second semester 2009 – 2010 assistant professor abed...

Islamic University of Gaza - Palestine

Department of Industrial Engineering

EIND 4306: Safety and Maintenance Engineering

Second Semester 2009 – 2010Assistant Professor Abed Schokry


Three Lines of Defense

1. Engineering Controls2. Administrative Controls3. Personal Protective Equipment


Safety Factors• Since there is a chance element in safety, we can improve our

chances by implementing a “safety factor”

– Scaffolding – 4:1• Designed to withstand 4 times the intended load

– Overhead crane hoists – 5:1– Scaffold ropes – 6:1

• Why not use 10:1 as a standard?? $$$$$

• Beware when using field tables or computer programs. Are the safety factors applied or not??


Fail-Safe Principles1. General fail-safe principle

• The resulting status of a system, in event of failure of one of its components, shall be in a safe mode

Example: spring-loaded switch on electric drill (dead man switch)Example: What happens to power steering and brakes when car engine

dies? Inert state is more dangerous than active state

2. Fail-safe principle of redundancy• A critically important function of a system, subsystem, or

components can be preserved by alternative parallel or standby units.

Example: Emergency generators at hospitals

3. Principle of worst case• The design of a system should consider the worst situation to

which it may be subjected in use. Example: Defensive Driving.• Murphy’s Law: If anything can go wrong, it will.


Engineering Pitfalls• False sense of security in technology• Recommendation for Reading:

– Set Phasers on Stun: And Other True Tales of Design, Technology, and Human Error. Steven Casey. Aegean Publishing Company, Santa Barbara, CA. 1993. ISBN: 0-9636178-7-7

– The Atomic Chef: And Other True Tales of Design, Technology, and Human Error. Steven Casey. Aegean Publishing Company, Santa Barbara, CA. 2006.

– ISBN 10: 0-9636178-6-9


HOW SAFE IS SAFE ENOUGH? Class Discussion

• What is “acceptable safe”?

• Not everyone agrees on whether things are safe enough

• BUT people would like to be free from risks, However, every activity has some risk,

• Society, through political, economic, and legal processes, will define the price it wants to pay for acceptable levels of risk.

• Can absolute safety be achieved?


How Safe is Safe Enough?

• Remember the concept of “risk”.• What is “acceptably safe”?• Be familiar with the Risk Assessment Matrix: Severity

versus Frequency


The Safety & Health Manager

Topics of this lecture

• The Safety & Health Manager

• Resources & organization

• Workers' Compensation

• Scorekeeping


Role of the S&H Manager

• Give reasons why a company would have a safety program?• Who is responsible for S&H?• Changing roles• OSHA• "Manager"• Standards• A reasonable objective


Role of the S&H Manager

• Give reasons why a company would have a safety program?• Humanitarian Reasons• Regulatory Reasons• Economic Reasons

• What is probably the best reason?


• Safety deals with acute effects of hazards, whereas health deals with chronic effect of hazards

• An acute effect is a sudden reaction to a severe condition• A chronic effect is a long-term deterioration due to a prolonged

exposure to a milder adverse condition• Some example safety hazards: unguarded belts, saws, presses, fires,

explosions, open platforms, open flammable or combustible materials, overloaded or defective cranes, lifts, ungrounded electrical equipment, exposed live electrical and conductors, amo.

• Some example health hazards: oil dust, cotton dust, chronic loud noise, asbestos, vinyl chloride, mercury, manganese and cadmium amo.

• Some Example for both safety and Health Hazards are:• Chemical: spray paint, coal dust, and benzene,• physical agent: noise, welding, and radiation,

Safety vs health


Normative Safety• Term used to describe products and designs that meet applicable

design standards (safety standards and safety conditions).

Substantive Safety• Means that the real-world safety history is favorable, whether or not

standards are met.

Perceived Safety• Refers to the level of comfort of users.

Safety measures:Chemical analysis, Stress testing, X-ray analysis, Training, Instruction

manuals, Drug testing, Industrial regulation, Government regulation, Safety margins (Safety factors), amo.

Types of Safety


• Industrial Hygienists, those who concentrate on health hazards, are known by their sophisticated instruments and scientific expertise

• The safety specialist, usually has more industrial process experience and practical on-the-job knowledge

Industrial Hygienists vs The safety specialist


Corporate structure

• Personnel?• Engineering?• Purchasing?• Legal?• CPSC (Consumer Product Safety Commission)• EPA (Environmental Protection Agency )• Bhopal


Organizational structure

• Line vs staff

• The achievement of worker safety lies principally in the hands of the workers themselves and their direct supervisors; thus it is principally a line function.

• The safety and Health manager acting as a facilitator in assisting, motivating, and advising the line function in achieving worker safety and health, thus it is principally a staff function.

