warehousing/distribution facilities
II: History and Current State of Safety Management
production facility as well as provide safety oversite at the various
Company has just hired its first corporate safety director who manages safety at the
Safety at warehousing/distribution facilities is co-managed by the site HR
III: The company has not yet implemented a comprehensive OS&H Management system
representative and either the maintenance or operations manager.
IV: The company has the following stand alone, safety programs in place:
(ie. System comporting to ANSI Z10, ISO 18000 or ISO 45000)
Powered Industrial Truck – Training and Management
Confined Space Entry
Lockout-Tagout
Hazard Communication (GHS Compliant)
Hearing Conservation
Electrical Safety-Related Work Practices
Personal Protective Equipment
PSM
V: Workers' Compensation Information
Current EMR = 1.2
Current Loss Ratio = 1.45
Most Common Injuries
Back strains/sprains
Repetitive Use Hand/Wrist Injuries
Foreign Bodies in the Eye
Slips/Falls
Caught Between
VI: OSHA Injury Stats
o Company Wide TRIR = 8.7
o Company Wide DART = 4.2
O Company Wide LWDI = 3.7
VII: OSHA Compliance
Three Comprehensive Inspections over the last two years.
Ten OSHA Inspections over the Last 10 Years
Two Employee Complaint Inspections Over the Last Year
O The company has received citations in eight out of ten inspections
The company
has received a repeat citation with respect to OSHA's
forklift standard.
The company
has received serious or other than serious citations in
the following areas:
Hearing Conservation
Hazcom
Lockout-Tagout
• Personal Protective Equipment
• Walking-Working Surfaces
Fall Protection
• Safety Stacking Materials
О
O
asurement Project Hypothetical - (Revised 7/24/18)
Use This Scenario for the Performance Measurement Plan Project.
Deliverables of Project:
1. Clearly and specifically recommend three to five leading metrics for safety
performance and WHY those are recommended (three is minimum);
2. Clearly and specifically explain what data will be gathered, analyzed and
3. Explain what mathematical and statistical tools / techniques that will be utilized in
Recommend goals that should be established for each performance metric.
communicated;
the process and why; and
4.
Scenario:
Uncle Joe's Distilling, Inc., has been in business just over 20 years. The company was
created to be a small-batch, Kentucky bourbon producer, and its founders had a humble
vision of operating a single facility that would distil, age, package and ship its bourbon.
Uncle Joe's product quickly gained world-renown as one of the best, and demand shot
through the roof. {Pun intended.} Because of the boon in business
, the company had to
triple production capacities at the single facility, and open packaging and warehousing
locations in California, Texas, Wisconsin and Florida. During this period, the
acquired two other companies that distill spirits. As of now, Uncle Joe's has facilities in:
Kentucky, California, Texas, Alabama, Florida, Wisconsin, Ohio and New York. The
company has over 2000 employees, and operates its own truck fleet to deliver packaged and
bulk spirits. The company has a corporate safety director, two regional safety managers,
a safety coordinator at each facility. The company's reputation for producing high quality
product and being a good corporate citizen are considered keys to it's success.
company
also
and
.
I: Some Hazards of the Operation
Unloading grain (corn, rye and wheat)
Maintaining grain storage bins and delivery systems
Maintaining fermentation tanks and stills
Hazards from a Variety of Industrial Maintenance Activities
Manually labeling bourbon bottles
Hand packaging bottles of bourbon into cases
Stacking cases of bourbon onto pallets for shrink wrapping
Operating forklifts to move materials and cases/pallets of finished product
Hazards associated with truck driving
O Motor Vehicle Accidents
Falls from entering/exiting cab
Falls from and tanker and hopper bottom trailers
Overexertion injuries from coupling/uncoupling and operating tanker and
hopper bottom trailers
O
O
HAZARD Q&A's
What are the...
Hazards associated with unloading grain?
There are over-exertion wrist motions from the valves which control the grain, and
strain on the back getting to said valves. Also, overexertion injuries to the back and
shoulder from using shovels to direct grain as it is unloaded.
Hazards associated with maintaining grain storage bins and delivery systems?
These bins are considered a confined space and there are dust inhalation hazards from
the fine grains.
Hazards associated with maintaining fermentation tanks/stills?
Confined space entry is integral to this operation. There could be fall hazards depending
on the height of the tank, and if the employee is on a ladder working on the top area of
one.
Hazards associated with variety of Industrial Maintenance Activities?
There are electrical hazards due to the energized machinery, so there would also be a
need for Lockout Tagout.
Hazards associated with manually labeling bourbon bottles?
Repetitive motion (wrists, fingers, hands)
Hazards associated with hand packaging bourbon into cases?
Ergonomic hazards: repetitive motion and bending/stooping with weight. (wrists,
twisting, back-depending on position of cases)
Hazards associated with stacking cases of bourbon onto pallets?
Another scenario of ergonomic injury. (lifting of the cases would put strain on the back,
and twisting due to rotation)
Hazards associated with operating forklifts to move materials?
Multiple hazards due to improper use of forklifts (vehicle to person, vehicle to vehicle,
vehicle to environment)
Hazards associated with transporting bulk and packaged liquor?
Tuggers – driving incident hazards?
HISTORY AND CURRENT STATE OF MANAGEMENT Q&A's
When does the company plan to implement a comprehensive OS&H
Management system? (ie. ANSI Z10, ISO18000, ISO 45000)
Within the next year.
How often do the regional safety managers visit the facilities?
Minimally, a two day visit twice per year. More as needs arise or facilities request
assistance.
pertaining to safety?
Does the HR representative handling safety receive any special training
Only receives training on Emergency Response and Recordkeeping/Reporting.
What PPE is required at your facilities?
earplugs, steel toes, gloves, safety glasses, fall protection.
How extensive is the training required to use Powered vehicles on site?
One day of training, then a re-training following incidents or near misses. 3 Strike rule.
DOLLAR FIGURES FOR COMMON INJURIES
Total Spent in Last Five Years – $2,500,000
Total from Common Injuries - $1,300,000
Back Strains/Sprains - $250,000
Repetitive Use Hand/Wrist – $450,000
Foreign Bodies to Eye - $75,000
Slips/Falls - $350,000
Caught Between - $175,000
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