958 National Safety Congress LABORATORY AND PILOT PLANT SAFETY (A Symposium) TOXIC CHEMICALS By RALPH V. MONTELLO Research Div., National Cash Register Co., Dayton, Ohio As Americans we are reared to believe that human life is most precious, and that human suffering can never really be meas ured in terms of dollars and cents. Today's accident toll reflects the major progress made by those persons who work diligently to cut down the accident rate throughout the United States. Yes, com pared to 50 years ago great strides have been accomplished in the untiring crusade against accidents of all kinds. With all of this progress, where are we today? Let's examine the field of industrial poisoning which concerns toxic chemicals. In one state, alone; for which figures were available, 408 claims of industrial poisoning occurred in a recent year. The direct cost of these claims amounted to $244,228. This breaks down to an average of two com pensable accidents per working day at a cost of $1,200. Far greater must the cost be in terms of personal suffering for which no adequate yardstick can be devised. Thirty-five of these claims were based on systemic effects due to chemical agents. Fifteen of these involved lead and its compounds, and eight were due to other metal compounds. Other toxic substances causing poisoning were: carbon monoxide and benzol, each with two injuries, and paints and paint thinners, a germicide, am monia, volatile petroleum solvents, and vola tile adds, each with one injury. The report further states that the poisoning due to the germicide was one of the most costly of all occupational disease injuries. It had a compensation cost of $3,939 and a time charge of over 2,000 days. Another un classified chemical agent was responsible for an occupational disease with systemic effects in which a total of $5,837 in com pensation indemnity was paid. These figures do not accurately reflect the near micw, but we can be sure that they were quite high. With the expansion of the chemical in dustry, an increase in the rate of acddents due to toxic chemicals can be expected. The report from winch the above statistics were taken shows that in the four years preceding, a definite rise in the trend had been noted. The problem of acddent prevention in the field of toxic chemicals has not been solved. We've got work to do! Surprisingly enough, the formula for safety bears a striking similarity regardless of the branch of safety or the type of industry. Whether we are dealing with toxic chemicals or general laboratory safety, a good safety record depends upon the effective distribution of sound safety prac tices. The similarity of safety practices referred to above include two basic concepts. The first concerns knowledge, knowledge of the hazards involved. A step by step analysis of the whole experiment should provide this knowledge. The second, and equal in im portance, concerns the dissemination of this knowledge to all personnel who require this knowledge to carry out their assigned duties safely. It is not enough to write good safety specifications only to find that no one opens the book of safety specifications to read them. In virtually every chemical industry acci dent reported in the National Safety Council newsletter someone was ignorant of the hazards. More often than not someone pays dearly for this ignorance. It is generally the case that the knowledge regarding the hazard was available, but somehow just never got to the victim. An interesting case history which illus trates the failure to adequately impress people with hazards of toxic chemicals can be told by the following story. This account relates that a trucker was transporting a cyanide salt in a cardboard container. On the same truck bed was a pint bottle of 98 Industrial Safety chromic add which overturned and wet the cardboard box. When the trucker arrived at a confined area, the generation of hydro gen cyanide was enough to overcome the trucker and several people who came to his rescue. Quick action on the part of the medical department saved the lives of these people. This was a near tragedy. If one were to look for the elements lacking in a safety program, the failure to acquaint each man with the specific hazards of his job must certainly qualify as one of the important missing links. Often this failure is not intentional, but results from the delegation of safety responsibility. When this responsibility is passed too far down the line, the strength of the safety program is diluted beyond the effective point This latter remark needs clarification. A non-management person is hardly the one to enforce safety rules or to give safety information to his co-worker. He lacks the authority. No one wants advice, safety or otherwise, that he does not ask for, es pecially from one who has equal or less rank. The safety program can deteriorate to a dangerous level with this kind of safety program. Let us be reminded that an accident is like a coiled spring--it's just waiting to happen. When supervision entrusts the re sponsibility of carrying out a safety pro gram to a departmental representative who otherwise lacks this supervisory control, supervision is inviting failure. Why? The answer is to be found in the words, "lades supervisory control." The use of safety representatives on a departmental levd is believed to be wide spread. Probably the main advantage for such a system is that the safety representa tive receives training in safety work and thereby -becomes safety conscious himself. This type of training is quite effective as long as the representative is active in the program. After the representative is re placed on the safety committee, he is no longer active. His interest in safety will lessen. It is known that the power of retention of safety awareness varies among individ uals. Seldom does it approach the 100 per cent mark. But what happens to the other laboratory personnel who are not on the safety committee? If the service of appoint ment on the safety committee is one year, and it usually takes this long for a new group of people to orient themselves and carry out a safety program, it would take 20 years to train every person in a depart ment of 20 people. This is, of course, too long and therefore unsatisfactory. In those industries whose safety records are outstanding the common denominator is active supervision. The active part played by the supervisor is then the keystone to any good safety program. A statement of policy of the A. O. Smith Corporation bears mentioning for it underlines the active responsibility management is expected to assume. "When a man enters the employ of A. O. Smith, he has a right to expect that he will be provided with a proper place in which to work, proper machines and tools with which to do his job, and that he will be able to devote his energies to Ids work without danger to his life and health. "It is a basic responsibility of all those carrying executive authority to make the safety of human beings a part of their daily, hourly concern. This responsibility must be accepted by each one who conducts the affairs of the A. O. Smith Corporation, no matter in what capacity he may func tion." The job that is expected of our super vision in maintaining an adequate safety program in the chemical industry is not an easy one. First he is dealing with chemi cals that non-technical personnel do not understand. The problem of training this land of personnel is often very delicate. No attempt should be made to scare them out of their wits and yet they must receive sufficient training to prevent a harmful ex posure to other themselves or others in the area. The minimum amount of safety informa tion necessary to get the job done safely is usually better than to list everything known about the process. This latter kind of in formation rests with the group leader or other member of supervision whose respon sibility it is to see that the safety rules are strictly followed. One of management's problems in the safe conduct of individuals who are on a technical level is the person who feels that his knowledge of the chemicals involved is 1958 National Safety Congress sufficient to exempt him from any safety suggestions. Once again, as was stated earlier, knowledge alone is not enough to prevent an accident An excellent film entitled "Knowings Not Enough" from the U. S. Steel Corporation was first available two years ago. This film which was shown to some 3,000 supervisory and non-supervisory employees at The Na tional Cash Register Company emphasized that most accidents occurred as a result of ignoring known safe practices. People get in the habit of taking chances perhaps be cause in the past they have gotten away with it. The symbol of the film was a yellow Sag--this warning meant slow down, there is danger ahead. We would all do well to heed the yellow flag. There are safety rules which point out the danger of using laboratory glassware to prepare food in the laboratory. And yet laboratory personnel who presumably should know better, violate this rule all the time: Another pet peeve of the speaker is the violation of the no smoking rule. Why some people will take chances, even though they are aware of the hazards, and others will not must have a complicated answer. On one thing we can all agree, any accident that can happen will happen. Once our people learn this, they are on the road to accident prevention, not in their daily job but also at home and on the highway. Every person should study a formal course in first aid. Records show that those people who study first aid taught by the American Red Cross have at least 50 per cent fewer accidents. In the chemical industry, data regarding toxic chemicals is available in a variety of publications. These include books, periodi cals, and pamphlets. A Bibliography of Toxic Chemicals has been prepared with the aim of providing interested personnel with as complete a reference list on this subject as possible. The use of this list should go far toward acquainting one with the litera ture available and providing him with the knowledge necessary to work safely with toxic chemicals. You will note that the bibliography con tains a section on books and a section on articles on toxic chemicals. The first Bibli ography of Toxic Chemicals was prepared in 1937 and was distributed at the National Safety Congress in Chicago, October 24, 1957. In an attempt to make the compilation more complete; the list of references was not typed until the week preceding the Na tional Safety Congress. As a result that work did not measure up to good library practice. The book section of the Bibliography of Toxic Chemicals for 1958 has been modified to meet these requirements. Any deviation from this practice was made to permit addi tional information. Some of the references on books now show a brief abstract of the contents. This will overcome a major criti cism of those individuals who were inter ested in specific safety information. Certain of these books bear mentioning as general texts on our subject and can usually be found in most technical libraries. According to J. A. Houghton, tiberty Mutual Insurance Co., the 12 most current books and data sheets on toxic chemicals in industry would include: (1) Industrial Hy giene and Toxicology, two volumes by Patty, (2) Industrial Toxicology by Fairhall, (3) Manufacturing Chemists Associa tion's Chemical Safety Data Skeets, (4) National Safety Council's Industrial Data Sheets, (5) Safety in the Chemical Labora tory, H. Pieters, (6) Chemical Safety Supervision, J. Guelich, (7) Occupational Diseases of the Skin, Schwartz and Tulipan. (8) Noxious Gases, Henderson and Hag gard, (9) Analytical Chemistry of Industrial Poisons, Hasards and Solvents, M. B. Jacobs, (10) Halogcnated Hydrocarbons, Toxicity and Potential Dangers, Von Oettingen, (11) A Manual of Pharmacology, Sollmann, and (12) Dangerous Properties of Industrial Materials by I. Sax. The format of each reference in the book section of the bibliography is as follows: (a) author, , (b) title, (c)-publisherr (d) date of publication or copyright, (e) number of pages, (f) price, and (g) abstract More than 50 publishers were contacted for in formation necessary to complete each reference. Not all of the publishers have replied. It will therefore be necessary for this year's bibliography to go to press with some incomplete entries. It you have a copy of the book for which the reference shows an incomplete entry, please forward to the speaker the information for next year's bibliography. 100 Industrial Safety The section entitled "Articles on Toxic Chemicals" has been revised. A standard procedure based on good library practice has been used in this year's issue of the bibliography. Our thanks go to Mrs. Janet S. Schroeder, head librarian of the technical library at the National Cash Register Com pany in Dayton, Ohio, for a careful revision of this section. In the book section the number of entries has been increased while in the section on articles, the entries have been reduced from 166 to 89. Some of the deleted articles were removed because the information given was obscure or the references were too incomplete to be useful. The section, "Articles on Toxic Chemi cals," could be an important asset to the Bibliography of Toxic Chemicals. But it will take the help of many people. If you would like to see this section grow, please submit the necessary information on the next safety article on toxic chemicals that you read. Use the form as shown in the bibliography, otherwise the article may be too difficult to locate. It may be possible, once this section has grown, to list these articles in groups according to a classifica tion which is based on the toxic chemical or the type of industry. Fed free to write to the speaker and let him know your opinions regarding the treatment of the section on "Articles on Toxic Chemicals." One of the problems which confronts the safety director in the chemical industry is the justification of complaints by em ployees who believe they' are being poisoned by chemicals encountered on the job. The question in the minds of management is whether the individuals who make such complaints have an ulterior motive. In all such cases, it would be extremdv helpful if a rapid analytical procedure which measured the concentration of the toxic material were available. While many good analytical procedures are available in the literature, some procedures require several hours to complete. Furthermore these pro cedures require analytical chemists who must have access to a chemical laboratory. In our larger industries which have well equipped analytical laboratories, this is no serious problem. The speaker would be interested in learn ing about the more recent methods of chemical analysis of toxic materials with the aim of editing a review of these methods and making a distribution to interested personnel similar to the distribution of the Bibliography of Toxic Chemicals. A very real service could be made to non-tecbnical safety directors who do not have a support ing chemical laboratory if a list of rapid and simple instrumental methods of analysis were made available to them. To pass judgment on whether a toxic condition does exist is at times very difficult The maximum allowable concentrations of toxic chemicals usually found in the litera ture should be used as a guide only. These limits are usually derived from studies on small animals such as the rat or mouse, guinea pig, monkey, dog, or rabbit The correlation between man and the test animal is not always known. The susceptibility of individuals will differ with body weight age, and general health. Even traces of materials not usually considered to be in themselves toxic have produced severe symp toms. There is the case of an employee who even though he used a commercial protec tive hand cream broke out in a severe rash about his fingers. This employee who worked near a degreasing operation was found to be allergic to trichlorethylene, a solvent used in the degreasing operation. Interestingly enough, the operator who removed stock from the degreasing bath was not affected. Nor were any of the other individuals af fected who worked in the area of the employee with the rash. Removal of this' person from the contaminated area to an other department showed a remarkable re covery in the condition of his hands. The literature reports individuals who are allergic, of all things, to strawberries. In fact only recently a woman who "worked' in a bank was found to be allergic to paper money. An excellent section on allergic disease in industry can be found in Sax's Dangerous Properties of Industrial Mate rials. There are agencies working on the state and national levels whose primary' aim is to turn the tide of waste of human life. The chemical industry is more alert than ever to the creation of new toxic hazards winch arise from the use of new materials. A survey of the more recent literature indi- 1958 National Safety Congress cates that knowledge is available to make it safe to work with these new materials. Permission has been granted by Interscience Publishers, Inc, to quote the dedica tion which appears in Analytical Chemistry of Industrial Poisons, Hazards and Solvents by M. E. Jacobs which was copyrighted in 1944. "I dedicate this book to those who toil. Within the factory', the shop or mine, To those who work with brain, or hand, or spine, To those who labor where foul vapors boil. To those who sweat their bread out of the soil. To those whom gases in the streets assail, To those whom industry may cause to ail, To all of those whom dust and fumes despoil No worker should his heritage so lose When there are ways most hazards to detect. When we can have our health, if we but choose, Why let a noxious cause have its effect? All those who work, this book will help, I trust. And spare them years ere they return to dust." HIGH PRESSURE EQUIPMENT --DESIGNING FOR SAFETY By DARRELL D. FREDERICK , _ > Chief EIngtin!eer, Autoclave Engineers, Inc, Erie, Pa. Safety with regard to high-pressure equip ment usually means two things--the safety of personnel performing the work and the protection of valuable equipment Naturally, the safety of personnel is by far the most important, and all precautions possible should be taken to produce equipment which will operate safely at its rated conditions. Safe practices involving the design and operation of pressure equipment usually are applied in varying amounts depending on conditions. For example, in considering the amount of work done in this country today utilizing pressure equipment, we find it varied in nature, ranging from small bench scale studies in the research laboratory to actual full scale plant operation. These studies in the laboratories are, for the most part, fundamental research in which development and search takes place for new products which can be made utilizing high pressure. There is a great deal of pilot plant work beingjdone in the use of high pressure as a tool in proving different processes. There is a definite trend today to use high pressure reactors for hydrostatic forming of molded parts previously formed in huge hy draulic presses. The use of reactors results in more uniformity of pieces, and economy and savings in time. Another important factor, increasing the need for pressure equipment, is the ex haustion of some of our natural resources. It has been determined that quartz can be grown synthetically under high pressure and temperature, producing crystals with grain structures more suitable than those found in natural quartz. Diamonds have been pro duced utilizing extreme pressure and temper ature These are a few examples indicating the uses of high pressure today. Certainly the usefulness will be expanded greatly based on the work done in fundamental highpressure research. Assume you have several experiments in volving the use of a high-pressure reactor. You should have some knowledge as to the type of reaction expected in the reactor. If the reaction is to be exothermic, proper pro tection should be obtained. This sometimes can be done by including a full-area blow out disc in the reactor. If you are running an experiment in which the final results are completely unknown, full protection against any type of accident must be sought If this cannot be accomplished in the design alone, then suitable barricading must take place. However, there are types of high-pressure work where the reaction taking place is well known, and safe prac tices in the design and operation of the equipment are well defined. Perhaps, one of the most serious effects due to the failure of a vessel or leakage of 102 we but jrn to Industrial Safety a connection is the resulting fire or explosion caused by the escape of the contents of the equipment. Every precaution must be taken to ensure against any accumulation of dangerous explosive gases. The field is broad, reaching from small bench scale work to actual plant operation, and there are many variables and consider ations one must weigh prior to designing a piece of equipment to be used in highpressure research or production. To become acquainted with practices used in safe design, it might be informative to outline briefly the typical considerations in the design of a reactor. Before beginning the design; a person must know the operating conditions, such as pressure and temperature, the type ot reaction expected, and what ma terials are best suited for the particular re actor involved, as far as their corrosion re sistance is concerned. Once these conditions are firmed up, the first step usually is the selection of the closure. If the reactor is to be operated at room temperature, we usually select a pliable sealing material. If the reactor is to operate at higher temperatures, a metal or heatresistant type seal must be used. The type of seal selected depends to some extent on the inside diameter of the, reactor. Incidentally, the smaller you keep the in side diameter, the easier it is to provide a workable closure because of the reduced end load. If possible, it is helpful to know the number of openings and closings expected during the life of the vessel. This also would have some effect on the type of seal applied. Any cycling effects of the temperature and pressure should be known, so an investigation of the fatigue of the materials can be made, if warranted. In one type of closure commonly used, we utilize a bolted closure for pressure ranges up to 5,000 psi. and temperature ranges up to 650F. This closure may apply to vessels up to 5 in. in diameter. As far as the gasket material is concerned, many different types may be used depending on the temperature at which the vessel is to operate. Another type, the set screw closure, is capable of sealing pressures up to 5,000 psi. and temperatures up to 1000F. It can be utilized on vessels as large as 15 in. inside diameter. Vessels of 15 in. in diameter have been designed for operating conditions of 3200 psi. and 850F, and vessels of 5 in. in diameter have been designed for operating conditions of 5000 psL and 1000F. The gasket used in this particular closure is a Flexitallic gasket made of a series of stainless steel spiral windings asbestos-filled. Various closures can be applied for more extreme conditions. The self-sealing metal gasket type closure has been used success fully for pressures up to 15,000 psi. and temperatures up to 1000F. This type of closure can be applied to reactors up to 3 in. in diameter. This closure is probably the most versatile closure for high-pressure and high-tempera ture combinations. Pressures up to and in cluding 100,000 psL have been sealed suc cessfully utilizing this closure. Through the selection of the correct materials,-this closure has operated in the range of 1450F. Also, the closure has been used on diameters up to and including 12 in. Then there is the closure utilizing a pliable gasket, and another closure using an "O" Ring. The "O" Ring closure is perhaps one of the most straightforward and simple de signs available. It has successfully held pres sures in the 100,000 psi. range. Since the gasket is not heat resistant, the temperature range must be below 200F. This type of closure also has been used on vessels up to 8 in. in diameter. The Full Bridgman type closure has been used successfully in pressure ranges of more than 150,000 psi. and depending on the type of packing, temperature ranges of 1000 de grees have been reached. This type of closure also may* be used on large vessels up to 15 in. in diameter. After the closure has been selected, the next step is to calculate the wall thickness based on the operating conditions of the re actor. In calculating the wall thickness of a vessel, we use, almost exclusively, the Lame formula. In the calculation of a wall thickness, the ASME Code and the Lame formula can only be used as long as stresses involved in the unit are below the elastic limit of the material. A good many of our units are de signed in accordance with the ASME Code regulations, but when we are faced with ex treme temperature and pressure conditions, the Code does *.ot apply. 