Unit I Assignment Instructions: This assignment involves reading a case and then helping an organization by identifying the training needs to meet OSHA requirements. This assignment provides you with an opportunity to demonstrate the following course learning outcome: 1. Explain safety and health training requirements specified by standard setting organizations. Read the case below, complete the table below, use the OSHA publication as a guide, save all of your work to this document, and submit it in Blackboard for grading. Background on Carter's Material Handling Equipment Manufacturing Company Carter's Materials Handling Equipment Company is a small business that employs between 38 and 55 employees throughout any given year. This firm manufactures materials handling equipment that includes small cantilever racks, hand trucks, and various dollies commonly used in the manufacturing sector. The facility was built in 1958 and is roughly 80,000 square feet. The firm receives raw materials in the form of round metal tubing, sheet metal, square tubing, and cold and hot rolled metal rods. Raw materials are removed from flatbed trailers using a large, LP-gas-powered forklift with the assistance of smaller, LP-gas-powered forklifts. These materials are stored in racks in the receiving/shipping department. From there, raw materials are moved via forklift and various heavy duty carts to the fabrication department. This department cuts, punches, bends, copes, and shears the various materials into parts used to make the final product. The metal fabrication department includes two 70-ton, part revolution mechanical power punch presses, three 250-ton, part revolution press brakes, a 300-ton hydraulic press, two pipe benders, a twelve-foot shear, a 10-foot shear, a mill for milling a bevel on hand truck toe plates, several off-hand grinders, and two large drill presses. The fabrication department can get quite noisy for days at a time (>85 dB), especially when making cantilever racks. The department includes maintenance workers to keep the machines running. After being cut, punched, bent, and formed, fabricated parts go to the welding department or the Work in Process (WIP) crib. WIP includes a mezzanine and an area populated with pallet racks for storage. In the welding department, there are 12 MIG welding machines that are used by welders to assemble the parts into the pre-finished items manufactured by the firm. The welders also use an assortment of handheld grinders and an oxyacetylene torch. Once welded, items either go in their pre-finished condition into inventory, or are further processed by the painting department. Pre-finished items that are inventoried are taken to one of two mezzanines or placed in storage racks. In the painting department, items are wiped down with various solvents and hung on an overhead hook conveyor. Items go into the paint booth where they are painted using various enamels. Xylenes and Toluene are common solvents used in this operation. The paints also contain these solvents. After painting, axles and wheels are applied, and the completed products are boxed up in the shipping/receiving department or, depending on their size, loaded directly on trucks with no packaging. Larger items, such as racks, are loaded onto flatbeds using an unmanned overhead crane controlled by a pendant control. Smaller items are typically loaded onto standard semi-trailers using battery-powered forklifts or pallet jacks. Carter's OSHA Form 300 log of injuries and illnesses for the past year reveals that eight employees experienced minor injuries (cuts) from handling metal parts, one employee lost 15 workdays after getting Page 1 of 2 debris in his eye while grinding, six employees lost two days each due to back strains, and four welders were treated for minor burns. The human resources manager provided you with this additional information about the departments and their employees: Shipping/Receiving Department: 60% male, 40% female. Age range 18-62. 80% have completed high school; some attend junior college. Temporary employees are added when production is high, usually in summer Metal Fabrication Department: 80% male, 20% female. Age range 30-45. All have completed high school and some have junior college technical training. Welding Department: 50% male, 50% female. Age range 25-50. All have completed high school and all have completed junior college technical training. Painting Department: 30% male, 60% female. Most have completed high school. Some are attending college, pursuing bachelor's degrees. While all employees understand and speak English, several employees in the Shipping/Receiving Department use Spanish as their primary language. All employees work 7 AM - 4PM with a one-hour lunch break, Monday through Friday. On Saturday, overtime is worked at peak production times, usually in the summer. The shop is not unionized, and employee relations are