Plant Managers S.

.V A'* 00 C=d Industrial Hygiene Digest July, I< ADDRESSES OF JOURNALS ABSTRACTED Air Eng.

f List of Exhibitors National Marker Corp., 2314 Pawtucket Ave., East Providence, R.

Occupational Health Nwmg Committee skin contact !

in safe working conditions and efficient opera tion We believe in the dignity and importance of the individual employee and m his nght to denve personal satisfaction from his em ployment Also spelled out in this creed is our belief that the safety of employees con tinues to be the first consideration in the operation of the business Safety is our responsibility in manage ment Without question it is our number one responsibility, taking precedence over every thing else Accident prevention and efficient produc tion go hand-m-hand All levels of manage ment have a primary responsibility for the safety and well-being of all employees This responsibility can be met only by working continuously to promote safe work practices among all employees and to maintain property and equipment in safe operating condition The manager is the key man m the safety program because he is m constant contact with employees No foreman, supervisor, or operating head may ever be relieved of any part of his responsibility for safety Safety is an operating function and cannot be trans ferred to a staff organization Safe practices on the part of plant workers must be part of all operations No job shall be considered efficiently completed unless the worker has followed every precaution and safety rule to protect himself and his fellow workers The ideals of production and safety must be inseparable "Total Safety" extends into three impor tant areas--company personnel, products and customers, and the public This policy is im plemented m these vital areas by 1 Development and application of safety standards both for production facilities (equipment, tools, work methods, and guarding) and for products, based on ap plicable legal and voluntary codes, rules, and standards as a minimum 2 Safety inspection to identify potential haz ards, both in production and in products Packaging, labeling, and instruction sheets are designed to minimize hazards, or alert users to hazards inherent in the product 3 Accident investigation to determine future preventive action 4 Accident records and accident-cause anal ysis to determine accident trends and pro vide targets for corrective action 5 Education and training in general safety principles and specific techniques Onthe-job safety instruction by the supervisor and periodic supervisory contacts for new instructions, follow-up, and general safety motivation 6 Protective equipment to provide injury protection 7 Industrial hygiene studies to identify potential health hazards and develop nec essary control measures 8 Safety publicity and promotion to step up program interest and participation 9 Off-the-job accident prevention in coopera tion with public and private agencies to promote the application of accident pre vention principles to nonwork activities Backing up words with actions Once a safety policy statement is estab lished, it should serve all management people as a continuous reminder of their obligation in this important area This statement should be posted in all offices of executives, super visors, and staff managers It should also be publicized so that every employee becomes familiar with it, particularly with those aspects which apply directly to him Meehngs, let ters, pamphlets, and announcements can be used Management actions speak louder than words Just formulating a policy and telling people about it is only the start Assigning a safetyman, joining the National Safety Coun cil, and putting up a few posters are other steps But unless top management shows real interest at all times, the best (but unen forced) safety policy can go nght down the dram The effectiveness of any safety policy and program vanes directly with the active sup port given it by management Expressions of management interest in clude award presentation ceremonies, safety banquets, rallies, carnivals, and special events attended by the top manager himself to show his personal support for company safety efforts 25

COMMON TO NEARLY EVERY PERSON Handles used for controlling liquids are expected to turn clockwise for off and counter clockwise for on Knobs on electrical equipment are expected to turn clockwise for on, to increase current, and counter-clockwise for off or to decrease current (Note this is opposite to the stereotype for liquid) Toggle switches are expected to turn "on" when flipped up, "off" when flipped down Certain colors are associated with traffic, operation of vehicles, and safety For control of vehicles m which the operator is riding, the operator expects a control motion to the nght or clockwise to result in a similar motion of his vehicle, and vice versa Sky-earth impressions carry over into colors and shadings Light shades and bluish colors are related to the sky or up, whereas dark shades and greenish or brownish colors are related to the ground or down Things which are further away are expected to look smaller Coolness is associated with blue and blue-green colors, warmth with yellows and reds Very loud sounds or sounds repeated m rapid succession, and visual displays that move rapidly or are very bright, imply urgency and excitement Very large objects or dark objects imply heaviness Small objects or light-colored objects appear light m weight Large, heavy objects are expected to be at the bottom Small, light objects are expected at the top People expect normal speech sounds to be m front of them and approximately head height Seat heights are expected to be at a certain level when a person sits down Source Woodson and Conover, Human Engineering Guide for Equipment Design more relative than absolute judgements Function 3--Man as Controller The third function man serves in the manmachine system is that of controller Just as principles exist for designing displays for man to use more readily, so, too, can controls be designed to eliminate error The control function in the man-machine system can be considered as the response to a given stimulus For many situations, a generalized response is given Most Americans, for example, ex pect a light switch to be turned on by flipping the switch "up" and off by a "down" move ment A clockwise motion generally refers to an increase Such responses are called "population stereotypes," a behavioral response common 115