103 /?.r ijz/'m k iSi 1958 National Safety Congress When designing for extreme conditions, we fit between the inner and outer shells, we usually have to choose what we term a have reduced this stress on the inner surface super-alloy for the material of the unit The to 75,000 psi. Code does not list the allowable stresses we can use with these super-alloys, and we have to choose allowable stresses based on engi neering data furnished by the makers of the material. Another example of composite design is the liquid head of a 60,000 psi. pump. As in the case of the vessel previously explained, if a pressure of 60,000 psi. were applied to the packing section oi this pump, the tangen We use 80 per cent of the stress value tial stress on the inner fibres of the wall of which will cause the material to creep 1 per the cylinder would be 75,000 psi. By utilizing cent in 10,000 hours. We have used higher the composite design, we have reduced these stress values than this for extreme con stresses to a value of 45,600 psi. ditions. There have been reactors designed based on only 500 hours of life. The ASME Code will allow you to design vessels for pressures up to and including 3000 psL and for temperatures up to 1500F. We do not consider a stress of 75,000 pa. to be extreme. In this case, we are faced with a problem of fatigue caused by the pulsating pressure encountered during the ac tion of the pump plunger, and we feel that As in the case of the closures previously by reducing the stresses as much as possible, explained, these conditions cannot be used the liquid head will have a much longer life. simultaneously, since the allowable stresses given in the Code for temperatures up to 1500F are exceeded when the 3000 psL pres sure rating is applied. The other tool used in the manufacture of high-pressure reactors is Auto-frettage. This may be defined as the process of automati cally setting up the effects of shrinking a In many cases when we design for con- number of infinitely thin hoops on one an ditions beyond the ASME Code and are other to make up the wall thickness of a asked by our customer to have the vessel stamped, we can always do so by applying to the proper state agency and obtaining the permission to construct the vessel in ac cylinder in such a manner that the inner layers are in states of residual compression and the outer layers in states of residual tension. cordance with the designs and calculations These effects are produced in a monobloc presented. cylinder by the application and release of an There are two other design tools that can be utilized when designing for extreme con ditions insofar as the wall thickness is con internal pressure on the bore, which during its application sets up yielding in some or all of the layers in the wslL cerned. One tool is the use of a composite After Auto-frettage the inner fibres of the design in which several cylinders (usually no cylinders are left in a state of compression. more than three) are shrank together. Since the greatest tensile stress caused by Composite design will allow you to design for pressures as high as 500,000 psL, pro viding the proper selection of materials is made. This is an extreme condition and is not utilized on a commercial scale. Vessels internal pressure is produced on the inner layers of the cylinder, a higher internal pressure can be attained in a vessel which has been Auto-frettaged before reaching stresses in_the dangerous range. large in diameter and to operate at high Now that the vessel wall thickness has pressures can be designed with a larger safe been determined and the required type of ty factor and in some cases more economi closure chosen, it is necessary to provide cally using, the composite design rather than tubing connections in the vessel. These con the monobloc construction. nections are machined in the covers and are By composite design, for example, con of various sizes depending on the size of sider a vessel designed for 100,000 psL and tubing to be used. with a 3 in. inside diameter. If this vessel Probably the most commonly known con had been made of a single cylinder and a nection used in high pressure work today, pressure of 100,000 psL was applied, a the cone and threaded joint, has been in tangential stress of 122,200 psi. would result sendee for many years. This joint should be on the inner surface of the cylinder. By considered as a precision piece of equipment using the composite design utilizing a shrink and treated as such. The most common error 104 Industrial Safety made by most operators when using this joint is the application of too much torque on the gland nut. Compare a properly made joint in which the seal is accomplished by line contact with a joint improperly made as the result of ex cessive torque: 1116 seal for the latter joint must be made over the entire surface area of the cone, because the tubing has been forced into the cone seat by the application of too much torque. If a joint of this type is found to be leak ing, it is important to know that it should never be tightened while pressure is in the system. If the joint leaks, it usually means that it was improperly made up and any further torquing or application of force in any way may cause the joint to fail. This joint has been successfully used commercially up to and including 100,000 psL Again, in a tubing joint used for lower pressures, compare a proper joint with an improper joint torqued to the point where deformation of the tubing has taken place. The rules for malting this joint are the same as the joint shown previously. It is of the utmost importance that you avoid the error of applying too much torque to a joint of this ltind. A cold-wall vessel illustrates the incorpo ration of additional safety into a vessel. This design is applied where it is necessary to provide a vessel which will operate with an extremely high internal temperature. This temperature is usually generated by the use of an internal furnace. To keep the wall cold so it can retain its strength, we have incorporated a liner con taining grooves on its outside diameter through which a cooling fluid may be cir culated. This arrangement has been found to be effective on vessels in which internal temperatures of 2000F and greater are generated. The problem of storing hydrogen at high pressures and temperatures is troublesome. because hydrogen atoms and molecules pene trate the steel and cause it to become brittle. If vessels for this service are not properly designed, hydrogen embrittlement can cause brittle fracture of a vessel in very short periods, sometimes in several hours. In a high pressure hydrogen storage ves sel, an internal liner can be utilized with a phonographic finish turned on its outside diameter. The liner is shrunk into the vessel. There are vents through the main pressure wall of the vessel which allows the H2 that has penetrated through the liner to escape to the atmosphere, eliminating embrittlement of the main pressure containing shelL Before a design can commence, one must consider all of the variables or all of the conditions expected, such as environment of the tests, the operating conditions, reactions expected, and personnel One can never be 100 per cent safe," be cause we always have the human element with which to deal. Equipment is only as safe as the operators that use it Pressure equipment ranging from only a few pounds per square inch to several million pounds per square inch is in use in this country today. It is only through proper design, barricading and proper training of personnel that actual plant operations are being safely conducted in pressures ranging as high as 50,000 psL Little can be said about safety factors, as such, that we would use in the design of a vessel because of all the conditions men tioned previously. The greatest safety factor possible commensurate with good design is strived for and maintained. For most com mercial applications of pressure equipment, a safety factor of at least 2:1 on the wall thickness can be used, and in the majority of cases 3:1 or better can be obtained. The higher the pressure, the lower the safety factor. There arecases where extreme conditions are present, and design and"calcu lations can carry' you only so far; from there on, the equipment is just built and tested. 105 1958 National Safety Congress LABORATORY VENTILATION By JAMES C. BARRETT Occupational Health Division, Michigan State Department of Health, Lansing, Mich. Today there is an increasing need for adequate ventilation in the laboratory. All around us are evidences of increased basic research, new methods of quality control, and the emphasis on science in our schools and universities. In our laboratories, chemists are work ing with materials of various degrees of hazards and toxicity, and with our growing family of radioactive isotopes. Especially in the laboratory, the safety engineer must have a working knowledge and appreciation of fundamentals of ven tilation and the things that ventilation can do to protect and safeguard the worker. Much has been written about the hazardous properties of almost all of the materials handled routinely in laboratory work. Our concern is with the available tools to provide a healthy and safe labo ratory, so it is most important to examine the fundamentals of ventilation and what it can do for us. Hood Design. Good laboratory ventila tion will confine the toxic contaminant and will exhaust it to the out-of-doors through suitable ductwork and fan, passing the material through a collector or scrubber as needed before release to the neighborhood. Consider a baric laboratory hood reduced to the bare fundamentals--a simple box. After confinement of the material in the box it may escape in any of three ways. First, agitation from chemical or mechan ical action may disperse the contaminant through the open doorway of the hood. Second, there may be thermal action from the chemical reaction or from the use of heating equipment to aid the reaction. Third, crosscurrents of air may be sufficient syphon the air and contaminant out of the hood. To overcome this tendency to escape, it is necessary to exhaust enough air to create an indraft through the face of the hood. Ventilation control cannot be achieved without adequate air flow. Capture velocity has been a controversial subject in recent years, but it is not as con fusing as it may seem. Since we must confine the material within the hood, there are to be a certain minimum velocity through the door. Certain velocities are recommended for laboratory bench-type hoods by the American Conference or Gov ernmental Industrial Hygienists. For chemical and moderate toxicity mate rial the average face velocity should be a minimum of 100 feet per minute (fpm) through the open door area with an 80 fpm minimum at any point For high toxicity and radioactive material this should be raised to an average of 125 to 200 fpm with an absolute minimum oi 100 fpm. Recently I had the opportunity to see a movie prepared by the staff engineers at the Ethyl Corporation Research Labora tories in Detroit for their own use in in vestigating the behavior and control of various laboratory hoods. Using standard equipment arrangements and a standardized series of movements by the chemist, they were able to obtain comparative results on several types of hoods exhausting at differ ent face velocities. By using chemical smoke (titanium tetrachloride) they could show visually the air flow patterns created. From these observations, as well as those we have made in industry and in labora tories, there is no question that a minimum of 100 fpm face velocity is needed. At lower velocities the material and air in the hood will follow the chemist, as he moves about in front of the hood or leaves the hood to perform some other function in the laboratory.__ These conclusions were also substantiated by a group of engineers at the Los Alamos Scientific Laboratory perforrping work for the Atomic Energy Commission. They print out that velocities less than 100 fpm do not provide adequate control. Some authorities claim certain labora tories (such as in schools and universities) do not use high-toxicity materials regularly and that the individual exposure may not be for a full working day. We have no guarantee that a material used in a hood on any given day or for a particular project 106 Mich. e must 1, there velocity ies are ich-type 3t Gov- y mateid be a (fpm) 80 fpm toxicity raid be 00 fpm 0 fpm. iritiated Alamos >rfc for y point do not laborarsities) gularly iay not ave no a hood project Industrial Safety may not be succeeded by a material of high hazard, whether flammable or toxic. We know also that with many materials the problem is not only one of chronic ex posure over long periods, but that serious illnesses or death can occur from even one short exposure. With such materials as the oxides of nitrogen, a single exposure may often be sufficient to kill or seriously impair the health of the individual. We cannot afford to have accidents. We cannot settle for anything less than adequate ventilation control, and adequate face velocities must be used. There are times when it may be practical to use lower velocities at the hood. Many chemical reactions progress over long peri ods, with the greatest danger coming when equipment is set up and before it is com pletely sealed. After setup by the chemist the apparatus may be left without direct supervision. Under these conditions, with a favorable location of the hood in the room, it is possible to reduce face velocities, since there are no operating personnel to disturb conditions at the face of the hood. Many companies have found that twospeed fan control is entirely satisfactory in these cases. For the low-volume operations, face velocities of 75 to 80 fpm have been used successfully. When the exhaust vol ume is reduced, the usual case is to find that the doors of the hood have been partially or completely closed as an addi tional safeguard. It must be emphasized that this can be accomplished only under ideal conditions with a minimum of disturbance at the face of the hood and with a minimum of agita tion or chemical reaction inside the hood. Either of these conditions will require the use of higher velocity to maintain ventila tion control. Another common type of laboratory hood used for work with radio-isotopes, tuber culosis germs and in many standard chem ical laboratories is the glove box hood. Here, the chemist is entirely outside of the hood, and his only contact with the interior is through the glove ports. This hood has actually been called a laboratory in itself, since it is usually equipped with water, gas, vacuum, lights and any other facilities needed. In some instances the hood is maintained with an atmosphere of inert gases for special pur poses. When using radioisotopes or neutral atmospheres in the hood, it is necessary to provide airlocks, so apparatus or materials may enter and leave the hood without ex posing the hood contents to the room. The exhaust volumes for this hood are based on maintaining a 50 fpm in velocity draft at any opening; usually this means an exhaust of 20 to 30 cfm of air for each glove box In many designs, filters are used in the exterior of the box in portions of the airlock doors to provide for dean entering air. If such filters are used, they should be located at the back or sides of the glove box so as not to expose the chemist's body in a puff-back or explosion of any materials in the hood. For radioactive materials where' it is im portant to keep the ductwork dean,'pre filters can be mounted at the duct inlet with provision for a deanup of absolute filter in the exhaust branch. In other designs the pre-filter is incorporated in the same endosnre with the absolute filter, so when these become loaded too heavily, they may be discarded as a unit, requiring less handling of the contaminated filter material. Hood Location. The location of the exhaust hood in the room is most im portant In one example; typical of many poor hood locations, there may be no means of supplying air to the laboratory except through the open doorway, and the hood is in the direct path of the incoming air stream. Cross draft vdotities will be in the range of 40 to 50 fpm across the hood face. We cannot expect the air will turn directly and into the hood, as so many trained arrows like to indicate. A second example illustrates a more favorahle hood location for the same room. In this case the distance between thehood and the doorway is such that the supply air will lose vdodty before coming within the influence of the hood. If this room were shorter, it would then be possible to get a condition where the entering air would come into the hood and still have sufficient momentum to rebound and cause turbulence inside the hood and at the hood face. A very simple hood can do a satisfactory job; but in a poor location--such as near to tiie doorway exhaust velocities must be 107 1958 National Safety Congress higher than the average to overcome cross drafts. In a simple hood constructed largely of glass and stainless steel, the hood located well away from die doorway through winch the air most enter can perform satisfactori ly at average face velocities. Exhaust Ductwork. Good laboratory ventilation provides that the ductwork inride the building will be under negative pres sure; thus, any leakage due to poor con struction or general depreciation of the ductwork will be into the ducts, confining the contaminant This is a relatively simple point and yet we find many poor installa tions. The most convenient location for the fan on top of the hood is generally the wrong one. While a fan on the roof or on the building wall requires weather proofing for the motor, it is still the pre ferred location. Another advantage is that in use of flammable materials there is a distinct advantage in mounting die fan out side the laboratory', since explosion-proof construction is not required for the motor, and the cost is much less. Also, in cases of motor failure, replacements can be ob tained rapidly and economically. The same principal holds true for large involved systems of ductwork with more than one hood connected to the exhaust system. All ductwork inside the building should be under negative pressure to pre vent leakage of materials. In these systems duct connections should be streamlined, with branch ducts entering at angles of 30 to 45 degrees, instead of the straight-T con nections we see so often. In handling the ventilation air at high velocities, streamlined connections are im portant, just as streamlined smooth-flow highways are required to handle high vol umes of modern-day traffic Ductwork must be sized to maintain minimum trans port velocities, whenever particulate matter is bring1 carried. Otherwise, settling of material will occur in sections where the duct is too large. The usual range of transport velocities is 3,500 to 4,500 fpm. In hoods intended to remove only fumes, gases, or vapors, the duct velocity may be reduced to any prac tical figure; the usual choice is about 2,000 fpm, since it offers a good compromise be tween horsepower servings and the space required by large ductwork. In recent years there has been rapid development in the field of corrosion pro tection for ventilation systems. It is im possible to do more than mention the variety of plastics, plastisol coatings, inorganic mate rials, as well as special metal alloys which may be used for this purpose. We see applications ranging from transite pipe of stainless steel alloys, metals coated with polyvinyl chloride and recently appli cations of fibrous glass-reinforced plastic ductwork. Each of these materials has its own special application, but there usually is considerable overlapping, allowing selec tion on the basis of everyday economics. The fan for the system should always be located outride the building. An often-over looked point is that the fan should be in stalled properly' to achieve its rated per formance. One typical fan connection uses an elbow directly at the fan inlet; usually the only excuse for' this is that it is con venient, since this elbow will reduce fan performance. All fans rated in accordance with the standards of the Air Moving and Conditioning Association are tested with straight runs of ductwork and the inlet and the outlet These are necessary to obtain expected performance of the fan. Usually laboratory fume hoods are not provided with collectors or scrubbers to remove the contaminant from the air be fore it is released to the atmosphere. There fore, the fan discharge must be located properly. Preferably the discharge should be a minimum of 5 to 10 ft above the laboratory roof. This cannot be applied as a rule, since the proximity of other buildings or the existence of peculiar wind currents will affect the ultimate paths of the exhausted air. Generally, the exhaust should not be so located that fumes are redirected to the laboratory' roof or in such a position that prevailing winds may carry fumes into the building at another point. Illustrating a poor fan installation, a straight T is sometimes used as weather protection. The exhaust is directed back down to the roof and may be carried over the roof and into the laboratory windows on the lee ride of the building. Also, in terms of fan efficiency, this is a very poor discharge arrangement 108 ep1 Jid don prot is imie variety nic mateys which > transite Is coated ly applii plastic s has its : usually Jg seleclomics. Iways be ten-overd be in* ted' per son uses : usually : is conluce fan cordance ring and cd with nlet and d obtain are not )bei--sto tlhct located : should ve the te, since or the nts will chausted not be d to the ion that into the idon, a weather :d back ied over rindows Mso, in ry poor Industrial Safely In a typical inverted cone type of weather cap, obsolete for years, the cap not only im poses additional resistance on the system, but also reverses the flow of the exhausted fumes and places them back on the roof. If high temperature or corrosive materials are in the air stream, you can imagine what happens. Also, since tins location is near the parapet the fumes may be trapped on the roof and may re-enter the building at any convenient point The most practical fan discharge is the straight vertical stack with no directional baffles or projections. A fume released ver tically will travel upwards considerable dis tances before being subjected to atmospheric conditions. A common type of stack head offering weather protection is the so-called butterfly type of damper. The variety of corrosive and toxic mate rials handled in the laboratory hood, plus the varying demands of air cleanliness, are such that use of collection equipment is a highly specialized problem, and each par ticular case must be handled separately. Generalization is dangerous at any time and especially here, since we have often seen the results of faulty collector application; usually the insides of the collector disappear in a very short time! However, proper en gineering attention must be given to the over-all problem of eliminating toxic and nuisance fumes from the atmosphere in which we live. Air Supply. We have discussed the fundamentals of removing the contaminant by exhausting air through the exhaust hood, glove box or other enclosure. To accom plish this, we are dependent upon an ade quate supply of clean ventilation air. "Make-up air," or in the broader sense air supply ventilation, is necessary in the labo ratory. Properly engineered, supply air ven tilation will not only supply sufficient make-up air to the exhaust system, but will also provide good ventilation for the labo ratory, offices, and often to the entire building. The supply of air in any room or building is not infinite. Since the air from the laboratory is exhausted outdoors, the supply of air must come from outside, whether directly to the laboratory' or indirectly through the offices and adjacent areas. In exhausting, a fan creates a pressure below atmospheric, a so-called negative pressure, causing air to flow into the hood and ductwork. Replacement air is attracted to the negative pressure area at the inlet to the exhaust system, which in the typical small laboratory is the room itself. Without provision for air supply there will be an inward leakage of air through the outside windows, doors, and in extreme cases through any other exhaust equipment in the room. Experience has shown that where there are two fans exhausting from the same space with no provision for make up air, the stronger fan will overcome the weaker, and air will actually enter the room against the weaker fan. In multiple exhaust hoods, when one hood is turned off, the results can be dis astrous, since outside air will immediately downdraft through the fan not in operation. When a farPmust exfiauSTout'of the room without air supply, the capacity of the fan will be reduced from the original design volume, and there may be less control at the hood. The only satisfactory ventitation system is one providing for exhaust of contaminated