good. The annual employee turnover is 5%. The average employee has worked for Carter for 6.5 years. Some employees have worked for Carter for more than 15 years. Instructions for completing the table below: You have been hired by Carter to develop an effective safety training program for his employees. Carter is concerned about being in compliance with regulations and standards, so your first task is to identify 10 training requirements from the OSHA standards that apply to Carter's operations. Carter's operation will be required to meet more than 10 OSHA standards; however, your job is to identify what you feel are the 10 most important. List the 10 requirements in the order in which they should be developed and specify which department(s) should receive the training. Then, provide a brief justification (rationale) for each training requirement identifiedwhy is it one of the most important? Use the following publication as your guide: Training Requirements in OSHA Standards (OSHA Publication No. 2254-07R 2015). Training Need OSHA Standard 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Page 2 of 2 Justification TRAINING REQUIREMENTS IN OSHA Training Need OSHA Standard Justification 1. Arc Welding and cutting 1910.254 To ensure that the employees handling welding and cutting get protected from cuts injuries. 2. Emergency plans 1910.38 Employee should have skills to respond to emergency issues at workplace. 3. Noise exposure 1910.95 Ensuring that the employees are exposed to limited amount of noise as required by OSHA. 4. Log out and tag out 1910.147 Limiting the exposure of machine energy to the staff. 5. Ventilation of workplace 1910.134 The workplace need to have enough ventilation to avoid respiratory problems. 6. Handling hazardous materials 1910.109 The Xylene handled by the employees are hazardous and they may cause injury to the workers. 7. Protective equipment 1910.132 All workers must wear protective equipment so as to ensure that they are not exposed to high risks. 8. Handling electricity 1910.332 Electricity is dangerous during welding and thus it is critical that the employees learn how to avoid being electrocuted. 9. First aid procedures 1910.151 There is need to ensure that the employees do have knowledge on how to provide first aid services to victims. 10. Handling fire break out 1910.155 Workers need to know how to use fire extinguishers and procedures of responding to fire breakout. CARTER SAFETY TRAINING PROGRAM FOR ALL EMPLOYEES CARTER OCCUPATIONAL HEALTH AND SAFETY POLICY Carter organization is committed to provide a safe and accident free working environment for all of its employees. A diligent commitment is therefore taken by the firm to ensure that the company safety policies are understood by everyone (Namian, Albert, Zuluaga, & Jaselskis, 2016). All our staff are required to understand the safety programs to minimize any possible injuries out of negligence. THE OCCUPATIONAL HEALTH AND SAFETY ACT The Carter's Occupational Health and Safety Act is set to provide the following to its staff: Provide a working environment from hazards Comply with all regulations, rules and standards provided by OSHA applicable to business operations of Carter Company. Require that all of the employees comply with safety regulations set forth by Cater on specific situations Encourage all employee to contact their immediate supervisors in case of any accident or incident for necessary action. TRAINING NEED IDENTIFICATION From the injuries that are reported in the above case, indicate that there are safety issues in cutting and welding department. This is because there employee who have reported cuts while handling metal parts. Moreover, are also affected by the repetitive works leading to back injuries. Other areas that have been noted include fire handling, lifting materials, first aid, log out and tag out, ventilation, hazardous materials, electrical work, and protective equipment. These areas need focus when carrying out the training exercise (Occupational Safety and Health Administration. 2015). In order to carry out the training effectively, responsibilities are shared among various stakeholders in the organization. HEALTH AND SAFETY RESPONSIBILITIES The goal of Carter is to provide protection to its employees from any injuries. Therefore, there are training duties and responsibilities assigned to the different personnel as shown below: Health and safety manager Train all employees on matters concerning healthy and safety Guide the staff and develop quality programs to eliminate the availability of hazards either chemical, physical, and biological. Training all of the staff working below him and ensure that they remain motivated to maintain health and safety rules. Production Manager Train the employees on the use of protective gears during their daily work as required by OSHA 1910.132. Implement safety programs within the production department. This shall ensure that all workers are aware of all the hazards facing them in their workplace. Teach employees on how to keep equipment in a good condition and carry out periodic health inspections. Checking on the levels of ventilation in the paces of production (Dawson et al., 2016). Middle Level Managers 1. Instruct and train the employees on the issues that relates with safety. For example, ensuring that the noise level exposed to the employees is minimized. 