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Reduce Worker Exposure to Nickel Dust
Project ManagerTito Battung, EH&S
Project Team: Ed Guida, R&D
Tom Conrad, Sales
Anthony Zepeda, Operations
Ellen Clas, Quality
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Project Proposal
• Local Exhaust Ventilation– Design– Installation
• Bob don’t want to die – a testimonial
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What’s the Problem?
Excessive Nickel Dust in the Metal Sintering Process
– Employee concern– Regulatory pressure (OSHA visit)– Process hazard analysis of nickel exposure– Analyzed worker compensation costs and
recordable incident rate– Risk Assessment Process
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Objectives
• Install a local exhaust ventilation system to reduce worker exposure to respirable nickel dust
• Assure that we remain a leader in industry by not killing our people
• Address Employee Concerns
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EHS Strategy MapKey EHS
Opportunities
StakeholderInvolvement
Learning &Growth
EffectiveProcesses
EHS Strategy MapKey EHS
Opportunities
StakeholderInvolvement
Learning &Growth
EffectiveProcesses
Establish engineering controls to reduce nickel inhalation exposure in metal sintering
operation below PEL levels in 6 months
• EHS Personnel – air sampling – within 1 month
• air sampling – post installation
• test airflow - Post installation
•Engineering – Installation - within 5 months
- Develop P.M. schedule
•Engineering – Design – within 3 months
• EHS Personnel – Recommend and certify design - within 75 days
EH&S and Engineering – Area Assessment and Control – within 60 days
Engineering - Industrial Ventilation Review Training – within 1 month
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Project Benefits
• Tangible– Lower WC costs
• Bob doesn’t die
• Intangible– Higher moral– Increased production– Reduction in potential
for OSHA and EPA citations
– Product quality improvement
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Estimated Project Costs
Year Ventilation Training IH Support Total Costs1 200,000$ 1,720$ 12,000$ 213,720$ 2 17,140$ -$ 3,000$ 20,140$ 3 17,140$ -$ 1,500$ 18,640$ 4 -$
Total Costs = 252,500$
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Estimated Savings
Year WC CLAIMS Savings 2 Savings 3 Total Savings1 50,000$ 50,000$ 2 25,000$ 25,000$ 3 12,500$ 12,500$ 4 -$
Total Saving = 87,500$
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Financial Analysis
Present Value of Savings: PV(Savings)
$77,653
Net Present Value of Savings: NPV(Savings)
($152,300)
Payback Period: 7.3
Gross ROI (3 Years): 34%
Internal Rate of Return(x Years):
N.A.
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Conclusions & Recommendations• Leader in Industry and Employer of Choice
• $252,500 over next 3 years– $213,720 over next 6 months
• Provide Healthy Work Environment by reducing exposure to nickel dust • Meet regulatory requirements