air and the replacement of the air with con trolled air supply. This may be done on an individual laboratory basis, or an air supplysystem can be designed to satisfy the gen eral ventilation requirements of the entire building, as well as the laboratory. In an air supply arrangement, such as that in a central air supply system, the main supplyduct is carried in unused space above the corridor ceiling, and the air supply is split. A portion of the air goes directly to the laboratory, where it is under the control of the exhaust fan at the hood. This air volume is less than the exhaust air requirements of the laboratory; the bal ance of. the exhausted air enters the labo ratory from the corridor through suitable grill work. The corridor obtains it's air supply from the adjacent offices, which receive a portion from the main supplysystem and are provided with returns to allow this air to pass through the corridor. In practice the offices are under a slight positive pressure; the corridor is under less pressure; and the laboratory is under a slight negative pressure with respect to the corridor and offices. In the event of exhaust fan failure or a reduction in volume due 1958 National Safety Congress to belt wear, fan corrosion, or the like, a sensitive control in connection with a metering orifice in the exhaust system will dose the direct air supply to the laboratory. The only air which the laboratory can obtain must come from the corridor, min imizing any possibility of leakage to other areas of the building. There is a considerable cost involved in supplying heated or cooled outside air to the building; air supply ventilation is not a luxury but a necessity. When air supply is used, it is often possible to eliminate auxiliary fans and roof ventilators to re move the nuisance or odor-producing mate rials which may be in use in other parts of the laboratory. For general ventilation of this type, one ctm of supply air more than offsets a cfm of additional exhaust air, since it provides a supply of fresh uncontaminated air~to the laboratory and eliminates a critical neg ative pressure situation that may be devel oping. Air Conservation. In recent years there have been a number of radical designs proposed for laboratory* hoods; these in dude so-called "low-velocity air-foil** hoods and "air supply hoods." These, it is claimed, will reduce the amount of air necessary for ventilation and will reduce the heating and air-conditioning load. In practice these designs do reduce the heating and ven tilating load, because they operate at lower exhaust volumes; but unfortunately the consensus is they are not effective in provid ing control. Basically, the air-foil hood design is good, since we know that with a more streamlined hood entry the better the flow characteristics will be. Flow characteristics at the face of the hood are not the only criterion for establishing face velocity. Face velocity must overcome both the tendency* for the material to leave the hood under its own power and the crossdrafts at the face of the hood. Experience shows a minimum of 100 fpm average velocity is required to give adequate face control. The use of air foils will be beneficial, but they* cannot be used to reduce the face vdotity. In so-called air supply hoods, the one design which has attracted a great deal of attention involves the use of air supply slots or grills at the face of the hood to blow a curtain of air across the opening; in most cases this air is taken directly from outdoors. We know from experience that any air jet supplied under pressure creates a con siderable amount of turbulence and tends to entrain adjoining air into the stream--a basic operating principle of air ejectors. We cannot see that this stream of supply air will always enter the hood without spreading contamination at the face of the hood and throughout the laboratory, since some of the entrained air must certainly come from the hood. We have yet to see an air supply hood that has been working properly. Once, where a hood of this design was installed in a small room to be used for radio isotopes, we were called in because o.f the chemist's fears that the hood was not functioning properly. This hood had been designed for the simultaneous supply and exhaust of air, the net exhaust volume bring equivalent to 50 fpm face velocity*. The hood also was provided with two-speed control of the exhaust fan; however, there was no way of preventing the air supply from bring used while the exhaust fan was on lowspeed! In addition, there was a large upright room air conditioner about 5 ft.- from the hood, creating excessive cross drafts. And the exhaust fan was running backwards and handling only 20 per cent of the correct volume of air! These problems were cor rected, but this hood is no longer in use. A second instance occurred in the chem ical laboratory* of a large manufacturing plant. Here there are three large bench hoods about 10 feet long, plus a 10 ft., walk-in ty-pe hood. These hoods also were designed to supply air through slotted ducts at the face; however, we were informed this supply air had never been used since the hoods were installed. We found that exhaust volumes were very low, and examination disclosed the various adds (nitric, hydrofluoric; and sul furic) had almost completely destroyed the exhaust fans. The company is nowpurchasing new fans to give adequate con trol velocities, and the firm is also proriding separate air supply to the laboratorythrough a perforated ceiling to avoid cross 110 enr \ in tl) j>m any air s a connd tends trearn--a ejectors, f supply without e of the y, since certainly Jy hood Once, installed ' radio: Of the 'as not *or the air, the t to 50 :o was of the *o way being :n low ipright correct e corn use. chemtnring bench 10 ft., were ducts armed since were i the 1 sulroyed now coniding atory cross Industrial Safety drafts and disturbances at the face of the mazoo, Mich. This firm, has used local hoods. exhaust ventilation to provide spot control There are three principal objections we with a small volume of air. have found to the tise of the hood with A small hood, moving on nylon rollers, the built-in air supply: exhausts 270 cfm, which is sufficient to con 1. There will be excessive turbulence at trol benzene vapors released. The nylon the face of the hood due to basic problems rollers and a bonding wire used in the of the design or to normal obstructions at non-metallie flexible ductwork are included the hood face. as fire safety protection. With this type 2. Over the course of the hood's life it of ventilation, engineers avoided the instal is to be expected that the various corrosive lation of a large bench type of hood which materials used in the hood will have a would have required many times more ex serious effect on the exhaust fan. Unless haust. this fan is given careful maintenance, it Li another application a form of local will lose efficiency and exhaust lower vol or spot exhaust ventilation is again used. umes of air. Many apparatus can be set up safely in the At the same time, the supply fan is laboratory room requiring exhaust at only handling relatively dean air and will pro one or two points. This can be done suc vide almost a constant volume. The result cessfully with short drops of flexible duct, is a steady decrease in face vdodty. with provision for petitioning these to give 3. Under many conditions of winter use, the necessary ventilation control. the cold supply air will cause condensation Additional technique provides the stand in the hood resulting in serious problems. ard bench hood with a horizontal sliding It is always possible to turn the supply air sash instead of a vertical sliding one. In off in the winter time, but this defeats the this way the hood can be large enough to purpose of the entire installation. give sufficient working space; yet the open We believe it is foolish economy to purchase hoods with two fans, two sets of ductwork and two sets of controls, with the thought of saving money in heating or cooling air. It would appear that the over-all increase in capital investment and area at the face of the hood is reduced in half. With this type of arrangement the chemist can have the luxury of large hoods with the safety advantages they possess and can still reduce the air volume to the mmimWTv maintenance will go a long way toward off The use of the glove box should increase setting any savings in heating or condition in the laboratory. It has the advantage of ing the necessary make-up air. bring small, occupying little space. It can In future laboratory ventilation, we ex be built to offer suitable protection for ex pect to find our laboratories will be han plosive gases and can be airtight to permit dling more materials of very high toxicity the use of special atmospheres. It is well or of suspected high toxitity, as funda suited for work with radioisotopes and mental research programs continue to ex bacteria. pand. We may also find that increasing The small size of the glove box makes numbers of radioisotopes are used in all it possible to move the entire box to a of our laboratories. central decontamination station; this is es As we handle more dangerous materials, pecially important when radioisotopes are we will be called on to provide additional bring used, since it isolates any possible ventilation in the laboratory, and the prob contamination. In one decontamination sta lems of air conservation will become quite tion we saw, large enclosing hoods were critical. I do not believe refinements of used. The individual glove box was placed existing designs (such as air foil hoods, in the decontamination hoods, and all op or air supply hoods) will assist us greatly erations were carried on through glove in meeting the problem. It is our responsi ports in the outer hood. bility to examine our techniques of ven We have also observed the use of a hood tilation and laboratory design. similar to a glove box in industry on an I have visited laboratory facilities with ordinary production arc-welding job in the engineers at the Upjohn Company in Kala manufacture of fractional horsepower 1958 National Safety Congress motors. With this installation the normal tire fans will not be operating under nega glass front was replaced with tinted weld tive pressure and to insure there will be ing safety glass, and instead of glove ports sufficient general ventilation to reduce con the hood had a slot at the bottom through centrations of nuisance materials. which the operator's arms could project The laboratory ventilation should be de The principle was the same, and good con signed to maintain slight inward leakage to trol was afforded with a minimum amount the room at all times to prevent the con of exhaust air. tamination of other laboratories or other We expect similar designs can give ade rooms in the building. quate ventilation and personal protection for We need to look for methods of con small, noisy operations. Obviously the use serving exhaust air. Effective ventilation of the glove box will reduce the necessary considers not only the problem in the in volumes of exhaust air required. dividual laboratory but the air balance of Successful ventilation of any process de the entire building. I do not believe sig pends on close cooperation of all persons nificant air conservation can be obtained involved, induding the chemist the safety through refinement of our existing designs. engineer and the design engineer. In im Proper air conservation can be obtained proving our techniques of ventilation we only by a re-evaluation of techniques. This should be able to make rapid progress in involves the dose cooperation of the ven the laboratory, since we are dealing with^ tilation engineer; the safety engineer and highly trained professional people who haive the chemist who will be working with shown themselves able and walling to absorb future ventilation. new teduiiques. To quote Mr. George Jepson, "The ad Local or spot ventilation will not work, ditional cost of 'adequate and safe' design if it does not recognize the nature of the over `barely sufficient' design is the cheap contaminant and the way it is dispersed, est insurance you can buy. There can be and if it is not used by the chemist. Similar only one practical limit to hood design and ly, the glove box technique will not be that is 'adequate and safe'." effective unless the chemist is willing to ACKNOWLEDGEMENTS accept minor inconveniences in his work to obtain the benefits of the additional safe ty that can be provided. If he wants to work in an air-conditioned laboratory, he must be willing to accept responsibility in 1. `Industrial Ventilation--A Manual of Recommended Practice*, Committe on In dustrial Ventilation, American Conference of Governmental Industrial Hygienists. helping to plan and use the ventilation pro 2. 'Design of Laboratories for Safe Use dded for him. of RadioisotopeAECU-2226, Donald R. Good ventilation is the result of careful Ward, Isotopes Division, U. S. Atomic planning and design. The hood must be Energy Commission. selected for practical use; the exhaust vol 3. 'Evaluation of Laboratory Fume ume of air must be determined on the baas Hoods', H. F. Schulte, E. C. Hyatt, H. S. of the hood's frontal opening and the con Jordan, R. N. Mitchell, Industrial Hygiene ditions under which the hood is used. Group, Los Alamos Sdentific Laboratory, For the ordinary chemical hood, the face' velocity shoult he an average of 100 fpm, with a minimum of 80 fpm. For highly toxic material and for radioactive material, Los Alamos, N. M. 4. 'Ventilation and Fume Hoods--Sur vey of InformationG. L. Jepson, Ventila tion Engineer, Upjohn Company, Kalama the velocities should be from 125 to 200 zoo, Mich., presented to National Safety fpm, with an absolute minimum of 100 fpm. Congress, October 24, 1957. The ductwork, fan, collector and dis charge stack must be designed to transport the material effectively and efficiently to the 5. Dr. A. Somerville, Director Isotope Laboratory, General Motors Corporation, Research Center, Detroit, Mich. out-of-doors, leaving no possibilties for re- 6. Mr. F. T. Schroeter, Safety Engineer, exposure to contaminated material. Proper Ethyl Corporation, Detroit, Mich. supply air ventilation must be incorporated 7. Mr. G. L. Jepson, Ventilation En in the over-all laboratory design to insure gineer, Upjohn Compart}*, Kalamazoo, Mich. 112 Id be deeakage to the Con or other of couentiladon i the iudance of teve sigobtalned designs, obtained es. This he ven eer and ig with sts. ' fe Use aid R. Atomic Fume H. S. `giene atory. otope ition, neer, Enlich. Industrial Safety AN ENGINEERING APPROACH TO MATERIAL HANDLING SAFETY By WALTER J. BYRNE Walter J. Byrne & Co., New York City Handling of materials is an integral and important phase of every business enterprise. But, despite the fact that great strides have been made in improving handling techniques in many industries during the last three decades, this segment of operations still ac counts for one of industry's biggest cost items. tematic and scientific. Following the Indus trial Revolution of the 17th Century and the beginnings of the transfer of skill from men to machines, factory managers operated on hunches and inspirations. Jlecause the de mand for goods was so great, `rule-of-thumb' snap judgments sufficed, with the numerous mistakes made being readily absorbed. Quoting reliable statistics, upwards of 20 As individual enterprises grew in size and to 25 per cent of all labor hours go into complexity, supply caught up with demand some form of handling: This considerable and competition commenced to show itself. expense item becomes all the more impres Of necessity, the rule-of-thumb management sive when it is recognized that "materials was replaced by a so-called 'systematic' pro handling adds nothing to the value of a cedure, wherein those methods and practices product" which seemed to work well in the past were In the opinion of many management au standardized. thorities, this improvement drag has been This technique, although a step forward, caused by a lack of appreciation of the prob was systematic only as it tried to reduce a lem and a lack of accurate cost data pertain set of practices that proved successful in the ing to it The major credit for what progress past to a routine for dealing with operations has been made to date would appear to be of a recurring nature. rightfully assigned to the research and de velopment of the materials handling equip ment manufacturers. Some sixty to seventy years ago, Frederick Taylor entered the scene and introduced the beginnings of scientific management to busi A seeming current required ingredient is a ness. Taylor's approach endeavored to look greater effort on the part of individual busi behind those methods and practices which ness concerns to explore their own oper appeared to bring about desired results to as ations, with the view to isolating deficient certain what laws and principles, if any, methods and practices and the adoption of were operating. more efficient procedures. Where the systematic approach asked the Handling of materials is the principal question, "What practices have worked in the single source of work accidents and injuries past?" the scientific approach asks, "Why do in American industry. Again quoting re some practices work out and others fail?" sponsible records, 23 per cent of all job in A recognized aim of a successful industrial juries stem from some form of materials -safety, program is to build-in accident pre handling. vention measures into work procedures and Despite similar great strides made in the physical facilities and thereby greatly mini last few decades in the broad field of indus mize the uncertain and unpredictable human trial accident prevention, materials handling factor inherent in all of us. Present-day ma accidents and injuries are a recurring prob chine guarding, dust and fume control, are lem. Could it not be that the same reasons examples of successful built-in safeguards. that apply to the efficiency lag may also be assigned to the safety lag as far as materials handling is concerned? On the subject of materials handling, the achievement of built-in controls has been spotty. Despite the ever increasing use of In tracing forward the evolution of mod mechanical aids, such as lift trucks, cranes em management, as we know it today, its and conveyors as a means of by-passing development can be broken down into three manual muscle-moving, hazards and injuries fundamental forms: rule-of-thumb, sys from this source remain numerous. 113 ./% 1958 National Safety Congress All of us are aware that an important and necessary ingredient towards arriving at any solution is an accurate spelling out of the actual problem in question. In this con nection, I have, found myself continually focusing attention on die strict meaning of an industrial accident, where materials han dling is concerned. As generally defined, an accident is an un expected happening which may result in per sonal injur}', property damage, or both. When one closely examines materials han dling incidents, is it not realistic to classify certain so-called work accidents as work in juries, not as unexpected, but rather as inherent in the job procedures bring fol lowed? Most competent observers attribute the primary cause of materials handling acci dents to personal actions undo- such specific headings as unsafe habits, improper lifting, etc Safety people have worked and continue to work long and hard trying to come up with more effective means of educating indi vidual workers in safer handling methods. Despite numerous recognized successes here, many others are doomed to failure on a long range basis. This suggests, in our view, a re-examination in the light of both hazard and inherent injury potential. It is here wherein we believe Taylor's fact-finding and analysis techniques provide the most ef fective means. In advancing this undertaking, we are not unmindful that a safety engineer is primarily a coordinator of accident prevention activi ties and not an individual who knows all the answers about everything. Where firms al ready employ methods, time study and similar staff specialists, is it not reasonable for the safety coordinator to present the fact-finding and analysis assignment to them? Perhaps it is timely fonnanysafety engi neers to break out of certain confining wraps concerning their activities and responsibilities within the organizational framework of their companies and take a more aggressive inter est in methods, particularly as they apply to materials handling. hr this connection, a review of process charts, layouts, individual operational studies, and a `questioning attitude,' all tools bor rowed from methods engineers, are presented herein. Fact-Finding The flow process chart is a written record or charting of a materials handling cycle, calling for data on the material to be han dled, the methods of handling and transport, the distances moved and similar information pertinent to the problem. The scope of indi vidual cycles would naturally vary with the type industry involved and its complexity. In a product manufacturing layout, where in the various machines and equipment util ized are placed in connecting sequence (chemicals, bakery, etc.), it is feasible to chart the handling and transport of indi vidual materials from their point of receipt as raw materials to their shipment as a finished product In a process manufacturing layout, where in similar machines and equipment are grouped in departments (machine shop), it is preferable to record the handling activity in three separate stages: raw material and pur chased finished part handling, transport and storage; materials-in-process handling, trans port and storage; and finished product han dling, transport, storage and shipment Coincident with process charts, layouts of the arrangement of production machinery, work centers and auxiliary activities proride the means of tracing the physical route of materials and identifying the adequateness of available space. The individual operational study focuses on the recording of the handling require ments of machine and equipment operators, fabricators, assemblers, and materials han dlers themselves. WTiile it is admitted that the recording of such operational data in even the smallest company can be extensive; the procedure is greatly simplified with little loss of thoroughness by breaking down simi lar handling routines into a reasonable num ber of groupings or classifications. Those who have engaged in surveys of any types of business procedures have undoubt edly learned that quick and easy mental analyses are conspicuous in their incomplete ness. The quest for safety in materials is no exception. There is no miraculous, overnight cure. Work involved in compiling written fact finding records need not be an overwhelming task. Detailed handling data associated with one commodity can be effectively applied to all similar situations. 114 Industrial Safety rfr Record idling cycle, 1 to be hannd transport, information xpe of indi ary with the nnplexity. .yout, whereaipment utilag sequence > feasible to ort of indi nt of receipt ipment as a yout, whereipment are e shop), it is ig activity in rial and purransport and idling, trans product hanipment s, layouts of II t machinery, 11 ities provide cal route of tquateness of nd Vcuses ing _Jjnireat operators, iterials handnritted that inal data in be extensive; si with little j down simiwnable numns. rvevs of any tve undoubteasy mental incompleteiterials is no is, overnight written factverwhehning iodated with ly applied to In a paint manufacturing concern, the 8. Are materials of different types, sizes handling of a drum of one chemical would and shapes segregated to insure a minimum be employable for analysis of other drum of reshuffling? chemicals in similar usage. Recorded data on the handling of small, medium and large castings would have wide, recurring appli cation at turret lathes, milling machines, and drill presses. Analysis 9. Does the plant layout consider adequate storage areas in warehouse and production areas as necessary' adjuncts to efficient and safe operation? 10. Are definite routes of travel and suffi cient unobstructed aisle space available to The gathering and recording of operational data is followed by the analysis phase. Most avoid congestion and uncontrolled movement of materials handling equipment? simply defined, this is a testing out of actual 1L Are overhead cranes, lift trucks and procedures by a series of pertinent questions other mechanized handling equipment of aimed at isolating hazard and injury produc sufficient capacity' to safely sustain the loads ing conditions. Suggested questions, some of to be applied? which overlap for greater assurance of com 12. Does a preventive maintenance pro pleteness, are as follows: gram insure the continued availability of 1. Can the handling operation be elimi sound equipment? nated in whole or in part? If a `don't touch' 13. Are employees well grounded in safe idea is apph'ed diligently and open-mtndedly, 'handling methods of a routine nature? Are the results may be most fruitful. special instructions given employees as to And an important axiom of efficient ma safe handling methods of a non-recurring terials handling has been often stated as: nature? Efficiency in moving materials is best ob Is protective apparel (gloves, safety shoes, tained bv not handling them. etc.) required where hazard or inherent in 2. Can the handling operation, assuming jury producing conditions exist? it is a required one, be carried out in a As these and other pertinent questions are simpler, safer manner?