2. Conduct weekly or monthly briefings with the employees. This shall ensure that the staff will remain updated throughout their stay in the organization. 3. Supervise the use of safety gears and teach workers how to use the protective kit and avoid injuries from welding and cutting. All Employees in Carter Organization All employees must be familiar with the safety practice and ask clarifications when possible (Namian, Albert, Zuluaga, & Jaselskis, 2016). Always use the safety equipment provide by the management Notify the management of any accident or incident causing injuries to the employees INJURY COMMUNICATION PROGRAM All employees are required to report injuries immediately. This will ensure that some of the injuries are treated on time. Exposure to chemicals and other hazards need to be reported to the nearest supervisor or call the hotline (Lundgren, & McMakin, 2013). However, the workers are advised to review the safety program. The Safety Trainers and Training Evaluation (External and Internal) The identified external and internal trainers covers all the issues that relate to employee safety programs. The objective of the training is to ensure that all employees remain injury free. The trainers and evaluators who carried out the training evaluates the success of the training. The process of managing these training is outlined in the safety policy. Evaluation and employee feedback Evaluation process relates with interviewing the employees on what they have learned throughout the training and what they believe that the administration shall improve in future safety training. It is important for the organization to take employee feedback so as to ensure that whatever it offers to the staff is quality and protects the lives of the employee. References Occupational Safety and Health Administration. (2015). OSHA training standards policy statement. Occupational Safety Health and Administration 1910.155 Dawson, A., Twaddell, M., Johns, C., Rode, N., Grigonis, A., & Hammerman, S. (2016). 1128: LONG-TERM ACUTE CARE HOSPITALS COMPARE FAVORABLY TO ICUS IN A VENTILATOR PATIENT SAFETY PROGRAM. Critical Care Medicine, 44(12), 358. Lundgren, R. E., & McMakin, A. H. (2013). Risk communication: A handbook for communicating environmental, safety, and health risks. John Wiley & Sons. Namian, M., Albert, A., Zuluaga, C. M., & Jaselskis, E. J. (2016). Improving hazard-recognition performance and safety training outcomes: Integrating strategies for training transfer. Journal of Construction Engineering and Management, 142(10), 04016048. TRAINING REQUIREMENTS IN OSHA Training Need OSHA Standard Justification 1. Arc Welding and cutting 1910.254 To ensure that the employees handling welding and cutting get protected from cuts injuries. 2. Emergency plans 1910.38 Employee should have skills to respond to emergency issues at workplace. 3. Noise exposure 1910.95 Ensuring that the employees are exposed to limited amount of noise as required by OSHA. 4. Log out and tag out 1910.147 Limiting the exposure of machine energy to the staff. 5. Ventilation of workplace 1910.134 The workplace need to have enough ventilation to avoid respiratory problems. 6. Handling hazardous materials 1910.109 The Xylene handled by the employees are hazardous and they may cause injury to the workers. 7. Protective equipment 1910.132 All workers must wear protective equipment so as to ensure that they are not exposed to high risks. 8. Handling electricity 1910.332 Electricity is dangerous during welding and thus it is critical that the employees learn how to avoid being electrocuted. 9. First aid procedures 1910.151 There is need to ensure that the employees do have knowledge on how to provide first aid services to victims. 