Document zOzgDaNZoVO8XkZOXqGz3KBm

CONTENTS AUTOMOTIVE AND MACHINE SHOP SESSIONS Fernando's Hideaway................................................................................................. Bruce Podsious 3 Tradin' Pott......................................................................................................................................................... Low Voltasc Shock Hatardt........................................................................T. W. McCreodie 18 POWER PRESS AND FORGING SESSIONS How Power Press Operators Get Hurt............................................................E. D. Sallee 22 The New Power Press Safety Code.............................................................Arthur S. Kelly 32 (a) Purposes and Scope ... Definitions . . . References to Other Codes. . 32 (b) Section IV--Press Construction, Installation.......................Norman Dunlap 35 (c) Section V--Safeguarding at Point of Operation. .Theodore A, IC/okfow 36 (d) Section VI--Power Press Auxiliary Equipment..............George A. Stiles 38 (e) Section VII--designing. Constructing, Setting Dies. ..LA. Faulkner 38 If) Section VIII--Inspection......................................................................Mormon Dunlap 39 A Note on Section IX--Operation Questions and Answers........................................................................................................................ ^3 Press Forging With Safety.................................................................................Harold J. Altar 45 Officers of the Automotive and Machine Shop Section. 1961-62............................ 47 Officers of the Power Press and Forging Section, 1961-62 ............................................. 49 Other Volumes in 1961 National Safety Congress Transactions.................Back Cover 2 AUTOMOTIVE AND MACHINE SHOP SECTION FERNANDO'S HIDEAWAY By BRUCE PODZIOUS Safety Director, Detroit Diesel Engine Div., General Motors Carp., Detroit, Mich. The Fernando that 1 am going lo discuss :> not a character in a song. Fernando is a machine operator at Detroit Diesel. Fernando's Hideaway was the inside of a machine :uul the object lluu he concealed was a tobacco can containing six small Allen wrenches. Every morning .t starting time lor four hundred eighteen (41S) con secutive work days, Fernando would care" fully remove four screws and take off a cover from the side of his borematic macliinc. Next, he would reach inside and retrieve his tobacco can treasure chest which he had hidden at quitting time the previous day. On the morning of November IS, 1952, Fernando's luck ran out. As usual, he first pressed the starting button for the motor in order to cycle and warm up the hydraulic system for the machine wherein the tobacco can was hidden. Next, he removed the cover. As he reached inside, his left third finger was caught and amputated between a revolving "V" lclt and a pulley. Fcrnando's Hideaway had finally been dis covered ! It was almost incredible that a General Motors employee working in a saictyminded plant could perform a flagrant ly unsafe act twice a tlay for four hundred eighteen (41fc>) consecutive days without ever having Iktcii detected or corrected by his supervisor, his fellow employees or his safety department. It makes yon stop arid think, doesn't it ? We in the safety dcfcirtment did plenty of thinking- At first we consoled ourselves by saying. "It is difficult to control the human factor/* Next, we reminded ourselves that the business of building Diesel engines is classified as heavy industry and serious accidents arc more likely to occur in hcavy industry operations. Then came the thought that in spite of the fact that cur safety program provided an (tour and a half safety induction talk to each new hire, in spite of the fact that sujvrvsory safety meetings were regularly held, in spite of d;.i!y five-minute safety talks to employee?, in spite of safety in spections. safety procedures, safe job in structions, safety rules, signs, slogans, bulletins.--in spite of all this and more, it could not be denied that Fernando's unsafe action climaxed an entire year of several serious accidents at Detroit Diesel. Some where we were missing the boa*. Four conclusions were finally reached: First: All people perform unsafe acts. Second: If one employee with better than average intelligence and with a previous accident-tree record was able to perform a Oagrant unsafe act twice a day for nineteen months, it would invohe higher mathematics to determine the number of unsafe acts that three thousand employees in the same plant would perform in the same lime interval. Third: In many instances a history of an cmpolycv's unsafe practices was discovered utter actual injury t<.ok place. We Deeded a plan of action to detect and correct unsafe Practices ref.-re an actual injury would rc*ulL Fourth: The safety department needed help--plenty of help. Early in 1953,'the Detroit Diesel "Unsafe Practice * iL>crvation Plan" came into ex istence. Management, traditionally safety minded, accepted the ``Unsafe Practice Observation Plan" as a supplement I* tin 'ufety program based on the General Molars "Six Paste Principles of Saiety/* It was decided to try the plan in the manufacturing division first. The energies and talents of thirty men were made avail able. These men were thirty manufacturing division foremen. Overnight the safety delurtmcnt had been enlarged 750 per cent. Theste foremen were the first recruits enlisted in an all-out war against the dangers of onployce unsafe practices. A letter from the works manager in formed all manufacturing foremen that an 3