^ asked about every step in the materials han 3. Does the handling operation ca'i for the transfer of materials from the floor to a conveyance, or rice-versa? dling process, safety* deficiencies evolve. No single handling category can fail to benefit from such a survey. 4. Are work places so arranged as to re quire machine and equipment operators, and assemblers to do a considerable amount of manual lifting; bending, stretching and posi tioning in connection with the materials they work with? 5. Are the weights of individual materials or unitized packages of same required to be manually lifted within a reasonable range? Is the added problem of a required position ing element coupled with a manual lift~takeir Underlying all of the foregoing fact-find ing and analysis procedure is work simplifi cation, utilizing the well-known and oftrepeated guiding principle the best way is the easiest and safest way. In the development and accumulation of the pertinent questions required to test out handling procedures, an analysis of past acci dents is invaluable. The worth of the anal ysis is in direct proportion to the relevance ojLlhe accident cause classifications used. into account? It has been my experience that many acci Are the limitations of female workers al lowed for? Where time study is used, do the standards allow for (and enforce the use of) crane time at prescribed weight limits? dent cause classifications have been mislead ing almost to the extent that they were un usable. It is urged that such data should receive careful consideration so meaningful cause classifications be established. 6. Are all dangerous properties of the ma terials accounted for? A further related subject pertinent to any organized industrial safety plan should con 7. Are raw materials, materials-in-process, sider, in our opinion, the item of compen and finished parts and products stored in sation claim costs. Safety people have long neat, stable piles? Is ease in rehandling taken based accident prevention performance on into account? frequency and severity, and particularly the 115 1958 National Scfeiy Congress former. The true meaning of these statistics is known mainly to the safety people them selves. It is our view that the higher echelons of management would be much more amenable and appreciative of safety efforts were claim costs to be included. The growing trend of permanent partial disability awards on `nondisabling* injuries has greatly watered down the significance of frequency data. It is impossible to examine the American industrial scene for long without coming to the conclusion that management is smarter than ever before. This is as it should be. It is evidence of progress. Perhaps it explains in part why one often hears the complaint that it gets harder and harder to compete. Thus, the theme for greater smartness becomes continuing dis satisfaction. The best executives are found to be those who won't ever admit that everything ^ going as well as it should. This is generally not a happy frame of mind but it sure leads to progress. Perhaps safety people should enthusiasti cally embrace continuing dissatisfaction as respects materials handling. I believe fact finding and analysis is a blueprint to point out the way. BOY SCOUT SAFETY GOOD TURN--1958 --A REPORT TO THE NATION Presiding: DON HIGGINS Health & Safety Executive, Boy Scouts of America Don Higgins opened the meeting and asked each one present to introduce himself. He then expressed thanks to all who aided in this very successful campaign. Mr. Higgins gave a brief summary' of how the campaign was inaugurated. He explained about the "kickoff" of the Good Turn year, beginning with Boy Scout Week in Feb ruary*. when a number of boys visited the President and subsequently each of the gov ernors of all the states and territories. Three aspects of safety were to be handled during the year; traffic, recreation, and home safety in that order. It was brought out that 40 million emer gency handbooks for the home were printed and sent to local Boy Scout councils for distribution by the scouts. The schedule called for .these booksto be- distributed in October. Mr. Higgins reported that the results of the campaign are being set down on a re port form. These reports will be collected by December, ihe results tabulated during that month, and a final report issued in Jan uary'- T. A. Krafclow, director of safety, John Deere and Company, Moline, UL, explained how he was first drawn into the Good Turn campaign through his work in safety for his company. He in turn enlisted the aid of others in his plant and also went to the Quad Cities Industrial' Organization for more help. Those who agreed to participate in the Campaign were assigned several scout units with which to work. The men visited their assigned units to get the leaders and the boys started on the campaign. With the "kickoff" everyone pitched in and gave everything they had to make the campaign a success. Mr. Kraklow said he thought his group did a good job, however, he cited an ex ample or what he believed was a most out standing job. The Peoria area safety en gineers banded together to assist in the campaign, and not only did they contribute to the success of the campaign, but also have shown great interest in staying with the Boy Scouts and continuing to help in other facets of the scouting program. Ivan Le Gore, safety director, Portland Cement Association, Chicago, related how he was favorably impressed with the mate rials being prepared by NSC for the cam paign when he viewed them in the summer or 1957. At the next meeting of the Na tional Executive Committee of the associa tion, 39 members approved of the program for the campaign. 116 y cow*, often h y and for inuing <&- to be those erything is is generally sure leads snthusiastifaction as Jieve factrt to point 3 ie aid of nt to the ition for te in the nut units ited their v *' 'the m [he nd gave mpaign a is group 1 an exnost outitety en: in the ontribute dso have vith the in other Portland :ed how ie matehe camsummer the NaassocialrogTam Industrial Safety Each member of the association was in formed of the campaign and was asked to cooperate with local Scout executives. Vari ous regional meetings were held where Scout executives attended as the main speakers. At 21 such conferences there were over 1,000 men in attendance. Mr. Le Gore reported that at this time he found many people already participating in scouting programs. The assistant chief scout executive of the Boy Scouts addressed a luncheon in Xew York of 330 association members to further build up enthusiasm. With the "kickoff" the campaign began in high gear and everyone devoted great effort and large amounts of dme to insure success. Mr. Le Gore cited some examples of what was done during the year to bring about this success. In June, some companies had the boys come out to the plants to assist in presenting various activities for safety*, such as first aid demonstrations, outdoor habits, etc. It was explained that June is a high ac cident month in the industry and it was hoped that the scouts could help make the employees more safety conscious. Taking an idea from the scouts, the asso ciation had printed for the summer part of the campaign the rules for the Scouts Merit Badge for Safety. These rules in the form of a leaflet were distributed to the members of the association and were received with enthusiasm. Even Boy Scout groups re quested copies for their use. Another PCA idea, reported in Rock Products, an industry' magazine, was to pic ture a hike through the month of June. The picture had various outdoor activities de picted and a winding path with the sections numbered to show each day. As the day passed without an accident the section was blacked out Mr. Le Gore, believes,.dm the campaign will have continuing effects and benefits to both Scouting and industry- J. S. Queener, manager of safety and fire protection for E. I. Du Pont de Xemours & Company, Wilmington, Del., reported that while he was immersed in the promotion of off-the-job safety activities, the Good Turn campaign appeared to offer equally good material to promote in conjunction with the O-T-J work. Key people of the Du Pont Company and oi the Wilmington area were asked to par ticipate in the "kickoff" of the campaign. Bands, scouts, and various organizations par ticipated in a big parade. Buses were char tered and used to bring boys from 200 miles away for the big event. Since a large portion of the area sponsor ing the activities was under volunteer fire men's protection, the Volunteer Firemen's Association gave their wholehearted coopera-' tion. A "Live For Tomorrow" pennant was de veloped for exhibit throughout the campaign. The boys in the area taking part in the scouting program did a wonderful job in the distribution of the Emergency Handbook for Home Safety. A scout was made available for high school assemblies to give talks on home safety. Mr. Queener said the campaign taught him that great gains can be made in various phases oi safety, such as off-ihe-Job, with the cooperation of organizations such as the Boy Scouts, Junior Achievement, Women's Clubs, etc Harold Heldreth of the Xational Safety Counril explained how the Coundl became interested in the Safety Good Turn Cam paign, the idea bring first discussed when the Safety* Merit Badge requirements were being revised in 1955. From this time the idea slowly developed until 1957, when it was definitely determined that 1958 was to be the campaign year. This caused the Council to take a good look at the potential oi youth in safetyactivities. It also caused the Council to further examine the program operation as a whole, to see if it could be used to better advantage in support of youth and other activities. The campaign finally began with the Coundl's full cooperation. Mr. Heldreth related that the campaign was promoted through the use of publicity in Council magazines, newsletters, and other media. Don Higgins listed other sources of pub licity, such as outdoor advertising. Metro politan Life Insurance pamphlets. Post Of fice posters, and others. Mr. Heldreth reported that, in conjunction with home safety, the Excello Corp. put safety messages on milk carton panels for dairy' companies to be distributed by the companies in their daily sales. It was re ported that 12 million half-gallon cartons had been printed. 117 '7-m jtj/. 'a&i 1958 National Safety Congress DECISIONS FOR THE FUTURE (INTRODUCTORY REMARKS BY THE CHAIRMAN) By DR. WILLIAM P. YANT Director of Research, Mine Safety Appliances Co., Pittsburgh, Pa. At its meeting in June 1957, the Board of Directors oi the National Safety Council charged the Council staff with the task of implementing the action program of the President's Conferences on Occupational Safety insofar as those recommendations ap plied to the work of the Council. During this Congress the Labor, Farm, and School and College Conferences are giving their attention to the aspects of oc cupational safety that lie within their scope of operations. Our program today will con sider those problems which are of interest to the Industrial Conference of the National Safety Council and to the American Society of Safety Engineers. Before one considers die problems of the future, accomplishments of the past and present status must be evaluated. The course for iuturc action can be charted only on the basis of a knowledge of past accom plishments. An evaluation oi experience over ant* period since the initiation oi organized oc cupational safety programs could not fail to indicate great progress. On a chart showing the curves for fre quency and severity rates of reporters to the National Safety Council from 1926 to 1957, frequency rates declined from a high of 31.87 in 1926 to 6.27 in 1957, a decline of 80.3 per cent. Over the same period severity rates declined 70.4 per cent from a high of 2,500 to the 1957 figure of 740. - A report ^-presented by David L. Arm, manager of the Council's Industrial Depart ment at the 1958 President's Conference on Occupational Safety, showed the progress in the ten year period from 1948 through 1957. It noted that while the work force increased from 46,700,000 in 1948 to 52^00,000 in 1957, or an increase of lib per cent, occupational deaths decreased 3.4 per cent and injuries decreased 5 per cent over this period. The decrease in deaths from 1951 to 1957 was lib per cent while injuries decreased 10.7 per cent in the same period. Although such reports indicate that great progress has been made, we would call to your attention that there is no reason for complacency now or in the near future. The 9,400 deaths and the 1,455,000 disabling in juries due to occupational accidents which occurred in 1957 in the areas under consider ation are an indication of the magnitude of the task which still confronts us. Even though the total of the work force and its composition were to remain static, these figures are a challenge to the imagina tion and initiative of all who work for oc cupational safety to find ways to reduce even further. Unfortunately, however, neither of these considerations will remain static. Ewan Clague, United States Commissioner of Labor Statistics, presented a paper entitled "Figures at Work" at the 1958 President's Conference on Occupational Safety. Mr. Clague said, "On the basis of current pop ulation data, and assuming favorable em ployment opportunities, our projections of the 1965 labor force show an increase over 1955 oi about 10JS million persons. "It is significant that only 1.2 million of this increase will be among men between the ages of 23 to 54, the primary working group of our population. The great bulk of the increase in the labor force will come from two groups -- women 35 years and older, and young workers between the ages of 14 and 24. Each of these groups will account for more than 4,000.000 of the total growth." Mr. Clague indicates that the work force will be increased primarily among young workers and older women with smaller in creases in the primary working group and among older men. He also points out that "we also know that safety programs designed for groups of all male workers require modification when applied to predominately female groups. We know that special safety training problems arise when large numbers of young people enter employment." 118 Industrial Safety We would emphasize that past experience --are the areas of employment where great indicates that three industrial groupings-- est emphasis is needed in order to show the construction, trade and sen-ice, and mining greatest progress. : that great >uld call to reason for uture. The isabling inents which a- considerignitude of work force nain static, le imagina>rk for oceduce even : r of these tic. Ewan ssioner of r entitled President's ifety. Mr. irrent popJrable emiect'-'ns of tc )>ver w million of n between y working at bulk of will come years and n the ages roups will t the total ] ; ] j i ! ] j rorfc force mg young mailer in group and s out that s designed -s require lominately dal safety e numbers j OBJECTIVES AND PLAN OF THE PRESIDENT'S CONFERENCES ON OCCUPATIONAL SAFETY By JOHN J. GILHOOLEY Assistant Secretary of Labor, Washington, D. C. Many present and former members of the groups sponsoring this panel have contrib uted immeasurably to the President's confer ence. You--and they--were consulted on the organization of the very first conference and hare partidpated in the planning of all subsequent conferences. National Safety Coundl staff and the ASSE have repeatedlyserved as technical advisors on program. Your leaders have addressed conferences and moderated panels and workshops. Many of you have served on conference committees and have influenced the objectives and plans of the conference by your counsel and advice to the President and the Secretary of Labor, who serves as general chairman. First, I should like to describe briefly the broad objectives of the Presidents Confer ence! They are directold: 1. To focus national attention on the im portance of occupational safety and the con tinuing need to do something about it. From the nation's capital it has been necessary repeatedly to demonstrate the con cern of the federal government and the per sonal interest of the President of the United States in reducing the social and economic waste of preventable work injuries. That done, we have been fortunate enough to en list the program participation of some of the country's outstanding Jeaders as speakers, moderators and panelists. We have pro gressively broadened the scope of the con ference until today attendance has tripled in volume and represents virtually every seg ment of the American economy. 2. To identify and emphasise emerging Problems in occupational safety. For example, at the 1958 conference we surveyed human motivation for safety, offthe-job accident prevention, radiation haz ards, and the safety contribution of indus trial medicine. We made a conscious effort to foresee the problems we would face in the next decade. The prompt recognition of such problems offers the type of challenge which I regard as the business of conference leadership. 3. To obtain a broad consensus of views and to formulate recommendations on mat ters which require consideration or action by appropriate groups concerned with occu pational safety. Recommendations have been made by suc cessive conferences, usually in the form of a report to the President, and disseminated by the Labor Department and even more widely and properly by the individuals and groups who attend. To carry out these objectives, the plan of the conference embraces a biennial session open to a broad cross-section of the econ omy; plenary sessions but also workshops to encourage individual participation, to obtain a consensus on specific problems and to for mulate recommendations for their solution. There, in brief compass, are the objectives and plan of the conference. Very early the conference had to demon strate its nonpartisanship and overcome fears that it cloaked * federal infringement of states' rights or management prerogatives. Soon to come was the policy to refrain from endorsing or opposing labor legislation. Since I have known the conference, those-in this room whose advice we sought on these mat ters have counselled us wisely. You have urged us, for example, to expand the scope of the conference to include all segments of the American economy. We have done so progressively until now virtually all segments are invited to participate. At the same time this expansion of cover age was sought, limitation of attendance to top echelons of management, labor, education and government was proposed by some; pro posed on the grounds that these echelons 119 1958 National Safety Congress carried the power of decision for or against safety programs in their organizations. But again, your wisdom reminded us that; constantly and by every means he can de vise; the professional safety man has to "seU" his superiors on safety and their joint attendance at the President's conference gives him a favorable climate for such sales manship. Conference attendance limited only by space accommodations and not by rank or other factors squared with the secretary's conviction that die President's name should not be associated with exclusiveness in the broad humanitarian endeavor to save life and limb. Accordingly, attendance is open to de cision-maker and professional alike. Nonetheless we are all aware of the im portance of convincing top management of the value of safety. You have urged us, and we have endeavored, to attract to the conference company executives, especially from smaller firms which may not have organized safety programs. At the confer ence last March, for example, nearly 1,200 of the 3,000 delegates came from business and industry and of these, 414 were company presidents, vice presidents, managers or di rectors of industrial relations; 226 were company presidents. Another question which arises periodically involves the nature of conference program ing. Should these programs be stimulative, promotional, inspirational? Should they deal with new and forward-looking develop ments? Or should they be what we might call operational--calling for progress reports from different segments of the economy or the safety movement and looking toward action to be taken by, or in the name of, the President's conference? These alternatives were carefully considered when we were planning die 1958 conference. Should we use our tenth anniversary to look forward or back? How much can the future learn from the past in safety? How much ot the past is assessible? Some of our advisory voices said, "quite enough to help plan for tomorrow." Others asked, "who can accurately assess safety progress even in a single industry'?" After a period of rather bride discussion there came from your ranks a consensus to the effect, "Look to the future instead of the past" This was counsel width in the main we accepted and which I judge you have accepted too. Questions such as these on program go bade to bade conference objectives. Is it an institution designed to carry out recommen dations formulated by delegates from your groups and others throughout the land? Or is it a forum where interested agencies and individuals exchange experience, surveyemerging problems, recommend action to be taken not by the conference but by them selves and others as appropriate, and by such association refresh and recharge thenown dedication to occupational safety in America? Viewpoints an these questions range all the way from criticism of the conference for not carrying out recommen dations to intense fear that it might attempt to do so. President Eisenhower has repeatedly ex pressed the philosophy of this administration, namely, that the federal government should do only those things which the people can not better do for themselves. A generation of safety experience, the existence of a strong * national safety movement removes work injury prevention from the area of exclusive federal implementation. In addi tion, such implementation would violate a baric conference policy against federal in fringement of stated rights or unwarranted government intrusion into private affairs. Summarizing conference objectives of 1958, I see this institution as non-partisan and voluntary in character; open to all seg ments of our economy and to top manage ment and safety professionals alike, but seeking to attract company executives espe cially from smaller firms; with purposes and programs which are stimulative and for ward-looking ; and dependent for effective application of its recommendations upon the organizations, agencies, and individuals, whether they attend its sessions or not, who care about saving human life and limb in the work places of America. As we search out what your program calls "the frontiers ahead," can we maintain or accelerate the present favorable downward trend in occupational deaths and injuries which Dave Ann outlined so brilliantly at the last President's conference? The past decade has demonstrated that these deaths and injuries can be reduced in the face of an increasing labor force. Those attending the last President's conference heard a lot about this problem. By 1965 we shall have 120 prr~^m go ve j, it an t t&Jiwnwi. > from your le land? Or agencies and ace, survey action to be ut by themate, and by charge their d safety in >e questions asm of the t recommenlight attempt peatedly exministradon, iment should people can\ generation stence of a ait removes the area of n. In addild violate a federal inunwarranted He affairs. ibjecdves of non-artisan a jlsegtop inages alike, but entires espepurposesand *e and forfor effective ms upon the idividuals, or not, who and limb in irogram calls maintain or e downward and injuries brilliantly at ? The past these deaths the face of ise attending heard a lot e shall have Industrial Safety a population of over 193 million in the United States. We shall have a labor force of nearly 80 million--10 and one-half mil lion more than in 1955--and it will look a lot different than it does today with a larger proportion of the young and the aged. We shall also confront the problem--as many of you know far more intimately than I--of a changing technology, changing-- literally, in many cases--with the speed of light. We have no panoramic portrait of tomorrow's technology but much of it will be found in industries such as aircraft and air transport, atomic energy, heavy construc