10. Handling fire break out 1910.155 Workers need to know how to use fire extinguishers and procedures of responding to fire breakout. CARTER SAFETY TRAINING PROGRAM FOR ALL EMPLOYEES CARTER OCCUPATIONAL HEALTH AND SAFETY POLICY Carter organization is committed to provide a safe and accident free working environment for all of its employees. A diligent commitment is therefore taken by the firm to ensure that the company safety policies are understood by everyone (Namian, Albert, Zuluaga, & Jaselskis, 2016). All our staff are required to understand the safety programs to minimize any possible injuries out of negligence. THE OCCUPATIONAL HEALTH AND SAFETY ACT The Carter's Occupational Health and Safety Act is set to provide the following to its staff: Provide a working environment from hazards Comply with all regulations, rules and standards provided by OSHA applicable to business operations of Carter Company. Require that all of the employees comply with safety regulations set forth by Cater on specific situations Encourage all employee to contact their immediate supervisors in case of any accident or incident for necessary action. TRAINING NEED IDENTIFICATION From the injuries that are reported in the above case, indicate that there are safety issues in cutting and welding department. This is because there employee who have reported cuts while handling metal parts. Moreover, are also affected by the repetitive works leading to back injuries. Other areas that have been noted include fire handling, lifting materials, first aid, log out and tag out, ventilation, hazardous materials, electrical work, and protective equipment. These areas need focus when carrying out the training exercise (Occupational Safety and Health Administration. 2015). In order to carry out the training effectively, responsibilities are shared among various stakeholders in the organization. HEALTH AND SAFETY RESPONSIBILITIES The goal of Carter is to provide protection to its employees from any injuries. Therefore, there are training duties and responsibilities assigned to the different personnel as shown below: Health and safety manager Train all employees on matters concerning healthy and safety Guide the staff and develop quality programs to eliminate the availability of hazards either chemical, physical, and biological. Training all of the staff working below him and ensure that they remain motivated to maintain health and safety rules. Production Manager Train the employees on the use of protective gears during their daily work as required by OSHA 1910.132. Implement safety programs within the production department. This shall ensure that all workers are aware of all the hazards facing them in their workplace. Teach employees on how to keep equipment in a good condition and carry out periodic health inspections. Checking on the levels of ventilation in the paces of production (Dawson et al., 2016). Middle Level Managers 1. Instruct and train the employees on the issues that relates with safety. For example, ensuring that the noise level exposed to the employees is minimized. 2. Conduct weekly or monthly briefings with the employees. This shall ensure that the staff will remain updated throughout their stay in the organization. 3. Supervise the use of safety gears and teach workers how to use the protective kit and avoid injuries from welding and cutting. All Employees in Carter Organization All employees must be familiar with the safety practice and ask clarifications when possible (Namian, Albert, Zuluaga, & Jaselskis, 2016). Always use the safety equipment provide by the management Notify the management of any accident or incident causing injuries to the employees INJURY COMMUNICATION PROGRAM All employees are required to report injuries immediately. This will ensure that some of the injuries are treated on time. Exposure to chemicals and other hazards need to be reported to the nearest supervisor or call the hotline (Lundgren, & McMakin, 2013). However, the workers are advised to review the safety program. The Safety Trainers and Training Evaluation (External and Internal) The identified external and internal trainers covers all the issues that relate to employee safety programs. The objective of the training is to ensure that all employees remain injury free. The trainers and evaluators who carried out the training evaluates the success of the training. The process of managing these training is outlined in the safety policy. Evaluation and employee feedback Evaluation process relates with interviewing the employees on what they have learned throughout the training and what they believe that the administration shall improve in future safety training. It is important for the organization to take employee feedback so as to ensure that whatever it offers to the staff is quality and protects the lives of the employee. References Occupational Safety and Health Administration. (2015). OSHA training standards policy statement. Occupational Safety Health and Administration 1910.155 Dawson, A., Twaddell, M., Johns, C., Rode, N., Grigonis, A., & Hammerman, S. (2016). 1128: LONG-TERM ACUTE CARE HOSPITALS COMPARE FAVORABLY TO ICUS IN A VENTILATOR PATIENT SAFETY PROGRAM. Critical Care Medicine, 44(12), 358. Lundgren, R. E., & McMakin, A. H. (2013). Risk communication: A handbook for communicating environmental, safety, and health risks. John Wiley & Sons. Namian, M., Albert, A., Zuluaga, C. M., & Jaselskis, E. J. (2016). Improving hazard-recognition performance and safety training outcomes: Integrating strategies for training transfer. Journal of Construction Engineering and Management, 142(10), 04016048