supervisor safety training page 1 sawmill industry

Supervisor Safety Training

Sawmill Industry


Accident Investigation

Role of the Supervisor

Legal Responsibilities

OSHA Requirements

Accident Prevention

Hazard Assessment

TOPICS of DISCUSSION


SUPERVISORSLEGAL

RESPONSIBILITIES


Ethical and moral duty, you have a legal responsibility for safety as a supervisor.

North Carolina law; supervisors can be held criminally liable for serious injury or death of an employee if proved negligent in their duties.

Fines/prison time for serious and/or willful violations.


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Fine and Jail Sentencefor

Worker Electrocuted

Company fined $140,000

Supervisor sentenced to a year in jail

Company had received notification and several warnings that no work was to be accomplished until a power line crossing the job site was de-energized (locked-out and tagged-out).

Supervisor knowing the hazard, directed an employee to drive a dump truck into the hazard area. Then provided instructions to the employee to raise the truck bed under the energized power line.

The employee was severely burned and died on the scene.

Information Source: Safety 21 OSHA-Compliant Workplace - October 2003


SUPERVISORY DUTIES



Responsibilities

Develop Safety Programs

Encourage positive behavior

Enforce safety rules and safety policies

Set the example

Communication skills

Training employees


Responsibilities

Shall not willfully or recklessly interfere with or misuse anything provided in the interests of health safety or welfare.

Shall not place at risk the health or safety of employees.

Administer or support action taken by employer to comply with state and federal regulations.

Enforce safety policies and safety rules.

Correct hazard situations and seek ways to improve safety.


:

Training

New Employee Orientation

Routine Safety Training

Two Types


General and specific safety rules to be followed

Work area and general hazards that may exist

Supervisor’s safety expectations

Accident/unsafe conditions reporting procedures

Job specific training

New Employee Orientation


Daily safety briefing

Weekly / monthly safety meetings

Pre-task training

On the job safety training

Machinery lockout/tagout safety

Employee Safety Training


OSHA Training requirements

Hazard Communication

Fire Prevention Plan

Initial Training

Annual Training

Personal Protective Equipment

Lockout/tagout procedures

Emergency Evacuation Plan

Hearing Conservation

Hazard Material Handling

Bloodborne Pathogens


Sender Message Receiver

Communication Skills Communication achieves one of four goals:

What is communication?

3. Inform

2. Convince 4. Entertain

1. To get action

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Follow company rules, policies, and procedures.

Always be consistent in your approach.

Do not play favoritism with employees.

Your actions will always speak louder than words.

Set the Example

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Safety Rules and Policies

Responsibility

Enforcement - must make sure everyone follows safe working procedures.

Job specific safety rules for each task in the workplace.

Safety Rules

Require employee commitment in writing.

Enforceable safety rules that apply to all employees.


Post safety rules and policies for employees reference


Assignment of Authority- Supervisors provide leadership- Safety committee

Safety Programs

Successful safety programs must have two qualities:

Management commitment - Real commitment - Active participation


Successful Safety Programs achieve:

Reduce Costs Associated with Injuries Average cost of injury $10,000 Indirect cost ~ 10 times direct cost

Reduce Equipment Damage

Comply with OSHA Regulations

Reduce Number of Injuries

Higher productivity & Higher morale

Company Safety Program

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Unsafe behaviors should be your focus.

Employee attitudes.

Focus on Behaviors, Not Attitudes

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-- Carelessness, “bad attitude” are not directly observable, hard to change.

-- Failure to use PPE, safe guards, and job procedures are concerns that can be corrected.


Unsafe behavior or attitude ??


OSHAREQUIREMENTS


Effectively implement safety program(s).

Enforcement of safety rules.

Safety equipment use (PPE, guarding).

Correct & report hazards as soon as possible.

Document all safety activities.

Cooperate with an OSHA officer.

OSHA Requirements


Consultative Services

Consultants are available on a request only basis. They will visit you company and provide advice on safety programs and required safety standards.

Employers scheduled for consultative review and are not subject to inspection by any other OSHA group.

No penalties are assessed, only a commitment by the employer to heed advice and make any recommended changes.

Requests are treated on a confidential basis. No information is shared with other OSHA groups.


Hazard Communication Program

Written Hazard Communication Plan

Inventory of Hazardous materials

System of labeling containers

Material Safety Data Sheets

Employee Training

Make written plan readily available to employees


Identify and evaluate hazards in the workplace.

Communicate hazardous materials information to employees.

Purpose:


Any material which may pose a substantial health hazard to humans of the environment when released or spilled into the environment.

Hazard material:

Hazards materials can cause measurable changes in the body such as decreased pulmonary function.

Effects:


Health Hazards are listed in two categories:

Chronic effects generally occur as a result of “Long Term” exposure and are of a long duration

Chronic Hazard

Acute effects usually occur rapidly as a result of “Short Term” exposure and are of short duration

Acute Hazard


APPROPRIATE HAZARD WARNINGS:

Label requirements:

NAME & ADDRESS OF MANUFACTURER

IDENTITY OF HAZARDOUS CHEMICALS

EMERGENCY PHONE NUMBERS

PPE REQUIREMENTS FOR HANDLING MATERIAL


Material Safety Data Sheets (MSDS)

The MSDS(s) must be readily available and accessible to employees.