tion, electronics, office machines and electric power. We also know that the demands of a soaring population, of science and national defense both in space and cm the ground will require higher skills than ever before; Higher skills among professional and tech nical personnel, among proprietors and man agers, among craftsmen, clerical, sales and sendee workers. Yon can count on future President's con ferences to advance toward our common goal of reducing work injuries. I hope we shall continue to merit General Stewart's con gratulations and his expression of pride that "council members had a role in tins successful and effective conference." The federal government representatives here have been happy to contribute to your evaluation of the frontiers yon see ahead and of the means proposed by your several groups of crossing them. Thus we have at tempted to serve our common objective of saving human lives and thereby strengthen ing, by all odds, our country's greatest asset 121 1958 National Safety Congress AVENUES FOR PROGRESS THE INDUSTRIAL CONFERENCE By GERARD O. GRIFFIN Safety Dir., Dravo Corp., Neville Island, Pittsburgh, Pa. The Industrial Conference is the policy making committee for the c rcupational acci dent prevention program of the National Safety Council The conference, through its standing committees, acts in an advisory ca pacity to the Industrial Department in all of its operating areas. Members of the conference are selected by two methods. According to the constitu tion of the National Safety Council the chairman and vice chairman of each section is automatically a member of the conference. This means..that each of the industry seg ments represented by the twenty-seven sec tions has equal representation. In addition, about 95 members-at-large are nominated each year which, with honorary life mem bers, and representatives from other confer ences, brings the total to over 160 members. Without a doubt, the Industrial Confer ence is the most influential body in the field of occupational accident prevention in the country. On the one hand, members are elevated from an industrial section because they have earned the respect of their fellow safety engineers in their industry. The aver age chairman of a section has been a volun teer committee member of the council for seven years before being placed on the con ference. Ample time for his fellow safety engineers to recognize his ability and ac knowledge his leadership. The remainder of the conference, or mem bers-at-large, are nominated by the confer ence itself, through its nominating committee. Here abilities beyond a single industry are recognized. The individual may have a tech nical knowledge, on a subject of interest to many "Industries, such as flammable liquids, radiation or standards. On the other hand, the member may be nominated because he or she has a proven ability in the promotional aspects of industrial accident prevention, such as visual aids, training, contests or awards. The total makeup of the conference mem bership is also studied, to be certain that representation is assured from every element interested in occupational safety. In this way, industry, insurance, governmental agen cies, both federal and state, associations and agencies are all able to have a voice in poli cies formulated by the Industrial Conference. To carry out its work, the conference meets three times a year. The new confer ence is named at the October meeting of the National Safety Congress. The winter meetmg is usually held in New York, and the spring meeting of late has been held in \arious parts of the country. There are twelve permanent standing com mittees of the conference and every member is assigned to one of these committees in accordance with his own indication of pref erence. In this way the members associate themselves with the phase of industrial safety in which they have a prime interest and in their own opinion can be most bene ficial to the conference and the safety movemenu These committees represent the most im portant functions of industrial safety engi neering and the members of each committee, by their own selection, have indicated their special interest in a particular phase of acci dent prevention. Consequently, comminee action is bound to be effective. Let us take the area of industrial safety training as an example . . . The training classes given at the Council office are under the cognizance of this committee. The chair man, and members of the training commit tee, work with the Council's industrial train ing director to improve the course and make it fit the needs of the enrolled students. Through volunteer committees, this same course has been set up in other areas of the country. Local safety councils, A.S.S.E. chapters, and extension departments of uni versities and colleges cooperate to provide classrooms, instructors and administrative guidance of the training committee. One of the important books published with the guidance of this committee was the Su pervisors Safety Manual. Some chapters of I i i ! 122 ity. In this mental agenxiations and .oice in poliConference. i conference new confer ecting of the winter meetJrfc, and the held in vari- tanding cotn'erv member immittees in ion of pref ers associate i industrial rime interest : most benesafety move- he most imsafety engih committee, die j their hast oi acci, committee istrial safety Hie training ce are under u The chair ing commitustrial train- se and make idents. s, this same areas of the Is, A.S.S.E. tents of uni to provide iministrative ee. lblished with was the Su~ chapters of Industrial Safety this book were re-written as many as four times before the conference committee con sidered them satisfactory for modem super visory training The fact that the first print ing of 30,000 copies was virtually depleted in a little more than two years, proves the worth of this effort by the committee. The original work had been done so well that practically no change was necessary in the second printing. In addition, the committee has been work ing on an extension course on safety for supervisors to be operated by the Council Industrial staff. The Training and Nuclear Energy Committee cooperated recently to present a special course on radiation hazards and control for safety engineers. Another special coarse on industrial faygene for safety engineers is planned for late this year. You'can see from the activities of the Committee that in the area of training the committee keeps the Industrial Department and the Council not only aware of current and new problems, but sets up the mechanism by which solutions to these problems can be accomplished. Since more than 80 per cent of large cor porations are members of the National Safety Council, it is obvious that big business has pretty well accepted its responsibility for accident prevention. The small company, however, has not accepted this challenge. It has been estimated that small business em ploys close to 70 per cent of our working force. The Council has been making prog ress with a Small Business and Associations program. Through trade associations, em phasis is placed on an industry acceptance of a safety program. Since such a large segment of the working force is included in the small business group, it certainly should be considered one of the main prob lems of the moment It is obvious that the representation on the Conference is such, that through its ef forts the National Safety Council is kept well abreast of the needs in occupational safety. As new problems arise they are brought to the attention of conference, re ceive the benefit of wide experience in the field of conference members and the Indus trial Department is guided in the correct course of action. THE INDUSTRIAL SECTIONS By W. O. WILSON Manager of Safety, Standard Oil Co. (Ind.), Chicago, IQ- Each of the more than 7,000 industrial & commercial members of the National Safety Council is affiliated with one of the 28 in dustrial sections. The section exists for the purpose of pro viding a primary group whose safety prob lems and interests are sufficiently related and applied to a large enough exposure that they warrant treatment as a segment of industry. The objectives of a section, therefore, are to disclose, study and define the safety prob lems of its segment of industry, disseminate information about these problems and bring them into the scope of activities of the Na tional Safety Council through the Industrial Conference. The publication entitled "A Report of Oc cupational Safety Activities Under the Di rection of the Industrial Conference," which is available for distribution at this meeting, outlines the current work of the sections. This report clearly indicates the wide di versity of projects which are being con ducted by these groupings of Council mem bers. Special note should be taken of the num ber of Data Sheets and other technical pub lications being developed by the sections. Each month a new data sheet appears for the first time in the National Safety News. In addition to these, at least 12 other data sheets are published during the year. During 1958, of the total of 24 data sheets published, 14 were originated, developed and written by sections. The report also lists special visual aids, such as films and safetygraphs, to gether with special sectional posters and poster series. Outstanding among the activities in which these sections engage, and an example of how they secure and disseminate informa tion, is found in the CouncQ's inventory of occupational accident prevention activities. 123 1958 National Safety Congress It has long been customary for a member The questionnaire used in this survey is with an industrial safety problem to ask die set up in 10 individual parts, each of which National Safety Council for assistance and covers one major area of accident prevention the Council has established a reputation for activity. finding a solution of the member's problem, Approximately 1,000 plants in the 14 in if it was not already at someone's finger tips. dustrial sections presently participating in The Council's Inventory of Occupational Ac the inventory provided completed question cident Prevention Activities is finding solu naires. At present the inventory is approxi tions to many problems and it is getting mately 20 per cent completed in these sec some of the answers before some of the questions are asked. tions. Accident prevention areas covered by the Of course, it is not always easy to get inventory questionnaire include: the answer to every question that comes 1 along. But, industry needs and asks for the Part 1, Records, and Classification of answers to such questions as: Plant; Part 2, Safety Personnel and "What land of induction and job safety training do other companies give to new employees?" Budget; Part 3, Supervision, Policy, and Safety Committees; Part 4, Accident In vestigation; Part 5, Physical Facilities and Environment; Part 6, Safety Inspections; "What is the cost of total compensation Part 7, Personal Protective Equipment;, and medical payments per plant employee in Part 8, Medical and First Aid Program; other plants?" Part 9, Employee Selection, Placement, Job "What land of safety contests do other Instruction, and Education, and Part 10, Off- companies find worth while?" The-Job Accidents. "Should job descriptions specify protec tive equipment and other safeguards to be used?" Long-range future plans for the inventory include its extension to 25 industrial sections, which would exclude only the Trades and This inventory seeks the answers to these Services Section, Occupational Health Nurs and to many other questions about industrial ing Section, and the Hospital Safety Com safety activities. To minimize the influence mittee. of variations in hazards between industries, the information is developed from within the individual industrial sections of the Council. The information provided by the member plants through the inventory ques tionnaire. Some of the information has also been publicized this year by articles in the January', May and September issues of the National Safety News. The function of the inventory is to fulfill one of the purposes of the National Safety Council; that is, to serve as a clearing house for the exchange of information on indus trial safety practices and techniques among industrial organizations. It is expected that this exchange of information will enable many plants to compare their own accident prevention activities with those of others in their own field, and thus enable them to evaluate the effectiveness of their own activ ities, and to improve their safety programs. It is anticipated that the information de veloped when the inventory is extended to 25 sections will be most valuable, and that much of it will find its way into Council publications and periodicals, as well as bring made available through sectional reports to members of the participating Industrial Sec tions. While many of the sections are fulfilling the objectives previously stated, too many are doing very little to stimulate accident prevention activities within their spheres of influence. Much technical information in certain occupational areas remains to be gathered, written and disseminated. Partici pation in the inventory should include more sections in order that the data being gath ered might be more completely representa tive of all occupational situations. As the chairman of this meeting has indicated, the years aheard are ones which present a great This inventory was initiated in 1956 by challenge to the intelligence, skill and in the Member Opinion Committee of the genuity of all who are engaged in accident Council's Industrial Conference. At present, prevention activities. Will the sections be 14 of the Council's industrial sections are prepared to assist in the attainment of the participating. desired goals? 124 his ''irvey is at j which mt prevention in the 14 inrtidpating in ted questiony is approxiin these sec- ivered by the situation of sonnel and Policy, and Accident InFacilities and Inspections; Equipment; id Programs acement, Job Part 10, Off- the inventory trial sections. Trades and Tealth NursSafety Com- ormation deextended to sle 'd that ini /roncil well as bong U reports to dustria! Sec- are fulfilling 1, too many late accident ieir spheres formation in ~ nains to be :eL Partidhclude more being gath' representa>ns. As the adicated, the sent a great kill and in: in accident sections be ment of the Industrial Safety TRADE ASSOCIATIONS By GUSTAVE L. NORDSTROM Executive Director, Foldmg Paper Box Association of America, Chicago, I1L During the next ten minutes of this work day, while I relate a few ideas as to the future of trade association safety activity, one man will be killed or permanently and totally disabled by an actident while at work. One hundred sixty others will be injured less severely. By tonight, 50 workers will have been struck dead or totally disabled on their jobs. Two hundred fifty will have suffered some permanent impairment, and 6,000 more will have suffered injuries that will keep them from work for an average of about 20 days. In a year--this year--14,000 deaths, 80,000 permanent impairments, 1,400,000 temporarydisabilities, and $2,000,000,000 expenses in wage losses, medical costs, and insurance overhead. A staggering figure, yes. And the fate of two billion dollars certainly deserves our combined attention. But--and this is the real dollars and cents point behind industrial safety development--this figure, gargantuan as it is, does not tell the whole story- Behind these already tremendous expenses loom towering costs that multiply the price of wage losses, medical service, and in surance. Replacement of expensive equip ment . . . retraining of personnel . . . depreciation of machinery . . . down time-- add them all together in the 3,000,000 busi ness installations and the 5,000,000 farms where men and equipment are at work, and you will have another $2,000,000,000 of loss --a total of $4,000,000,000 as the cost, direct and indirect, of work accidents. - Note how this works. In a folding carton plant out East, not too long ago, a worker was using a crane to move stock on the factory railroad siding. While trying to save time, he overextended the crane, causing it to crash down a steep embankment Fortu nately, the worker jumped free and incurred but a few scratches--which were quickly bandaged. The crane, however, plowed down the embankment into an adjacent metro politan sewage installation and tore it up, causing extensive damage. Since the work in process was of great importance to the company, another crane had to be rented in order to clean up the debris caused by the downfall of the first crane and to pro ceed with the original work. Since the plant's crane operator had received just a few scratches in the accident, he was able to stay on the-job. But, perhaps unsteadied by the mishap, he swung the newly rented crane into action, smashed it into a wall, damaged the wall, and snapped the boom. Medical cost of this accident: a penny for a bandage. Cost to the company: $10,000 dollars plus time lost on the job. Since the net profit ratio in the folding carton industry is running at approximately 2.21 per cent this plant would need to realize gross sales of about $150,000 to re coup a $10,000 loss at the net profit level. At present paperboard evaluation, this, in turn, would require gross sales of 1,200 tons of folding cartons. Seventy-seven tons of cartons are manufactured at this plant during an average day. A little arithmetic yields the startling fact that sixteen working days would be required to earn back $10,000 of lost profit--profit which appears on the safety ledger as one cent, the cost of a few bandages! The fact that property insurance covered the damage does not alter the point, which is that the property damage tends to be overlooked when safety costs are analyzed. Only the penny bandage cost shows. Happily, though, this coin has two sides. If accidents cost money and eat into a company's profits . . . then prevention of accidents can serve' to add to a 'company's profits. Because the trade association is vitally concerned with the over-all develop ment of its industry, safety has a genuine dollars and cents importance. I think we have witnessed an important change in safety philosophy in recent times, one which I hope will characterize future safety activity. Formerly, the matter of industrial safety was relegated to a factory safety engineer or line supervisor. Today, more and more, safety is becoming a con cern of top management--as important to a 1958 National Safety Congress company's operation as cost accounting and assembly line efficiency. Although much -work remains to be done here; management executives are bong made aware of the fact that'industrial accident prevention is a profit-making consideration. And where profits are involved, executive attention becomes sharply focused. This, it seems to me, is the area in which the trade association can make the most dramatic contribution to industrial safety, and to increased member company profits. United States Department of Commerce estimates that through these 12,000 asso ciations can be reached most of America's 3,000,000 employers. Together with the re gional groups, the multiple association spe cial interest groups, the ad hoc committees and other organizations, they hold over 75,000 conventions and meetings each year. That gives us quite an audience. With an audience of this size, associations can achieve things for their members that the members cannot achieve as individuals. The formula is basically simple. First, Associations can exploit and disperse to convince the corporate executive that in their memberships the benefits of all the dustrial safety is his concern; second, de combined knowledge and experience repre velop an industry program which will involve sented by companies on their rosters. Mem every workman in active safety practice. ber firms have mutual safety problems, To be sure, tins problem is a difficult similar operations and equipment, much one--fortunately, being met on many fronts. overlapping of experiences. The National Safety Council's promotional Through sponsoring associations, spall campaign is aimed at the businessman, not companies can join in spirited safety com the safety engineers. The Council's many petitions. Individually, their lade of size is fine awards have set high standards of in a severe handicap to any effective competi dustry performance which must require the tion. They cannot organize inter-depart attention of corporate management. But mental competition as do larger plants. Only more needs to be done. Too many business through an association can they join together men still evaluate the success of their pro in constructive, industry-wide safety com grams by the size of their insurance pay petition. And competition, of course; is one ments. And this criterion is so woefully in- ' of the most successful ways to increase the adequate today that dependence on it prob standard of performance. ably does more harm than good--as we can see from the $10,000 crane mishap, and from hundreds of other similar catastrophes. Many small plants keep no accident rec ords, or inadequate ones. Association activi ties can serve to stimulate meaningful record That the trade association can do a valu keeping, as well as thorough accident anal able job in these areas is attested by past ysis and follow-up, to aid in future accident performance. The Can Manufacturers' Insti prevention. tute reduced its accident frequency rate 50 per cent in the first five years of its safety program and estimates savings of $15,000,- Safety meetings, industry-wide, and asso ciation sponsored, can bring about a free and beneficial interchange of information, 000. The National Association of Refriger and members can profit from one another's ated Warehouses saved $160,000 over a experiences in solving accident problems, three-year period. The Pressed Metal In developing educational safety activities, stitute of Cleveland cut its frequency rate stimulating interest among employees, 68 per cent in 10 years, with corresponding in other areas. savings. My '`own group, the Folding Paper Box Association, estimates savings to members Industry communications, through the me dium of the association, can reach company management and involve the business, as a since the start of our program in 1951 at dues-payer, in constructive safety develop over $4,000,000 in workmen's compensation ment costs alone, representing additional savings in plant and equipment of over $16,000,000. And accident frequency is down 50 per cent Safety educational materials, developed within the framework of a specific industry, with specific problems, are more apt to hit There are now over 10,000 local, state, the mark than those developed elsewhere. or regional associations, and about 2,000 The trade association is ideally situated to more with nation-wide representation. The provide this service. 126 Commerce .0T Asso4 lea's th. uie reation spesommittees bold over each year. ssodations nbers that idividuals. isperse to )f all the ice repre ss. Manproblems, nt, much ms, small fety comof size is : competier-departints. Only n together Fety com ae; is one crease the ident recion activifuj ''wd ic Jble accident and asso rt a free `ormation, another's problems, activities, yees, and h the mecompany less, as a develop- developed industry, apt to hit dsewhere: taated to Industrial Safety As an example, the Folding Paper Box Association recently produced a new guide to accident prevention in the folding carton industry. Since the guide deals with safety problems peculiar to our membership, users have given it a fine welcome and have called it extremely useful. Other industries have produced similar guides with much success . . '. and many others will surely find the technique applicable. Associations may also work effectively with suppliers of mechanical equipment to ward desirable modifications of machine de sign to achieve better guarding standards. An association of manufacturers understand ably, will have more influence with a machine supplier than would a single manu facturer. There is much the trade association can do to contribute to the development of industry safety. Through meetings and con ventions, letters to members, joint study conunittees, and a dozen other means, asso ciations can rally their memberships to a high level of enthusiasm--once they have made appropriate safety studies of their own industries. The stakes are high enough--in lives and dollars--to warrant the interest and coopera tion of every installation in the country where men and equipment are at work. Associations can provide the impetus; they are the quickest and most effective way to reach and sell the masses of American busi nessmen, large and small. Those of us who have seen the results of association safety work have reason to be enthusiastic about the enormous potential in this field. We solicit your support--in your company and in your association. I thank you for your attention during these few minutes. Although we are too late to save the man who died or was crippled in an industrial accident while I've been talking . . . and too late to save the broken equipment and the needlessly en dangered company profits, we're not too late to save tomorrow's lives and tomorrow's dollars. Just let us get to work today 1 INSURANCE ORGANIZATIONS By DONALD G. VAUGHAN Sec'y., Safety and Engineering Dept, Aetna Casualty & Surety Co., Hartford, Conn. It will be impossible in the few minutes allotted to give you in detail the many ways in which the Insurance Industry has tied in with the nationwide occupational safety movement The President's Conferences held in Washington every two years have gathered together the key people interested in fur thering the efforts to reduce occupational accidents. Insurance safety engineers have played an important part in every one of these Presi dent's conferences. To mention just a few items, the committees at the 1950 confer ence had more than 20 insurance safety engineers as committee members. At the 1952 conference, four insurance men were members of the co-ordinating committee and more than 30 of the delegates were insurance safety engineers. In 1954, six insurance engineers were members of just one of the committees, the Engineering Committee. I do not have figures as to representation on the other committees for that conference. Last spring at the 1958 conference, we find seven speakers from insurance companies on the program.