Maintaining Interest in Safety Departmental meetings have many safety uses Their purpose may be to discuss the company safety program so that employees will better understand what is going on They may be held to provide information about accident causes and accident types They may be purely inspirational, to create an awareness of hazards and a desire to pre vent accidents In many company programs, departmental safety meetings are held monthly The trend is toward meetings conducted by the foreman, who may receive assistance in planning as well as materials, such as visual aids, from the safety department The program for a departmental meeting may include the following 1 Report of injuries in the department since the past meeting, report of a safety inspec tion in the department, and report of the department's standing in a contest (The total time spent on reports must not be so great that this part of the meeting becomes tiresome ) 2 Discussion by the foreman of where ob servance of safe practices needs to be im proved 3 Talk, demonstration, or visual-aid presenta tion on an appropriate accident prevention subject The speaker may be the foreman, a member of the department, the company safety director, an outside expert, or an executive of the company Departmental meetings give the foreman an opportunity to point out in a forceful man ner the dangers of certain unsafe practices By condemning those practices, he practically binds himself to set a good example for his men In addition, most workers welcome an opportunity to "get off their chests" whatever safety ideas thev have At the conclusion of departmental meet ings, the foremen should be required to pre pare written reports for presentation to the plant safety committees and review by the managers Small group meetings with men doing sim ilar kinds of work can be held at or near the work place The supervisor or foreman may discuss the causes of an accident of which the men have personal knowledge or m which they have personal interest The men should be encouraged to join m the discussion, and a conclusion should be reached as to show the accident might have been prevented The supervisor may present a problem that has developed because of new work or new equipment Again the men should partici pate and offer their views At times the supervisor mav present a film or chart talk on a subject related to the work of the group members Other visual aids such as models or exhibits may be used Safety devices or pieces of equipment or material mav be shown and discussed "Production huddles" are instruction ses sions about a specific job being done that in cludes safety Such meetings are particularly useful with maintenance crews when an un usual job is about to start The plans for doing the job safely and efficiently are gone over and a procedure is agreed upon Public utility line crews use this type of meeting and call it a tail board conference Before start ing a job, the crew gathers around the truck and discusses the job, laying out the tools and materials they will need and agreeing upon the part each man is to do A particular advantage of small group meet ings is that they provide excellent opportuni ties for presenting all types of information, including safety information, directly to em ployees and stimulate exchange of ideas that can benefit the accident prevention program To be successful, the small safety meeting must include a tangible message, originality of presentation, opportunity for audience par ticipation, and a conclusion that spurs action toward an attainable goal Planning programs Making the safety meeting interesting is of the utmost importance There should be no complaining or scolding Talks should be definitely limited in time and thev should start and end on time The subject matter of a talk should be considered in advance to make sure that it is pertinent and does not repeat other talks recently presented Large occasional meetings need even more careful planning and timing than do small meetings People who are to speak, includ ing company executives, should review what they intend to say with the person planning 174

FlC 9-5 --Cooperative planning with editors and program directors is the basis for effective news coverage Here camera crew covers ceremonies marking the completion of a defensive driving publicity film At far left are Howard Pyle, president of the National Safety Council, and Jack Adams, president of Diamond Rio Truck Division of the White Motor Corporation Courtesy Pilot Productions, Inc can say in a press interview The section "TV, Radio, and Newspapers" in Chapter 37, "Planning for Emergencies," has some suggestions on how the press can help when dealing with large-scale disaster situations See page 1139 Working with Company Publications If a safetyman thinks that safety has been neglected m his company publication, it is time to correct the situation This safetyman should ask the editor frankly how to get more news value and human in terest into safety stones He should tell the editor he wants the program to be just as newsworthy as it can possibly be and that he realizes he needs something besides cold facts and colder figures to make safety articles and pictures attractive to his readers The editor is just as eager as anyone to pub lish interesting news and features, and he will go more than halfway to think up ways to put news value and reader interest into safety doings Here is an example of how the safety pro fessional and the editor can team up to make a 211