• Top management support


Resources & Organization

• Certification• CSP “Certified Safety Professional”• CIH “Certified Industrial Hygienist” Societies• ASSE “American Society of Safety Engineers”• AIHA “American Industrial Hygiene Association”• ACGIH “American Conference of Government Industrial

Hygienists”• NSC “National Safety Council”Government agencies • OSHA “Occupational Safety and Health Administration”• The "new" OSHA NIOSH “National Institute for Occupational

Safety and Health”


• American Insurance Association• ANSI Z16.1 system (American National Standards Institute)(METHOD OF RECORDING & MEASURING WORK INJURY EXPERIENCE)

• Frequency• Severity• Seriousness

Scorekeeping


References

a. 29 Code of Federal Regulation (CFR) 1910b. 29 CFR 1926c. 29 CFR 1960d. 30 CFR 56e. Executive Order (EO) 12196f. Federal Acquisition Regulation (FAR) Clause 52.236-13g. Army Regulation (AR) 40-5

Scorekeeping


Personal Protective and Safety Equipment Hazardous Substances, Agents, and Environments Lighting Accident Prevention Signs, Tags, Labels, Signals, Piping System

Identification, and Traffic Control Fire Prevention and Protection Control of Hazardous Energy (Lockout/ Tagout: LOTO)(LOTO or lock and tag is a safety procedure which is used in industry and

research settings to ensure that dangerous machines are right shut off and not started up again earlier to the completion of maintenance or servicing work)

Hazardscontrol and Protection


Rigging (scafolding and ropes) Machinery and Mechanized Equipment Conveyors Motor Vehicles and Aircraft Pressurized Equipment and Systems (under pressure)! Floating Plant and Marine Activities Safe Access and Fall Protection Work Platforms Demolition Floor and Wall Holes and Openings Excavations (make holes)! Underground Construction (Tunnels), Shafts, and Caissons



Concrete and Masonry Construction and Steel Erection Hazardous Waste Operations and Emergency Response

(HAZWOPER) Blasting (stoppage) Hand and Power Tools Material Handling, Storage, and Disposal Welding and Cutting Electrical



• Human behavior is very complex and it is not fully predictable• Often, behaviors contribute to accidents• Behavior is affected by many things including physiological

condition, biochemistry, situational characteristics, health, relationships with others, personal desires and goals, individual factors and so forth. This section looks at human behavior and important characteristics of it.

Descriptive theoriesAllow characterization or classification of a person after observing

that person’s behaviorPredictive theoriesThey try to predict what a person will do given information about their

past, their surroundings, or internal attributes. The information is obtained by introspective, subjective, or objective means

Human Behavior and Behavior Theories


Workers' Compensation (WC)

• State function• Rates• Insurance• Loss control representatives• Experience rating


WC Concept

• Developed as a way to allow injured employees to be compensated suitably without having to take their employer to court

– fairness to injured employees, especially those without resources to take legal actions

– reduction of costs to employers associated with workplace injuries

• No-fault approach


WC Concept Cont.

• WC is a compromise between needs of employers & employees

• Employees give up their right to seek unlimited compensation for pain and suffering thru legal action

• Employers award the prescribed compensation regardless of the employee’s negligence


Costs

• US employers spend about $100B annually for WC insurance– ~25% for medical care– ~50% for compensation payments– <1/3 for administrative costs for S&H and legal services

provided by insurers• Average cost is about $2 per $100 of payroll (Pay sheet)


Objectives of WC

• Vary widely from state to state• Widely accepted objectives

– Replacement of income (about 2/3)– Rehab of injured worker

• pays medical costs until “fit” to return• vocational training

– Accident Prevention• fewer accidents result in lower premiums

– Cost Allocation• higher risk pays higher premiums


Who is Covered?

• Varies widely by state• Employees generally not covered or limited in coverage:

– Agricultural, domestic, casual, hazardous work, charitable / religious, railroad & maritime (FELA), contractors, subcontractors, minor, extraterritoriality employees, employees of small organizations


WC Legislation

• Varying WC laws are present in all 50 states, DC, Guam, and Puerto Rico

• Born out of the “sweat shop” era(Sweatshop (also known as "sweat factory") is a working environment with

unhealthy conditions that are considered by many people of industrialized nations to be difficult or dangerous, usually where the workers have few opportunities to address their situation.)

• In recent times, medical costs and insurance premiums have skyrocketed, making survival difficult for many small businesses

• Most companies purchase WC Insurance to satisfy WC obligations


WC Insurance

• States vary widely• Three primary types

– State funds– Private insurance– Self-insurance

• Arbitration is available for disputes


WC Insurance Premium Determination

• Manual Rating– a manual of rates is established for various occupations

• Experience Rating– employers are classified by type and compared within

• Retrospective Rating– rate is established, at end of period - adjusted for exp

• Premium Discounting (quantity discount)• Combination Method (2 or more methods)


WC Benefit Eligibility (justification)

• WC benefits are owed only when the injury arises out of employment (AOE) or occurs in the course of employment (COE)– work prescribed in job description– work assigned by supervisor– work normally expected of employees


Disabilities

• Temporary Partial Disability• Temporary Total Disability• Permanent Partial Disability

– At one time the loss of a hand in PA ($116K) and CO ($9K)• Permanent Total Disability

– More expensive than death!


Monetary Benefits• Disabilities

• Death & interment benefits

• Medical treatment & rehabilitation

• Payments for permanent partial disability

– Whole-Man Theory• % of whole, fully-functional person

– Lost Wages Theory• Actual loss in wages are compared to a standard

– Loss of Potential Earnings Theory (most common)• Future earnings capacity is estimated using factors such

as impairment, age, occupation, gender, education


Problems with WC

• Stress claims• Waste and misuse flags

– claimant is never home, injury coincides with layoff or termination, active in sports, has another job, is in line for early leaving, has made full recovery, only a PO Box, no witnesses, history of filing, during hunting season, etc.

second semester 2009 – 2010 assistant professor abed...

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