- The staffs of both the stock and mutual insurance associations were members of the technical advisory com mittee and among the delegates to the con ference we find over 50 insurance safety engineers. The follow-up of these conferences in Washington is through local effort; both state and individual community. ,,Many of our insurance engineers participate at these levels. There is hardly a local safety coun cil in this country that does not have several insurance engineers as active members par ticipating in the activities of their several committees. It is interesting to note that the insurance industry has helped over the years in ad vancing accident prevention activities. In I H- 1958 Xalional Safety Congress 1894 the first safety specialist was employed by an insurance company. The first work men's compensation law in the United States was passed in New Jersey in 1911, some 17 years later. The year 1911 has been con sidered by many to be the birthdate of the industrial safety movement. Industrial acci dent frequency and severity and death rates have been steadily reduced since that time. The earliest figures available, those of 1913, givfe 9.1 workers per 10,000 lolled in indus trial accidents. This has been reduced to 2.3 deaths per 10,000 workers in 1957. In 1926 the average industrial severity rate was 2,500 while in 1957 this had been reduced to 740. This severity rate is the number of days charged per 1,000,000 man-hours of exposure. Frequency rate, number of dis abling injuries per 1,000,000 man-hours of exposure, has also been reduced from 31.87 in 1926 to 627 in 1957. These records while achieved by industry, reflect in a great measure the activity of the insurance industry for each year casualty companies employ thousands of safety en gineering specialists and spend a sum of money in excess of $30,000,000 to support their activity. DEATHS OF WORKERS At Work (Blue) 14,200 (Indudes, Agriculture, Motor Transport, Mining, Logging-- All Occupations) Manufacturing 2,000 Away From Work (Pink) Motor Vehicle Public (Non Motor Vehide) Home Total 18,500 6,900 6,400 31,800 INJURIES TO WORKERS At Work (Blue) 1,950,000 (Again Includes All Categories) Manufacturing Away From Work (Pink) 400,000 Mtfor Vehide 650,000 Public (Non Motor Vehide) 850.000 Home 950,000 Total 2,450,000 Insurance companies have, year after year, given their support to national safety organ izations. They have given financial assistance and their representatives have participated in the major activities of these organiza tions. Such support has been given to die National Safety' Council. Members of 100 different current safety code committees of the American Standards Association are from insurance companies. Some of the other organizations similarly supported are the American Society of Safety Engineers, the American Society of Mechanical Engi neers, the Industrial Hygiene Foundation, the National Fire Protection Association, the American Chemical Society, the Center for Safety Education at New York University, and the Northwestern University Traffic School. The insurance industry has been most active in the problem of rehabilitation of injured workers. In addition to seeing that the best possible medical and hospital care is provided, they have sought ways and means of training the handicapped worker to return as quickly as possibleJo a gainful occupation in industry. Unfortunately word has spread around falsely that insurance companies advised against the hiring of the handicapped worker. I would like to point out that there is no provision in workmen's compensation insurance policies or rates that penalizes an employer for hiring handicapped workers. Several pamphlets have been published by the insurance industry encouraging employers in the proper placement of the physically unpaired so that they can safely be made a part of the working force. Research studies by the federal govern ment and others have shown that when placed at proper jobs, the handicapped have an acride.it experience that is as good as their able-bodied fellow workers, and many times is superior. Individual insurance companies and their associations annually publish many safety posters and booklets for assistance in fur thering, the safety education of industrial workers and industrial supervisors. Millions of these pieces of literature are furnished grads each year. Motion picture films and sound slidefilms have been produced and circulated by the insurance industry. No fair estimate can be made of the millions of workers who re ceive and benefit from these safety messages each year. Special studies have been made by the insurance industry of unusual hazards in volved in chemical processes manufacture. 128 ieip*^ -s ot jtteesi xaanon are me of the >ported are Engineers, lical Engi- Foundation, riation, the Center for University, ity Traffic been most litation of seeing that spitaj care ways and id worker a gainful d around s advised ndicapped that there ipeasation aalizes an workers, lished by employers physically e made a at when ped have good as nd many nd their y safety in fur- adustrial Millions umished lidefilms lyr the s can be who re- tessages j by the ids infacture. Industrial Safety transportation and handling of such mate rials as liquefied petroleum gas, anhydrous ammonia, plastics, flammable liquids, etc. More recently studies have been made by the industry of the problems connected with impaired hearing from exposure to noise in industry. Insurance people hare kept abreast of the precautions to be taken in handling materials with nuclear exposures. This pro cedure is the same as when they tackled the silicosis and lead exposure problems several years ago. All of this research work has been con ducted in order to assist management, who are the insureds and customers of the in surance industry, in adequately and safely controlling these hazards. This has helped to make these exposures less hazardous and helped to keep thousands of workers from being involved in serious injuries. The automobile accident problem is part of the industrial safety picture Last year, that is 1957, 2,900 workers were lolled by motor vehicles while they were at work. Another 18400 workers were killed by motor vehicles while they were off the job. Insurance companies have been most active in the highway safety field. The furtherance of safety education in the schools, driver education and other highway safety activi ties have been encouraged, financed and promoted by the insurance companies. For many years insurance companies have been assisting in the maintenance of safety with respect to hazardous objects. Inspec tions of boilers, pressure vessels, machinery and elevators are made regularly. In many states these reports by law are filed with state authorities and serve as the state checkup on these devices. In addition it must be remembered that the safety codes governing the installation and operation of these objects were developed with the aid and assistance of insurance company safety engineers. This briefly gives a summary of the active participation of insurance companies in the occupational safety movement. For many years this assistance has been contributed ot only at the national level in Washington but also at the state and local level. While governmental departments in Washington can initiate and stimulate occupational safety on a national scale, the real activities must be conducted at the state and local level. Finally, plant management and labor must be sold and must cooperate if continued re ductions in accidents are to be accomplished. The insurance companies as they have in the past will continue to be an important part of this activity. Insurance representa tives will be willing to support accident pre vention activities at all levels. Insofar as their resources will permit, they will con tinue to assist industry to become an even safer place in which to work The following material is quoted from the proceedings of the March 1949 Presi dent's Conference on Industrial Safety. This gives some indication of the part played by Insurance Companies and Insurance Asso ciations. "We visualize a two-fold concept for the providing of accident prevention service to industry by insurance companies and insur ance associations: 1. Services originated and offered directly to industry solely by the insurance carriers. 2. Services developed by insurance asso ciations and made available other directly from the associations or indirectly to in dustry, through the association members. In each of these two areas, consideration must be given to services presentable to the small business whose insurance premium is not great enough to support the cost of technical assistance. We must accomplish our aims by follow ing these steps: (a) Review of the insurance accident prevention services available to industry-- emphasizing the small plant (b) Collecting-recommendations on acci dent prevention services desired from in surance companies and associations. (c) Analyzing and correlating this mate rial. ~ ---- (d) Deriding which areas can best be developed by the insurance companies, by the association, or both. This brief form serves to outline our approach to the problem. It is detailed as follows, each step to be considered solely in terms of its relation to insurance com panies and association services, with em phasis on the small plant (a) The coordinating of results obtained by other committees of the President's Con ference, which can be distributed by or 129 y. /7A VI \ s. 1958 National Safety Congress employed in connection with insurance serv ice. (b) The means for attacking the human problem as the cause of accident 1. Training (supervisory and employee). 2. Proper job placement to insure the success of the worker (handicapped and normal). 3. Education (differentiated from train ing; referring to visual aids, posters, meet ings, publications, lectures, radio programs, etc) accenting human interest approach. 4. Psychological. 5. Organization (methods of forming and duties of interplant service committees). 6. Coordinating of plant safety activities. (c) Inspection and engineering--recom mendations for standardization in guarding and compliance with existing standards. (d) The convincing of industrial manage ment and supervisory personnel of the need for and importance of accident prevention; for example, by simplifying information on insurance costs and their relation to acci dents. (e) Accident statistics (their value, how to maintain them, and their use). (f) Study of incentive reward plans based on accident experience. (g) Recommendations of agencies con cerning methods that might be employed to supplement insurance company services. THE SAFETY ENGINEERING PROFESSION By JOSEPH C. STENNETT Dir., Accident & Fire Prevention, National Association of Mutual Casualty Cos., Chicago, HL Delivered by EDWARD B. LANDRY Safety Director, U. S. Postoffiee Department, Washington, D. C. It is with a great deal of pleasure that I represent the American Society of Safety Engineers at this important meeting--to participate in a joint effort to evaluate the past in order to make "Decisions for the Future." This is an opportunity to estab lish new goals, to set new sights and to re activate projects that remain to be done. Many members of our society believe that a meeting such as this one has been long overdue. The American Society of Safety Engi neers is an organization of 7,500 profes sional safety engineers with a grass roots organization of 69 chapters located in the large industrial population areas of this country; it also has members in many foreign-`countries and chapters in Canada and Hawaii. The Society is composed of dedicated men banded together for two principal objectives: (1) To promote the conservation of life and property through accident prevention, and (2) To encourage the development of safety engineering as a profession. It was only natural for the society and for its individual members to take a keen interest in the President's Conference for Occupational Safety from its inception. Members served on the planning and steer ing committees and on all technical and other committees; they participated in the programs of each of the conferences and cooperated in the preparation of reports. In fact, a large percentage of the delegates at each of the conferences and more than half of the membership of many of the com mittees were members of the ASSE--and in 1954, members of the society served as chairmen of six of the seven technical com mittees. Yes, the American Society of Safety Engineers had had a large stake in the President's Conferences and had a great deal to do in drafting conference reports and recommendations. The society is vitally in terested in the implementation of the con ference recommendations on which so much time and effort were spent In 1954, the President's Conference on Occupational Safety was composed of seven technical committees essentially the same in 130 Industrial Safety scope is those in the previous conferences. Hence, the 1954 proceedings contain an 8-year consolidated report of these com mittees and include approximately 130 rec ommendations in the seven different areas. It is my understanding that today we are to evaluate the progress made in imple menting these recommendations--and to plan for the future! Broadly, the recommendations covered the fields of (1) research, (2) community safety, (3) government services to industry, (4) public employee safety, (5) safety edu cation, (6) engineering and (7) accident records. I am happy to report that the society has had active projects in most of these areas for many years and some were developed before the President's conferences were established. The ASSE continues to carry out many projects in these fields of activity'. For example, it has completed, in coopera tion with the National Safety Council, a number of important research projects. The society has also developed others yet to be done. It has conducted a broad program of education, especially in engineering colleges and universities--and has extended, through its chapters. Industrial safety institutes. En gineering training and foremanship training programs. Tt the area of community safety many chap.ers of the society have cooperated in local community safety projects. For ex ample, the voluntary inspection by ASSE members of public and private schools for safety and fire hazards. It has devoted much time in the prepara tion of technical information for accident prevention, most of which has been made available to the National Safety Council for publication. The society has also assisted in developing many American Safety Stand ards. ASSE has been of service to city and state governments in setting up accident records and statistical analyses--and in some localities, chapters on request, have assisted in setting up safety programs for public employees. The society is proud of its accomplishments and recognizes the urgent need to continue its efforts to further the common goals of accident prevention. Plans for the future will be materially more effective if they are tempered by the experiences of the past The American Society of Safety Engi neers, during the past year, has given serious thought to its role as the official representa tive of the safety engineering profession, in the President's Conference on Occupa tional Safety. The evaluation of the resources and capa bilities of the American Society of Safety Engineers, as well as consideration of its responsibilities to the safety engineering profession have resulted in the identification of the following "Decisions for the future: 1. Expand and intensify activity in all of the society's program areas which par allel recommendations of the President's conferences. 2. Realizing that the solution to most safety' problems is attainable only at the grass roots level, the ASSE will concen trate efforts to give leadership and to co operate with other agencies in organizing community safety organizations in locations without such facilities and give additional and more inspired leadership in those com munities where safety organizations have become weakened or otherwise require stim ulation and assistance. 3. By research or by other means deter mine the personal and human factors in occupational accident causation and pre vention,--through studies of people and work places--through design of machines and work areas--through new methods-- through job analysis and job requirements-- through studies of employee selection and placement as well as environmental influ ences in relation to physiological and psycological characteristics of people--determine information and find methods for wide dissemination and use of such safety knowl edge. 4. Study and evaluate the peculiarities and variables in the organizations methods, procedures and techniques of accident pre vention programs from the viewpoint of determining the essential components and most important details of successful safetyprograms for particular situations and also to determine the deficiencies and weaknesses of unsuccessful programs. 5. Develop better methods and improved media for achieving wide dissemination and application of present available knowledge of occupational accidents and to study and evaluate available safety services to industry- 1958 National Safety Congress 6. Maintain increasing emphasis to im prove the professional development of the safety engineer by appropriate professional training programs and by other means such as professional registration. 7. Develop a career selection program to attract young people to the safety engineer ing profession in order to meet the increas ing demands for professionally qualified personnel not only in the basic business enterprises but also to meet the newer technological developments in the nuclear energy and space age which is now un folding. 8. Accelerate the society's program of cooperation with other engineering and pro fessional societies to the end that these or ganisations will have a better appreciation of the signficance and import of the integra tion' of safety engineering into their areas of activity. These are the Decisions for the future-- for which the American Society of Safety Engineers feels it is in a position to con tribute and to exerdse leadership. Before dosing, we wish to present one more decision for the future--a decision which we hope will meet with general acceptance. This is of vital interest to all of the partidpating groups of the Presi dent's Conference on Occupational Safety. 9. An objective study and evaluation should be made of the organizational struc ture of the President's Conference on Occu pational Safety. It is the considered judg ment of many of the leaders in the safety engineering profession that there is a press ing need for a continuing top-level policy committee, appointed by the President of the United States, representing business, labor, government, the organized safety movement, and the safety engineering pro fession. Such a top-level policy committee, com posed of national leaders in each area, would serve the important and necessary function of prodding continuing direction jki the objectives and action program of the President's Conference on Occupational Safety. This is not an untested concept. Such an organizational pattern has been suc cessfully functioning for several years in the critical area of combatting the national traffic accident problem. Industrial Safety THOSE WHO CAUSE LARGE LOSS INDUSTRIAL FIRES By CHESTER I. BABCOCK Manager, Fire Record Department, National Fire Protection Association Last year 41,000 industrial fires caused continually worsening record of bad in property damage totalling $232,000,000. Of dustrial fires. these 41,000 fires, only 161 accounted for $106,000,000 loss or 46 per cent of the total loss caused by all industrial fires. Who are these people? They are the plant owners, operators or safety directors whose responsibility it is, whether they know it or These few fires, with individual losses not; to protect their properties against seri ranging from $230,000 to $14,000,000 are ous fires. They fall conveniently into three the ones that dose down plants, put people groups. out of work; unsettle insurance company reserves and disrupt our national economy which depends on continuous and ever ex* panding production for its existence. One includes those who have never given fire protection more than lip service or even completely ignore it, possibly under the il lusion that an- insurance- policy premium Is it any wonder, then, that the large solves all their fire problems. loss industrial fire has beat the subject of continuous study? We must find out what causes these fires and cure our country of this economic disease. A second group includes those in positions of authority who realize they'd better do something along the lines of fire protection but; because of lack of understanding of Almost from the day the NFPA was the complexity of the problem or, because of founded more than 62 years ago, large loss lack of proper guidance, make certain ges industrial fires have been the subject of ex* tures in the direction of fire protection that haustive study. What have we found to be may stop one or two holes in the wall of the causes of these fires? We've found all fire defense but leave others unmended. They sorts of things--weaknesses in fire-safe de fail to recognize that fire defense is no sign of buildings, such as open stairways, defense unless it is complete. This is a excessively large fire areas, highly com pathetic group that wants to do the right bustible interior finish; we found that other thing but doesn't know how. large fires are caused by substandard or non existent fire protection--improperly main tained sprinkler systems; substandard watch men and a lot of other fire protection fea tures which should be well known to every man responsible for plant fire protection. Then there is the third group. This in cludes those in authority who have looked beyond the insurance policy to the fire pro tection standard. They have provided protec tion which on paper appears to be adequate in all respects, but in so doing have over It you are interested in a review of these looked the fact that fire protection rec and the other factors responsible for last ommendations invariably depend upon one year's large loss industrial fire experience- or more .people -somewhere along the line if see the April 1958 issue of the NFPA the protection is to do the job assigned it. Quarterly. Automation in fire protection is still a long But underlying all these factors responsible way from a reality. for large loss industrial fires is one primal Let's take a look at some of the large loss cause--people. Every one of these factors, industrial fires of last year to see just how and consequently every large loss fire, is people go about it to cause this fire waste. caused by some person--and it is these per The first group, you will recall, includes sons that I want to talk to you about today'. those who, for one reason or another, com These people are the cause of our dis pletely ignore fire protection. You all know graceful annual record of large industrial of some such individuals--and I don't plan fires and it is these people that must be to dwell on them at length, but since they helped if we are going to put a stop to the are responsible for more than half of our 1958 National Safety Congress bad industrial fire experience, they certainly demand first mention. The man responsible for a $283,000 feed mill