Industrial Buildings and Plant Layout FlC 16-1 --A bridge provides safe crossover of a freight yard Be sure construction and personnel protec tion are adequate Courtesy Guardian Engineering O Development Co Floors, walkways, stairs, ramps, platforms Storage facilities, including those for ex plosives and flammable materials, for harm ful substances, for finished products, and yard storage Electric winng and installation Illumination Mechanical handling equipment cranes, conveyors, industrial trucks Elevators Boilers and other pressure equipment Ventilation, heating, and air conditioning Fire control Health and safety water, waste disposal, first aid, personal protective equipment, distribution and repair facilities, isola tion of excessively noisy operations Water supply adequate for fire fighting Personal service facilities parking, restau rants, rest rooms, employment, and training Site Planning Selection of a site involves consideration of a number of factors possible hazards to the community and their relationship to cli mate and terrain, space requirements, type and size of buildings, necessary facilities, transportation, market, and labor supply Of the factors listed, those of direct concern to the safety professional are discussed below While the safety professional is not directly responsible for specialized plant and process engineering and design, still it is his duty to keep the engineers and architects as safety conscious as possible, and to anticipate poten tial safety hazards and try to have them "de signed out" of the system before the construc tion stage begins Location, climate, and terrain Plants producing or using highly flammable or toxic substances in bulk should be located 392

Industrial Buildings and Plant Layout Stairs and walkways Stairs are taking the place of ladders in boiler rooms and other places both inside and outside of buildings Circular stairways should be avoided, but ifabsolutely necessary, should be designed with a minimum variation m tread width Treads should be covered v'lth a durable antishp material The preferred slope for a stairway is be tween 30 and 35 degrees from the horizontal (Fig 16-5 and Table 16-B) The most smt- TABLE 16-B SLOPE AND DIMENSIONS OF TREADS AND RISERS Angle of Stairway with Horizontal Riser (inches) Tread and Nosing (inches) 28 27' 29 25' 30 25' 31 26' 32 28' 33 32' 34 37' 35 44' 36 52' 38 2' 39 12' 40 25' 41 38' 42 53' 44 9' 45 26' 46 44' 48 4' 49 24' 50 O' 61/2 6% 6% 6% 7 7% 7% 7% 7 Vi 7% 7% 7% 8 8 Vs 8% 8% 8V2 8% 8% 8,3fi 12 11% 11 Vi 11% 11 10% 10>/2 10% 10 9% 9'/2 9% 9 8% 8'/2 8% 8 7% IVi 7% able slope for a fixed ladder is from 75 to 90 degrees A tread width of not less than 9Vi in plus a nonslip nosing of 1 in are recommended Riser height should not be more than 8 or less than 5 in , and should be constant for each flight A flight of stairs having four or more risers should have a standard handrail as specified in ASI Standard A12, Safety Code for Floor and Wall Openings, Ratlings, and Toe Boards Rails should be 30 to 34 in from the top sur face of the stair tread, measured in line with the face of the riser A center handrail is rec ommended for stairways over 88 in wide Consult applicable local and state codes Hardwood handrails should be at least 2 in diameter If standard black iron pipe is used, the diameter should be at least 1V& in Clearance between the handrail and the wall should be at least 1V4 m Rails are mounted directly on a wall or partition by means of brackets attached to the lower part of the handrail, to provide a smooth surface along the top and both sides of the handrail Brackets should be spaced not more than 8 ft apart, and the mounting should be able to withstand a 200 pound load applied on the handrail Because of space limitations, a permanent stairway sometimes has to be installed at an angle above 50 degrees Such an installation (commonly called an inclined ladder or "ship's ladder") should have handrails on both sides and open risers Design should not include long flights Landings every tenth or twelfth tread are recommended by some authorities At least one state limits the vertical distance between landings in factories to 12*/ ft Adequate illumination by lights located so thev do not cause glare is important Outside stairways should be covered to keep off rain, snow and ice, if possible It is good practice to enclose all inside stairs with partitions of fireproof or fireresistive material and to install approved fire doors to prevent the spread of smoke or flames from one floor to another Check codes and insurance men about this Stairs and landings should be able to sus tain a live load of not less than 100 pounds per square foot with a factor of safetv of four The original plans should specify elevated walkways and platforms on tanks, bins, big machinery, and other places where men must go during normal operations or for mainte nance purposes Conveyors should be pro vided with crossovers having nonslip sur faces Railings and toeboards should also be provided Many injuries are due to standing on lm- 412

Hoisting Apparatus and Conveyors mg beneath the boom Otherwise, if the truck wheels should roll into a low spot m the pavement, the boom might suddenly crash through a car roof If not disassembled, a crane being trans ported should have the crane engine running and the operator in the cab to swing the boom when necessary to avoid fouling trees, poles, or buildings when the vehicle turns comers Before heavy, slow-moving equipment, or heavy equipment on a low-slung trailer, is moved over any public or private railroad grade crossing, a responsible representative of the railroad company should be notified The railroad then can provide flag protec tion to guard against a train's striking the equipment while it is moving over the cross ing, or if the equipment becomes stalled or "hung up" on die crossing This is an im portant precaution for the benefit of both the equipment owner and the railroad company Electric wires.

be fitted with a locking device to hold the con veying unit at vanous fixed elevations The mechanism for raising and lowering the boom on all types of portable conveyors should be closely checked periodically, it con stitutes one of the greatest sources of hazard in the use of such machinery' Any positive type may be used, but the self-walking worm or jack-screw tvpe is preferable Gear drives should be completely housed and run in oil All chains within easy reach of workmen should be thoroughly guarded, and a system should be provided for convenient oiling of chains In warehouses, the boom of portable conveyors usually consists of two sections to permit their use in a small space These con veyors should be so designed that material will not roll back from one section to the other at the transfer point When portable conveyors are used for load ing or unloading railroad cars, a suitable safety device should be provided to prevent the car from being shifted dunng the operation The device should not be removed until the crew is sure that no one is in the car A red banner or a standard blue warning sign at each end of the car is recommended as a warning to switch men (See the section "Plant Railways" in the next chapter) When portable conveyors are used in rais ing or lowering construction matenals, ample stairs or ladders should be provided in the immediate vicinity of the conveyor Walking on idle or moving conveyors should be pro hibited Gravity conveyors The fact that gravity conveyors (Fig 20-34) depend wholly upon the natural force of grav ity for their operation often leads to disregard of some necessary safe practices Even though it is not power-dnven, this equipment can be the source of senous accidents There is real danger if an employee climbs upon a conveyor to release a blockade He may either slip on the rollers or be knocked down should the jam suddenly be released and strike him To guard against this hazard, workers should be prohibited from climbing onto conveyors In addition, steel or wood plates should be installed between rolls that are far enough apart to permit a worker's foot or body to go between them Gravity conveyors are divided into two gen eral classes --chute conveyors and roller or wheel conveyors Chute conveyors Chutes of polished metal sheets or bars are used to lower packing cases, cartons, and crates from one floor to another or from the sidewalk to the basement of a mercantile building through a sidewalk ele vator shaft or other opening The inclined chute may be straight, or it mav be straight with a vertical curve of large Courtesy Conveyor Equipment Manufacturer's Assn Fig 20-34 --Types of gravity conveyors Left and below roller conveyor Right spiral chute 575

Hoisting Apparatus and Conveyors radius to deliver packages onto the lower floor without impact or damage Some gravity-chute conveyors are built m the form of a spiral around a vertical pipe with a slope at the outer edge between 18 and 30 degrees In removing packages from the delivery end of spiral chutes, workmen ffequendy in jure their hands, which become caught by descending packages or are mashed against others on the delivery table Where the chute is enclosed, a warning sign should be placed over the delivers' end A simple me chanical or electrical device that will give warning when a package is about to be de livered from the chute is advisable, especially where the packages cannot be plainly seen in descent Spiral chutes present a senous fire hazard because they form flues from lower floors to upper floors through which fire will spread quickly Two methods of eliminating this hazard are m general use one is to enclose the chute in a tower made of fire-resistant maicnal, such as steel, concrete, or masonry, the other is to provide automatic fire doors (draft checks) where the chute passes through floors The enclosed tower has doors at each charging station and a door at the delivery end The charging station doors should be kept closed, except when charging is being done The door at the delivery end should close automatically m case of fire Shutoff doors (draft checks) are of two kinds--the vertical sliding and the shutter tvpe Both types should have fusible links so that they will close automatically in case of fire Where an open chute is used, a guardrail and toeboard should be provided at each floor The charging stations should be guarded either by a movable railing or by a hinged door or gate Roller or wheel conveyors Gravity roller or wheel conveyors are similar to chute con veyors, except that the angle of slope is much less (2 to 4 per cent) The conveyors, there fore, can be used to convey packages for con siderable distances on one floor If the rollers or wheels are placed radially instead of paral lel, the course of travel can be changed from a straight line to a curve The principal hazards m the use of roller conveyors are that material may run off the edge of the rollway and fall to the floor, and that loads may run away A guard railing often is provided on each side of the roller conveyorway, to guide the material and pre vent it from running off Such guardrails are especially advisable at comers and turns and on elevated conveyors under which men must work or pass Where heavy loads are conveyed, retarders, brakes, or similar means should be provided to prevent the loads from running away, or a power conveyor on which speed can be con trolled should be substituted A vertically swinging hinged section of a roller or wheel conveyor should be hinged to that end of a stationary section of the conveyor from which the material is flowing to help block the oncoming material The open end of the conveyor line should have a stop that automatically projects above the level of the rollers or wheels when the hinged section is opened and automatically retracts when the hinged section is closed Where a horizontally swinging hinged sec tion occurs in a conveyor, the open ends of stationary sections (the two ends adjacent to the hinged section) should be equipped with retractible stops to prevent loads from drop ping off the conveyor when the hinged sec tion is open Live roll conveyors A live roll (or roller) conveyor consists of a senes of rolls over which objects are moved by power applied to all or some of the rolls through belts or chains Where installed at floor level or used in working areas, live roll conveyors should be designed to eliminate hazards from pinch points and moving parts, unless other provi sions are made to prevent personnel from coming in contact with or crossing the con veyor Vertical conveyors Vertical conveyors handle packages or other objects in a vertical or substantially vertical direction The Conveyor Code designates three types Vertical reciprocating conveyor a power- or gravity-actuated unit that receives 576