fire in Madera County, California, is typical of those plant operators who, for all intents and purposes, have never heard of fire protection. Local papers labelled the cause of the fire a mystery but, to anyone who took the trouble to investigate the facts, the fire was no mystery. It became abundantly clear that it was caused by the person in authority at the mill who per mitted it to exist without sprinklers, watch man or any other form of private fire pro tection, despite the fact that the mill was Lcated 18 miles from the nearest fire sta tin. The fire broke out after the plant had closed for the night and was out of control when discovered at 3:15 a.m. A lumber mill fire at Palmyra, N. is typical of those that are caused by-people who give lip service to fire protection but for all practical purposes ignore it. Al though the proprietor of this plant did make the gesture of providing watchman protec tion, it turned out that the man he hired for the job suffered from palsy. This so handi capped his speech that in the excitement of discovering the fire he was unable to tele phone the alarm. The fire was later dis covered by a passing truck driver. Excessively large areas that should have been subdivided by division walls were among the factors responsible for 55 of the 161 largest IT. S. industrial fire losses last year. One example was a tire recapping plant in Columbus, Ga. The fire originated at a barrel of rubber cement solvent in the 1story section and after enveloping the 1story section spread through doorways to the 4-story section. A hasty decision might place the blame for this fire on the employee who wasfrying to fix a leaking faucet on the solvent drum when the fire started. But a little more thought would show that the responsibility clearly lay on the man who was so blind to fire hazards that he was willing to conduct Ins hazardous business in an unsprinkled building and did not recognize the im portance of separating the 1- and 4-story sections by installing fire doors in the inter vening wall and by bricking up windows in the expose side of the 4-story section. Before leaving this fire I should comment on the construction of the 4-story section. This building, although reported to be of "fire resistive" construction, demonstrated the fundamental principle that the fire load of a building must be taken into consideration when determining adequate fire resistance for structural members. In this instance columns and girders were insulated with two inches of concrete, and floors and roof slabs were 3j4-incb reinforced concrete. Since the upper stories of the building were loaded prin cipally with rubber tires and rubber re capping material, it is not surprising that parts of the roof and two upper floors collapsed. I wonder what the directors of a Key stone, S. D., feldspar plant were thinking about when the subject of fire protection came up. Perhaps they glanced at their in surance policies and passed on to the next item-mtheagenda. Tire fire originated in a small shed containing an oil-fired hot water heater. It was discovered by an employee without.appretiable delay, but in the absence of a cut-off between the shed and main plant, and due to the complete lack of pri vate fire protection, the fire spread from the shed to the communicating main build ing. The only water for fire department use was a shallow creek. This was frozen solid. Water carried on apparatus from neighboring towns froze on the way to the fire. Perhaps we should have more compassion on the directors of this plant Perhaps it was too cold to think clearly about the possibility of fire. So much for examples of that group of industrial plant people who caused large loss fires last year because of ignorance of the value of fire protection or lack of in terest in it It is safe to say that, because of their experience, this particular group oilpeople^now know that fire is something they cannot afford to have and will take steps to prevent a recurrence. But what wilt they do? Will anyone offer them the sound advice needed for complete fire protection? Or will they advance only to membership in the second classification of plant management-- those who, because of lack of understand ing or guidance, fumble in the dark, so to speak, do a partial job, and leave weaknesses that may combine to cause another disastrous fire for some future year's record. 134 Industrial Safety Here are some large loss fires caused by The owners had failed to cut off the people in this second group. boiler room from the rest of the plant and The management of a tractor assembly plant at Baraga, Mich., did do some thinking about fire. In fact they decided they would solve all their fire problems by permitting the local volunteer fire department to house its engine in a partitioned-off corner of the as* had neglected to install sprinider protection. Fed by several thousand gallons of oil escap ing from the broken pipe the fire spread rapidly from the boiler room to the com municating main building and was out of control when firemen arrived. sembly plant They also agreed to have the village fire siren mounted on top of the building. A person across the street discovered the The stories of some of these fires would be laughable if it weren't for their disastrous results. One plant was destroyed despite good watchman protection because the boiler room are at 6 p.m. He tried to operate the fire siren, only to discover that it had already been put out of order by the fire. He then was stymied in his efforts to get the fire was not cut off from the main building. At a furniture factory at Fort Smith, Ark., the operators did nothing about watchman pro tection but apparently they had heard that station door open to get at the engine. During the next IS minutes while unsuccessful at tempts were made to rescue the engine, the small fire areas mean small losses, since they subdivided their 250-ft-long building into three sections with two parapeted fire partitioned-off fire station became enveloped in flames. The fire department of aneighboring town was then called. A $430,000 fish cannery fire occurred at Anacortes, Wash, last November and was beyond control when discovered by an out sider at 5:55 a.m. Why was the building destroyed ?--Because the owners were willing to leave the building without watchman or automatic fire alarm protection during the night, and because they chose to drain the sprinider system to prevent its freezing, rather than make certain changes in the system that would allow it to remain in oper ation without freezing during the winter months. A shirt factory at Souderton, Pa, was swept by a $925,000 fire last year. Word ap parently had filtered through to manage ment that fires must be discovered promptly if the fire department is to have a chance to bring them under control, since they' hired a night watchman. They forgot about Sun days, however. The fire was beyond control when discovered one Sunday morning by a~ neighbor, about an hour after the night walls. The fire originated in the middle section during the night. In the absence of watchman or automatic protection it is not surprising that it was through the roof before discovery by a passerby. Nor was it surprising that the fire entered and destroyed an adjoining section when it was learned that the fire doors in the division wall had been allowed to be blocked open. One of the most pathetic incidents in last year's large loss fires was a $2,400,000 fire in a Cleveland paint factory. I won't go into the details of the fire except to say that it started in the basement where cartons of filled paint cans were stored, and spread quickly to communicating sections through unprotected openings and to upper stories through chutes and other vertical openings. The saddest part of the story is the fact that management had recently accepted the advice of professional fire protection engineers and had agreed to install complete sprinkler pro tection-. The fire occurred before the system could be installed. watchman had gone home. Seven paper-making machines were de The owners of a washing machine as stroyed in a $5,000,000 fire at Comerbrook, sembly plant at Greenville, Ohio, provided Newfoundland, last year. From outward ap a supervised night watchman, and apparently pearances the fire protection appeared ade went to bed each night confident that they quate to prevent any fire serious enough to could never have a bad fire. The watchman cause a shutdown. Among other things there did as was expected of him--discovered the was a trained fire brigade, the paper machine fire promptly after an oil supply pipe to the room was sprinklered, deluge sprinklers pro oil burner broke in the boiler room. And yet tected driving gears on the machines and the fire eventually levelled the plant and there was a two-source water supply for caused $660,000 worth of damage. Why? sprinklers and standpipe hoses. 135 A ! iv. 195S National Safety Cotigress Then a fire broke out at the drier end of up adequate fire prevention and fire pro one of the machines that quickly exposed tection programs, do just about averything two serious weaknesses in the protection. The you or I could ask, and then, because they first showed up when burning paper fell neglect to keep their defenses up, in other through a floor opening and ignited loose words, permit a slight relaxation of the paper or broke in the basement beneath the maintenance program or let up a little in machines. Since sprinklers had never been training employees, allow hidden cracks to installed in this basement, the fire spread develop in their plant's protection that only rapidly and was soon coming up through show up after a fire occurs. floor openings under the seven paper ma chines. An example is the fire protection at a drug factory in Linden, N. J. Three men The deluge sprinklers operated but these lost their lives when a vacuum still ex only protected the driving gears and the ploded last year. The explosion is believed fire spread to the unsprinklered hoods over to have occurred because a small amount the machines and then to the wood roof of caustic that had been used to dean where several hundred sprinklers opened. apparatus had been allowed to remain in the It was then that the second serious weak equipment. Careful attention had been given ness in the fire protection showed up. It to fire and explosion prevention at this plant had to do with the water supply. A connec and there was no skimping where fire pro tion to a 12-inch city main and three fire tection was concerned. Yet this explosion pumps should have been able to supp[y~the - occurred--killing three employees and caus deluge and regular sprinklers but did not ing $270,000 damage--all because of one because more than 800 domestic and process little slip-up. connections also took water from the fire A plastics manufacturing plant at Pitts main, and the suction supply for the fire field, Mass., had a somewhat similar ex pumps' was not adequate when the three perience. An explosion in a reaction kettle pumps were operating simultaneously. The plant fire brigade was unable to use stand pipe hoses until after deluge valves were closed. The brigade was then able to attack and control the basement and root fires. killed three employees and caused $500,000 property damage. The operators of this plant had not spared expense or effort in their desire to avoid such a disaster, yet it oc curred because somebody apparently added In a tenant manufacturing building fire in New Haven, Coiul, last year, 15 lives were lost and property damage totalling $325,000 resulted. On the plus side, the building had too much catalyst or added it at the wrong time. Perhaps some employee had forgotten the importance of handling catalysts in just the right way. a central-station-supervised automatic fire alarm system, but on the negative side there was no sprinkler protection, rubbish was al lowed to accumulate in the hallways, self closing doors to the main stairway were A fiber pipe plant at Orangeburg, N. Y. was sprinidered, manually operated open sprinklers were installed at pitch impregnat ing tanks, a good supply of portable ex tinguishers was on hand and employees had blocked open and employees had not been taught how to release the latched up-swing ing lower section of a fire escape stair. been taught what to do in case of fire. Then a fire occurred at a pitch tank. Employees at tacked it with dry chemical extinguishers This New Haven case is the last^one I shall cite as evidence that a substantial number of bad industrial fires are .caused by people who recognize the need of fire protection but through lack of proper guid ance have failed to do the job properly. and bad it practically out when they ran out of extinguishers. What about the open sprinklers? No one thought to turn them on. The fire spread to the roof and had soon opened so many sprinklers as it spread over pitch residues that the water supply was These people need help, and what's more, overtaxed--another case where fire protec they have demonstrated by their willingness tion collapsed because employees were al to do something that they would be amenable lowed to forget one part of the emergency to suggestions as to how to do the job right procedure. The third group of people responsible for What better illustration is there to close bad industrial fires include those who set our discussion of fires caused by people in 136 i fi~~\proa Jhing xauae they P, in other on of the a little in cracks to i that only aion at a Tiree men still exs believed 11 amount to clean ain in the >een given this plant fire pro explosion and caus: of one at Pittsailar ex on kettle $500,000 this plant in their st it ocly added e wrong or \n > L. .at x. V. id open pregnatble ex ecs had e. Then yees atruishers ran out : open tem oa d soon td over ly was Industrial Safely this group than a $14,000,000 rubber re claiming plant fire at Butler, N. J.? Those responsible for the fire protection at this plant apparently had taken all the steps neces sary' to protect the plant against a serious fire. It was completely sprinklered with a good water supply, a steam smothering sys tem protected the rubber drier, there was a standpipe hose system and a trained plant fire brigade. The fire originated in the drier, and flames bursting from openings ignited lint and dust on building members overhead. The fire pro tection immediately took over as scheduled --the steam smothering system and sprinklers operated and the fire brigade went into action --when the hidden flaw in the protection showed up. You know the story. An employee who had run to the street to pull a fire alarm box heard what he thought was a shout for water. It was dark out He checked the post indicator valve in the yard controlling sprinklers, and not being aware that this particular valve was one of a few lefthand valves at the plant, dosed it under the impression that he was opening it There after die fire spread beyond control. There aren't very many bad fires in this category and that's to be expected since the fire protection in these plants is in the hands of people who insist upon a superior grade of protection--far above the average. The few cases that do show up each year, how ever, emphasize that a plant fire protection engineer can never drop his defense for a moment He must be ever on the job to seek out hidden hazards and to be sure that the protection he has provided will not fail because somebody else slipped up. The plant fire protection supervisors in this third group warrant our sympathy but I doubt if they can. use our help. They know., their problems and how they should be solved and only they can know whether they themselves have done everything neces sary- to assure good protection when fire occurs. So there are a few cases from last year's large loss industrial fires to demonstrate my contention that bad fires are caused by people. I am sure you know this as well as I, but I do feel that in our efforts to spare people's feelings, particularly people who have experienced a disastrous fire, we fail to make it clearly understood that although the fire was caused by one or more fire protection weaknesses, some person allowed these weaknesses to exist Now, the purpose of this talk is not to point the finger at individuals. My purpose is solely to point at the fundamental cause of bad fires so that our efforts to prevent them can be directed more effectively. For I do feel that the fire protection program fails so often in its objective because the human element is not sufficiently appreciated. Bad fires. .are not .caused by any serious deficiencies in the science of fire protection. The trouble is with the way men think about fires and fire protection and unless we keep this point continually in mind we have little chance of making real progress in putting a stop to this needless industrial fire waste. What does this mean to the fire protection engineer, to the plant safety supervisor, to the public fire official, to all of us who are trying to lick this problem? It means just this: In addition to our knowledge of fire protection, we must also be skilled as teachers, psychologists and dip lomats. For the basic task is to change the thinking of the plant owner or manager-- to convince him that fire protection is his responsibility and-must have his full and continuous support To accomplish this goal may require all your powers of persuasion, but once he is convinced, the rest wil1 be easy. You will now have a sympathetic and willing ear for your fire protection recommendations, and you will have the assurance that fire pro tection will be an important and continuing activity in that man's plant 1958 National Safety Congress PORTABLE FIRE EXTINGUISHERS --A CHANGING PICTURE By DALE K. AUCK Director, Fire Protection Division, Federation of Mutual Fire Insurance Companies Chicago, I1L Unfortunately, fire and its resultant loss in property, lives and jobs seems to be a part of the cost of doing business in our na tional economy. Why there isn't a line on the balance sheet of every plant for this fire cost item has always been a mystery to me. I suppose you could construe the expense item of fire and business interruption in surance as the "fire" item of the balance sheet but that is only part of the whole story--insurance merely endeavors to lessen the economic shock suffered by a company that has had a fire. It is not a'panacea or a cure-all or a substitute for adequate fire protection. Modern merchandising and industry* has a very tangible stake in the American econ omy. A conservative estimate of its worth would be in the neighborhood of $165 bil lions of dollars. That is a lot of money even to us blase Americans when it is ex pressed in terms of our present day dollars. I didn't pick this $165 billion figure out of thin air. The U. S. Department of Com merce publishes annual estimates (by states and counties) of the assessed valuation of non-farm residential, farm, mercantile, and industrial property. These are the valua tions for taxation purposes. Another group within the same governmental agency is constantly studying the ratio of assessed valuations to current sales prices, also by states and counties. By taking the state totals of assessed valuation and sales prices, I arrived at the alleged sales price of all industrial property in the country for 1956 and that came to $165 billion. That figure does not include the industrialization of any tax-free facets of industry nor does it include any indus trialization within the armed services. They'd make it much higher than $165 bil lion. The National Fire Protection association recently reported that in 1956, industry suf fered 38,300 fires within industrial struc tures--that's 5 per cent of all structural fires occurring that year. The dollar loss for them was $207,500,000--that's 20 per cent of the total structural fire loss for that year. Last year, there were 125 "large loss'* industrial fires that caused $97,700,000 loss. (A "large loss" fire is one where the loss exceeds a quarter of a million dollars.) Thus we begin to get the overall picture of "flaming" industry. Modem industry has been pretty well schooled to act promptly in times of fire emergency--the first thing they are taught to do is "call the fire department," whether it be the local plant fire brigade or the municipal tax-supported fire department. It takes an interval of time for any fire department to arrive on the scene and begin fire fighting operations. An old axiom, true regardless of its age, is that the first five minutes of work on a fire are more important that the next five hours of fire fighting. All fires start out in life as lit tle fires--if they can be caught then, the fire extinguishment job is correspondingly small. So, what to do until the fire depart ment arrives? The answer lies in another old axiom-- "The Lord helps those who help them selves". Who is present when the small fire starts during working hours? The employee. Who is present when the small fire starts after working hours? The se curity force. What of the plant that has no watchmen or guards for the night period? They need either a good dependable automatic fire detection system or the prayers of the faithful. They're really vulnerable. What can this employee or this security guard do when fire starts? He can use a portable fire extinguisher, provided a suit able one is available and he has been trained in its correct usage Employees in industrial plants have a stake in industry also. If their plant has a serious fire they face the possibility of an immediate layoff until the plant is rebuilt. 