Powered Industrial Trucks Safe Operation FjC 22-7 --Triangular guard prevents the operator from riding a powered handtruck the truck must be maneuvered in close quar ters The wheels of many powered handtrucks can be considered guarded by their position under the frame or lift platform However, where the wheels might injure the operator or others, guards should be installed Highlift platform rollers and chain sprockets should also be guarded Many trucks, however, are being manufac tured with a platform for the operator to nde in a standing position If this practice is per mitted, the operator should be protected against foot or leg injuries Pnsm-shaped covers can be installed over the battery box to discourage operators from sitting on the truck during operation (Fig 22-7) Remotely controlled trucks Since they are operated electronically with out the guidance of an operator, remote con trol (programed) trucks (Fig 22-8) must be provided with some means of bringing them to a complete stop if someone steps m front of the truck These trucks should be equipped with a lightweight, flexible bumper which, when contacted, shuts off the power and applies the brakes There should be suffi cient clearance between the bumper and the front of the truck to permit the truck to come to a full stop without contacting anyone m its path Powered industrial truck traffic accidents can be prevented by putting into operation the same safe practices that apply to highway traffic For example, a powered industrial truck operated at excessive speed is being run at a speed too high for the conditions at a given moment Safe speed is the rate of travel which will permit stopping the truck well within the certain clear distance ahead, and permit making a turn without hazard of over turn Wet or slippery floors require a slowerthan-ordinary speed Specific speed limits for trucks should be established A favored maximum speed for loaded power trucks moving forward is 6 mph, although this speed may be too high in con gested areas Many companies have installed governors, locking them in some instances Collisions between trucks and stationary objects often occur while trucks are backing, usually while turning and maneuvering In such cases, the operator may be so intent on handling the load that he forgets where the rear of his truck is going Backing accidents Fig 22-8 --Electronically controlled robot tnick (guided by floor stnp shown at lower right) has bumper which shuts off power when contacted Courtesy Barrett Electronics Corp 616

Open Type SWAGED SOCKET Closed Type 100% WIRE ROPE SOCKET--SPELTER ATTACHMENT 100% PRESSED SIEEVE LOOP RACK THIMBU ATTACHMENT I in diameter and smaller 1 Vi tn diameter and larger PS% 92.5% FLEMISH LOOP WITH MECHANICAL SLEEVE ATTACHMENT 1 m diameter and smaller 1% m diameter and larger WEDGE SOCKETS (depending on design) 95% 915% 75-90% CUPS (number el dtps vanes with size of rope) 75-80% THIMBU SPLICE--HAND TUCXB) 1/4 in 5/16 tn 3/6 in 7/16 in 90% 89% 88% 87% 1/2 in 5/6 m 3/4 m 7/6 in and larger 86% 84% 82% 80% LOOP SPLICE-HAND TUCXH) Efficiencies of loop splice are the same as these given for thimble splice FlC 23-4 -- Efficiencies of attaching wire rope to fittings m percentages of strength of rope 647