138 >mpanies foliar loss :'s 20 per : loss for 125 "large 597.700.000 where the i dollars.) ill picture etty well is of fire re taught ' whether e or the rtuient any fire uid begin 1 axiom, the first ire more s of fire e as litihen, the ondingly axiom-- p themie small ? The ie small The sehat has e night ?endable or the ; really security a use a a suits been have a wt has >* of an rebuilt. Industrial Safely They also face the potential possibility of not having any job at all because the fire has caused the firm to lose many customers during the rebuilding time and thus cur tailed production. Note the limitations I imposed on the em ployee a moment ago--they're the keynote of this talk. Let's talk about several words --"suitable", "available", "trained" and "usage". Now everything in the world seems to go hand-in-hand with its opposite. We have male and female, high and low, good and bad. So it is with portable fire extin guishers. we have good and bad, approved and unapproved. So we need a yardstick w measure them to determine if they're good or bad. tt'e have such a yardstick--it has two pans. The first part is the Technical Com mittee on Portable Fire Extinguishers of the National Fire Protection Association. They are an aggregation of technically qualified engineers from fire equipment manufacturers, rating bureaus, testing lab oratories. industry, fire departments and in surance companies. They have published a standard for the performance of good fire extinguishers. Based on this standard, the second part of this yardstick comes into play. The three nationally-recognized fire protection equipment testing laboratories relate this standard into criteria of manufacture to insure the required performance. The manu facturers of repute of fire extinguishers submit their products to these laboratories for checking and testing. If the extinguisher unit meets the criteria of the labs and test shows it meets the performance desired by the standard, the manufacturer is per mitted by the labs to attach a brass label to each unit manufactured that shows it is "approved" and-is "listed" in their list of worthwhile protection devices. Insurance companies and fire insurance rate making bureaus will recognize ONLY fire protection equipment with an Under writers' Laboratories (US & Canada) or Factory Mutuals Laboratories label on it There may be others of equal worth but we who write the liability on the plants and pay the losses most be assured of the in tegrity of the protection device and we recognize only these two laboratories in this regard. The standard which the NFPA technical committee has prepared is known as NFPA phamplet No. 10. An industrial safety man or fire protection engineer cannot function efficiently in the best interests of his em ployer unless he has procured and has read and understands this pamphlet At the point of being trite; condescending and insulting your intelligence, I must state the basic fundamentals of the fire tri angle at this time--whenever you have a burnable substance, the heat equivalent of the substance's ignition temperature, and air, all present in the same place at the same time, you cannot avoid having a fire. Conversely, if you want to extinguish that fire, merely remove one, any one, of the three constituents causing the fire. Fire extinguishment is very simple--you either . remove tht_fuel from the fire, you coo! the burning material down below its ignition temperature or you exclude air by smother ing the blaze. There are three fire and extinguisher classifications, again very simple. They're A, B, and C. "A" fires involve ordinary combustible materials where the coolingquenching effect of quantities of water solu tion are most effective. "B" fires are those involving petroleum products, flammable liquids and greases where the smothering or oxygen-excluding effect is best suited for fire extinction. "C" fires are merely "A" or "B" fires involving "live" electricity and thus the extinguishing medium must be a nonconductor of electricity to protect the user from electrical shock. Now that wasn't very hard to take, was it? Just 3 lands of fires. A, B and C Just 3 kinds of extinguishers. A, B and C. All you have to remember is to use A units on A fires, B units on B fires and so on. Tins pretty well sums up what we meant by "suitable" in our original thesis. Now let's talk about the word "available." Obviously this means that management has to buy and install some fire extinguishers so that they are available but what kind shall they buy, how* many are needed, what size is best, and how shall they* be dis tributed? Down in the comer of the testing lab oratories label it says that this extinguisher is classified as "4A,6B'' or "10A" or "6B,C" or some other cryptic designation. We have 1958 National Safety Congress already discussed the A, B and C To digress for a moment at this point, The numeral is indicative of the approxi this 2J4 booger factor should give you in mate relative fire extinguishing potential of dustry men a due to good fire protection the unit For instance, a 4B unit will ex and the best argument you can advance to tinguish twice as much fire as a 2B one will, management for having a good trained fire \ or it will extinguish only half as much fire brigade in your plant. Suppose you deter as an 8B unit wilL Thus the numeral ex mine that a certain hazardous area needs presses a ratio or relativity of one unit when an 8B unit. You install one there. That compared with another of the same letter means that an UNTRAINED employee can classification. use it and be reasonably sure to extinguish Class C extinguishers have no numeral the fire that required the 8B unit. Bui; if shown. The size of the Class C unit pur your men in your fire brigade are trained in chased should be commensurate with the size and extent of the area involving the electrical hazard or containing electrical equipment to be protected. The type and the degree of enclosure of electrical equip extinguisher usage, that 8B unit has the inherent potential of extinguishing 2J4 times the amount of fire that may occur in that area. That gives you plenty of reserve ex tinguishing power. ment is also a factor. Who says that training doesn't pay off? How did the testing laboratories ever determine what numeral an extinguisher should have? Their - determination was based upon actual fire tests. They con structed a series of square fire pans of heavy metaL These pans had surface areas of 2*J sq.ft, 5, 10, 15, 20 and on up to 100 sq.ft They were all filled with water to die same depth, they all bad a certain number of inches of gasoline floated on that water, they all had the same number of inches of bare metal sides above die gasoline surface. Let's imagine a 10-lb. dry chemical unit was up for test The 2$4 sq.ft pan was first ignited, allowed to burn for a specified time, the unit was applied and the fire was extinguished before the extinguisher became exhausted. Then the 5 sq.ft pan was fired and extinguished, and so on until a pan was reached which could not be extinguished by Now before you can determine bow many extinguishers you should have to adequately protect a building or a portion thereof, you must determine what class of occupancy you want to protect. Is it a light hazard such as offices, class rooms or libraries? Is it an ordinary haz ard structure such as a manufacturing build ing, metalworker or a warehouse? Does it contain extra hazard occupancy such as paint spraying, flow coat dipping or wood working? You may even have a building where all three types of occupancy are present In that case, you must determine which is the predominant one and its degree of cutoff from the rest of the building and base your extinguisher coverage on that in creasing the coverage in those portions of higher occupancy hazard. die total content of the extinguisher. In The reason you must make this occupancy the 10-lb. dry chemical size, this usually was determination lies in the fact that it de the 25 sq.ft pas, so they went back to the termines two things; Le. the travel distance successful extinguishment on the 20 sq.ft to the nearest extinguisher and the floor pan as the unit's limit space that each unit will protect They_ then divided, this 20 sq.ft by a factor of 254 and this gave the numeral 8. The extinguisher was then rated as 8B. How you ask, where did they dig' up this 2J4 factor? Thor call it a "booger factor". By actual test they found that a trained fire laboratory engineer could extinguish 2$ times as much fire as could an untrained person who bad never operated an extin guisher before in his life. They actually tried this out numerous times, taking the "man in the street" and letting Jam put out test fires. In speaking of Class A extinguishers, the standard states the following: Light hazard occupancies 100 ft travel distance 2500 sq.ft per unit Ordinary hazard occupancies 50 ft travel distance 1250 sq.ft per unit Extra hazard occupancies same as ordinary hazard, plus ad ditional ones as determined by authority having jurisdiction. 140 Industrial Safety In speaking of Class B extinguishers, the Standard states the foliowing: There is no light hazard B occupancy. Ordinary hazard B occupancy 50 ft travel distance 625 sq.ft per unit Extra hazard, deep-layer flammable liquid fires, as in dip or quench tanks, use 1 numerical unit of B extinguisher for each square foot of dip tank surface: Now things begin to get a bit complicated, i don't expect any of you to remember every last item I talk about from here on --I respectfully recommend to you a de tailed study of Pamphlet No. 10. However, 111 mention a few items for Hi<a-nc<nnn Many times Class B hazards are con tained in Class A buildings. In establishing - the number of extinguishers-aecessaxy, you must provide for the building's protection first If it has 10,000 $q.ft of floor area and is of ordinary combustible construc tion, you need 10,000 divided by 1250 or 8 units of "A" extinguishers. If the oc cupancy therein is all spray painting (an extra hazardous occupancy) you will need 10,000 divided by 625 or 16 units of "B" extinguishers. An ordinary 254-gal. sodaadd unit is rated as 2A so you would need 4 of them to get a total of 8A extinguishing potential. An ordinary 254-gal foam ex tinguisher unit is rated as 4B so you would need 4 of them to get a total of 16B ex tinguishing potential. If you don't like foam, you could use four 4B 10-lb. CO* units or ooe 16B 20-lb. dry chemical unit. However, the standard states that an extinguisher carrying BOTH A and B classifications can be accepted for area requirements under each individual letter classification. Now a foam unit of 256-gal capacity has such a dual designation, it's 2A.4B. Thus 4 such ' 254-gat foam traits wtgsld do"the trick, they're good for four times 2A or 8A build ing protection and also four times 4B or 16B occupancy protection. When you have a dip tank in the area, you do essentially the same thing--you de termine the A units needed to protect the structure and the B units needed for so many square feet of surface area of the dip tank. Of coarse, if there happens to be some extensive electrical equipment in the B area, you may want to use units hav ing both a B and C classification. Believe me, no matter how you write these rules, it can be a bit complicated in this actual determination of extinguishers. Maybe the best way is to throw the prob lem back to the fire insurance rating bureau having jurisdiction in your state and let them tell yon how many yon need to get an extinguisher credit in your insurance rate. I know the question you're going to ask me now--it is "Why did the NFPA com mittee establish such a complicated set of rules to determine what should be a very simple thing?" They, too, had a reason. Prior to 1955, we had only a few classifi cations of A and B extinguishers. They were A-l .or A-2, B-l or B-2, C-l or C-2. The labs had only one test fire for each class. If an extinguisher put out the A fire, it was A-l, if it didn't, they called it A-2 meaning it took 2 of them to do the job. That was fairly good until some sharp engineers with some of the extinguisher manufacturing concerns started to improve their extinguishers. In the pre-'55 days, CO* and dry chemical units were compar able; they both got B-l classification in any thing above the 5-Ib. size. But good design and better applicators, together with im proved dry chemical soon had the dry chemical units engineered to the point where they were putting out twice the amount of fire as did the same sized CO* units. However, these improvements cost money and the price of the dry chemical units was slightly higher than die CO* units. Since both types of units had the same B classi fication and since both types had the same* square footage criteria, it was obvious that when one recommended Class B protection for a hazard, management would buy the less expensive type regardless of the fact that for a few dollars more they could get uruts having twice the extinguishing power. Further in considering only one class of extinguisher, say the CO* class, all units above a certain size merely had a B-l classification and there was no incentive for management to buy the larger units which the increasing hazards of our modem tech nological advancement were bring brought into consideration for protection. Thus, the NFPA committee establishing the standards for fire extinguishers had to develop a formula that would recognize the differences in extinguishing potential and 1958 National Safety Congress extinguishing efficiency rather than a mere designation as to type of extinguishing media. That alone is the reason for the revised fire extinguisher standards today. Many of you have extinguishers presently in your plants that were purchased prior to 1955 and which have the old A-l, B-l classifications on their laboratory labels. In order to meet the requirements of the new standard, you must know how to evaluate these old classifications in the light of the new classifications. In the appendix to pamphlet No. 10 is a list of all types and kinds of fire extinguishers manufactured. Each has its old and new classification in dicated and it is an easy job to relate vour old units to the criteria under the new standard. That's just another reason why you must have Pamphlet No. 10 in your library--yo"can't get along'Without it Another facet in the changing picture in fire extinguishers is the recognition in the new standard of the difficulty in extinguish ing metal fires, a product of our expanding technology. Fires in magnesium, calcium, zirconium, lithium, sodium and potassium are really tough ones to control. Normal ex tinguishing agents are not too effective, the extinguisher industry must come up with some new answers to this problem. Present day extinguisher units may intensify these fires rather than subdue them. Specialized techniques are under development and if you have these hazards in your plant, you should sit down with reputable manufac turers and let them advise you what is the best they have to offer at the moment Another facet in the changing picture of fire extinguishers is the new requirement for the hydrostatic testing of extinguisher shells. Most units should be so tested to not less than 300 psi or more than 350 psi every --five years they have been in service. Certain ones that have not been subjected to the five year test required by the ICC must be tested at 12-year intervals. Extinguishers which have been physically damaged by dropping or have had their shell deformed by any means need to be hydrostatically tested. It should be kept in mind that extinguishers develop considerable internal pressures as a result of chemical interaction or release of stored pressure in side and therefore, the pressure container or shell should be able to withstand these pressures, if plant and employee safety is to be considered. The standard contains speci fic rules on how the testing is to be con ducted. One more facet to the picture--manage ment must be responsible for providing this all important first line of fire defense. Fire protection is not a luxury--it is a tangible expense of doing business. We hear a lot about labor-management relations these days. Labor has a stake in this protection picture. We hear a lot about the demands labor is continually making on management, such as wages raises, more vacations, free insurance, other fringe bene fits. The time has come when I feel that management should make some demands from labor. In many plants, labor (and I use the word in its collective sense) indulges In certain horseplay and practical jokes, many of which involve playing around with fire protection equipment. I had this horseplay matter right square in my lap some years ago when I was the fire marshal of a major American industry. We got labor to agree that any employee who was found indulging in horseplay or maltreating any fire pro tection device, whether it be an axe, an extinguisher or an instruction card telling how to use an extinguisher was summarily fired on the spot and had no case before the union grievance committee. It took a bit of selling to the labor union to impress them with the utter neces sity of insuring at all times the integrity of every bit of fire protection installed in the plant, but when they saw their jobs were at stake, they agreed to management's request in holding fire protection equipment inviolate. Gentlemen, don't sell the lowly fire ex tinguisher short in the industrial, production race we're all engaged in. It is the one item which answers the question of "What can I do until the fire department arrives?'* Don't think that its use will cheat the fire laddies out of some fun, they'd a thousand times rather pull up to your plant and have you tell them that you knocked it down with an extinguisher. The fire extinguisher is right down at the grass-roots level of fire protectionright tvhere fires start All it needs is a bit of training and intelligence in its proper application and it will pay you big dividends. 142 ta' specitd j con- e--manageaviding this ifense. Fire a tangible OFFICERS OF THE AMERICAN SOCIETY OF SAFETY ENGINEERS EXECUTIVE COMMITTEE 1958-59 management a stake in a lot about making on aises, more :ringe beneI feel that * demands I use the indulges in okes, many d with fire s horseplay some years of a major or to agree id indulging y fire proan axe, an mrd telling i summarily case before President--DONALD G. VAUGHAN, Secretary, Aetna Casualty & Surety Co, Hartford, Conn. First Vice-President--JOHN F. JONES, Safety Supervisor, Commonwealth Edison Co, 72 W. Adams St, Rm. 1933-E, Chicago 90, IlL Second Vice-President--GEORGE L. GORBELL, Safety Director, Personnel Relations Dept, Monsanto Chemical Co, Lindbergh & Olive St Rd, St Louis 24, Mo. Secretary and Managing Director--J. B. JOHNSON, American Society of Safety Engi neers, 425 N. MicKigSrAve, Chicago*!!, 111. Treasurer--MICHAEL F. BIANCARDI, Manager, Safety Services Dept, Allis-Chalmers Mtg. Co, Box 512, Milwaukee 1, Wis. Members-at-Largc Term Ending 1939--FRED CLAIBORNE, Safety Assistant, Pan American Petroleum Cdrp, P.O. Box 3092, Houston 1, Tex.; FRANK E. LADERER, Director of Safety, Nationwide Insurance, 246 N. High St, Columbus 16, Ohio; E. PETER MARCONI, Manager, Safety Branch, Aro, Inc, Tullahoma, Term. V Jrabor utter neceste integrity >n installed r their jobs anagement's 1 equipment ly fire ex: production is the one i of "What it arrives?" 1 cheat the l, they'd a > your plant ou knocked it down at protection-- needs is a a its proper g dividends. Term Ending 1960--GEORGE M. KINTZ, Chief, Accident Prevention & Health Div, U. S. Bureau of Mines, Region VI, 1114 Commerce St, Rm. 1602, Dallas 2, Tex.; CLYDE F. SCHLUETER, Accident Prevention Manager, Employers Mutuals of Wausau, 407 Grant St, Wausau, Wis.; VIRGIL L. WOMELDORFF, Safety Director, Illinois Power Co, 500 S. 27th St, Decatur, IlL Term Ending 1961--JOHN V. GRIMALDI, Consultant-Safety & Plant Protection, General Electric Co, 570 Lexington Ave, New York 22, N. Y.; LEE B. JOHN SON, Chief Safety Engineer, Northrop Aircraft Inc, 1001 E. Broadway, Haw thorne, Calif.; WALTER E. MONTGOMERY, Safety Director, Robertson, Hall I & Henshaw, Ltd, 1510 Drummond St, Suite 102, Montreal 25, Que, Canada. Regional Vice-Presidents Eastern Region--ARTHUR H. CHRISTIAN, Corporate Safety Engineer, American Viscose Corp, 1617 Pennsylvania Blvd, Philadelphia 3, Pa. Sortheast Region--MERRILL C. M. POLLARD, Safety Director, National Gypsum Co, 325 Delaware Ave, Buffalo 2, N. Y. Southeast Region--P. W. LOGAN, Division Manager, Engrg. Dept, Li?-?rty Mutual Ins. Co, 828 W. Peachtree St, N.W, Atlanta, Ga. Central Region--JOHN A. DePEW, Director of Safety, Dohra Transfer Co, Robin son Bldg, Rock Island, IlL 143 East Central Region--MYRON L. MILLER, Supervisor of Safety, Westinghouse Electric Coip, 700 Braddock Ave, East Pittsburgh, Pa. West Central Region--HOLLEY P. BRADLEY, Supervisor of Safety, Service Pipe Line Co., Box 1979, Tulsa 2, Okla. Southwest Region--FRED W. SCHATZMAN, Safety Engineer, Chance Vought Air craft, P.O. Box 5907, Dallas, Tex. Western Region-- Past Presidents--EDWARD B. LANDRY, P.O. Box 7580, Benjamin Franklin Station. Washington 4, D. G; HENRY B. DUFFUS, Administrator, Accident Prevention, Westinghouse Electric Corp., 3 Gateway Center, P.O. Box 2278, Pittsburgh 30, Pa; JOHN F. JLiLI, Safety Manager, Consolidated Western Steel Div, U. S. Steel Corp, Box 2015, Terminal Annex, Los Angeles 54, Calif. Standing Committee Chairmen Committee on Awards Sr Honors--MELVIN G. BULLOCK, Supervising Engineer. Transit Casualty Co, 901 W. Washington Ave, St Louis 1, Mo. Committee on Chapters--OTTO C HAIER, Safety Director, Standard Oil Co. of ------- Ohio, 1540 Midland Bldg, Cleveland 15, Ohio Committee on Cooperation with Engineering Colleges--FRANK E LADERER, Direc tor of Safety, Nationwide Insurance, 246 N. High St, Columbus 16, Ohio Committee on Cooperation with Engineering Societies--JOHN V. GRIMALDI, Con sultant-Safety & Plant Protection, General Electric Co, 570 Lexington Ave, New York 22. X. Y. Committee on Finance--MICHAEL F. BIANCARDI, Manager, Safety Services Dept, Allis-Chalmers Mfg. Co, Box 512, Milwaukee 1, Wis. Committee on General Publications--GEORGE F. NUERXBERGER, Safety Dept, Kaiser Steel Corp, Fontana, Calif. Committee on Membership--EDWIN B. LOCKE, Manager, Engineering Dept, Texas Employers Insurance Assn, P.O. Box 2759, Dallas 21, Tex. Committee on Public Relations--ROLAND G BAUER, Safety Supervisor, Koppers Co, 1248 Koppers Bldg, Pittsburgh 19, Pa. Committee on Research--ROBERT HAGOPIAN, Research Engineer, AccL Prev. Dept, Association of Casualty & Surety Cos, 60 John St, New York 38, N. Y. Committee on Safety Laws and Regulations--THOMAS R. LEADBEATER, Super visor of Safety, Niagara Frontier Div, Bell Aircrait Corp, P.O. Box 1, Buffalo 5, X. Y. Committee on Safety Standards--CLYDE F. SCHLUETER, Accident Prevention "Manager, Employers Mutuals of Wausau, 407 Grant St, Wausau, Wis. Committee on Technical Publications--HENRY G. LAMB. 10 Wiltshire St, Bronxville, N. Y. Special Committee on Action Program--J. C. STENXETT, Manager, Accident & Fire Prev. Dept, National Association of Mutual Casualty Cos, 20 N. Wacker Dr, Chicago 6,11L Special Committee on Congress Program--JOHN F. JONES, Safety Supervisor, Com monwealth Edison Co, 72 W. Adams St, Rm. 1933-E, Chicago 90, III. 144 Win Station. Prevention, rgh 30, Pa. ; Steel Corp- RER, DirecOhio ALDI, Con. Ave- New rvice.e Dept.. afety Dept3e, }'exas or, Hoppers AccL Prev. 38, N. Y. ER, Superc 1, Buffalo Prevention Bronxville, Accident & N. Wacker visor, ComL Special Committee on Junior Achievement--HOMER K. LAMBIE, 7473 Stockton .Ave., El Cerrito^ Calif. Special Committee on Long Range Planning--HENRY B. DUFFUS, Administrator, Accident Prevention, Westinghouse Electric Corp., 3 Gateway Center, P.O. Box 2278, Pittsburgh 30, Pa. Special Committee on Membership Services--E. PETER MARCONI, Manager, Safety Branch, Aro, Inc- Tullahoma, Term. Special Committee on Motor Vehicle Operation--A. E. NEYHART, Admin. Head, Institute of Public Safety, The Pennsylvania State University, General Extension Annex, University Park, Pa. Special Committee on NSC-Society Relationship--W. P. YANT, Dir. of Research & Development, Mine Safety Appliances Co., John T. Ryan Memorial Laboratory, 100 N. Braddock Ave- Pittsburgh 8, Pa. Special Committee on Review of the Constitution and By-Lazos--WILLIAM N. COX, Jr- Prof, of Safety & Industrial Engr- School of Industrial Engineering, Georgia Institute of Technology, Atlanta, Ga. Historian--EDWARD B. LANDRY, P.O. Box 7380, Benjamin Franklin Station, Washington 4, D. C National Safety-Council Representative--DAVID L. ARM, Manager, Industrial Dept, National Safety Council, 423 N. Michigan Ave- Chicago 11, IU. 145 n\ ^/ 1 i-\ > i f . Other Volumes in this (1958) Series {t Users of fhb volume will find much value in Hs companion volumes, which offer the complete record of the 46th National Safety Congress! Here is the fish Single Vol. No Title Copy Stock No. i General Sessions and Index to all Volumes............... .... MS 2 Aeronautical industries; Air Transport......................... .... .65 3 Automotive and Machine Shop; Power Press and Forging MS 4 Cement, Quarry and Mineral Aggregates................... .... .40 S Chemical ..................... ..................................................... 6 Church Activities; Women's Activities; Youth............. .... MS 7 Coal Mining................... ........................ .......................... 8 Commercial Vehicle....................................... ............. .... .65 9 Construction: Public Employee............... ................... .... -65 10 Electrical Equipment ....................................... .40 II Farm ................................................................................... 12 Fertiliser ............................................................................ .... MS 13 Food and Beverage; Meat Packing. Tanning and Leather Products: Trades and Services................................... .... MS 14 Glass and Ceramics; Rubber......................................... MS 15 Home ................................................................................. .... MS 16 Industrial Subject Sessions (Sponsored by ASSE)... .... .90 17 Labor ................................................................................... .. .. MS 18 Marine................................................................................. .... MS 19 Metals ................................................................................. .... MS 20 Mining ............................................................................... .... MS 21 Occupational Health Nursing....................................... .... MS 22 Petroleum .......................................................................... .... MS 23 Printing end Publishing.................................................... .... .40 24 Public Utilities.................................................................. .40 25 Pulp end Peper.................................................................. .... MS 26 Railroad ............................................................................ .... MS 27 School and College.......................................................... .... .90 28 Traffic ................................................................................. .... .90 29 Transit ................................................................................. MS 30 Wood Products; Textile.................................................. .... MS 31 Early Morning Sessions (Getting Results Through Team Play) .................................................................... .... MS 022.28--I 02228--2 02228--3 02228-4 02228--5 02228-6 02228--7 02228-8 02228-9 02228--10 02228--11 02228--12 02228--13 02228--14 02228--15 02228--16 02228--17 02228--18 02228--19 02228--20 02228--21 02228--22 02228--23 02228--24 02228--25 02228--26 02228--27 02228--28 02228-29 02228--30 02228--31 COMPLETE SETS (31 Volumes)......... ............................ $10.50 022.18 QUANTITY ORDERS: On purchase of 10 or more copies of individual volumes, those single-copy priced (I to 9) at 40 cents each are .35 each; 65-cent volumes are J>5 each, and 90-cent volumes are .80 each. All prices shown era subject to e 10 per cent discount to National Safety Council members. NATIONAL SAFETY COUNCIL 425 NORTH MICHIGAN AYE. CHICAGO 11. ILL. 1800043902 PRlSTtD IM O.t.A. .022 28--16 148