Should be kept in a central location in the workplace.

Employees must receive initial familiarization training and any time a new material hazard is introduced into the workplace.

MSDS(s) must be current and up-to-date.

Must be maintained in the workplace for a period of not less than 30 years.

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*

1. General Information

2. Hazard Ingredients

3. Chemical Characteristics

5. Reactivity Date

4. Explosion/FireData

6. Health Hazards

7. First Aid Information

9. Safe Handling Instructions

8. Special Protection Information

Label Info.


Storage Trailer

See another hazard ?

Missing Hand-rails


Enforcing safe work habits is your responsibility

Fire Extinguishers must be properly hung and identified

Require 30 day documentedinspection


Bloodborne Pathogens Program

To provide safe working conditions to protect employees from unnecessary exposure to health hazards.

OSHA estimates 5.6 million workers are

Purpose:

OSHA concern:

at risk to bloodborne pathogens such as human imunodeficiency

(HIV) and Hepatitis (HBV).


Communicating the hazards to employees.

Enforce the wear of appropriate PPE.

Enforce decontamination and waste control procedures.

Recording cases of exposure.

Ensure medical procedures are followed if exposure occurs.

Supervisor Responsibilities

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Annual training requirement.


Lockout/Tagout Program


The purpose of lockout/tagout is to prevent energy sources from accidentally being released while a machine or equipment is being serviced.

The ultimate goal of lockout/tagout is to protect the safety and health of employees.

“Over 70% of all accidents come from improperly applied procedures or non-compliance”

Purpose


Develop company policy for implementing lockout/tagout procedures for the control of hazard energy during maintenance operations.

Management Responsibilities

Train authorized and affected employees on proper use of procedures.

Establish written machine-specific procedures to include applying the locks and tags, release, and notification from lockout.


Supervisors Responsibilities

Ensure employees receive initial training on lockout/tagout.

Ensure retraining if job assignments change, new machines, control procedures or modifications occurs.

Monitor refresher training to keep employees up-to-date.

Enforcement of machine-specific procedures to include applying the locks and tags, release, and notification from lockout.

Check for shortcuts, mistakes, or unsafe work practices.


Training employeesis essential to ensuringproper compliance.


Lockout/Tagout

Prepare for shutdown

Thermal

Chemical

Know equipment hazards:

Electrical

Mechanical

Hydraulic

Pneumatic

#1

(7 steps)


Shut down equipment

Use normal shutdown procedure.

Turn all switches to OFF.

Double check your steps to ensure shutdown procedures are complete.

#2


Isolate all energy sources

Shut control valves.

Open electrical breakers and disconnects.

Disable all sources of energy: do not over look air & hydraulics.

#3

“Coast Down Time” (most over-looked hazard)


Example: Coast down time for chipper/hogs


Chipper blade

Accident Investigation Photo


Valves and electrical disconnects.

Block or disconnect air/hydraulic lines.

Lock and tag blank flanges.

Install Locks and Tags

#4


#5

Block elevated parts

Relieve system pressure

Stop rotating flywheels

Drain fluids

Allow for shafts, blades, flywheels and moving part to completely stop before continuing !!

Release or block stored energy


Verify equipment isolation

Check locking devices securely placed

Attempt normal startup

Return Controls to OFF/Neutral

#6


Page 34


Release from LOTO #7

Inspect Area and Equipment.

Ensure all Machine Guards in place.

Account for tools and parts.

Inform others of startup.

Remove Locks & Tags.

Restore equipment to normal and conduct normal startup.


Conduct annual audits to validate effectiveness of the lockout/tagout procedures

Review procedures annually or when required, especially after an accident has occurred.

Additional lockout/tagout requirements:

Maintain an equipment survey that list the equipmentrequired to have lockout/tagout procedures, type(s) of energy sources, and magnitude of energy.

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Did I Lockout the Carriage ?

Employee locked-out head saw but failed toensure carriage machine was locked & tagged.


Machine not locked-out


Warning signs you may see:


Accidents you may see:


From finger(s) to complete hand.


Do you enforce lockout/tagout ??

This worker wished his supervisor had.

3rd degree burns….

Failure to deplete hydraulic pressure-- line ruptured.


Machine Guards Violations

Machine guards - General

1,726

Pulleys

1,285

Point of operation1,100

Number of Serious Violations OSHA- FY 94


See any hazards?Shade glasses ?

Hard hat ?


Powered Industrial Trucks

Employers shall ensure operators have successfullycompleted training prior to operating lift trucks.


Training requirements:

Workplace safety operating procedures.

Lift Specific operating procedures.

Proper lifting and moving of loads.

Test operators knowledge through written exams.

Conduct operators performance evaluation every three years and/or observed unsafe operating procedures.


Supervisors responsibilities:

Ensure employees are properly trained prior to operating lift trucks

Ensure pre-start inspection is conducted.

Observe lift operators performance -- correct unsafe acts.

Enforce company forklift safety rules


Pre-start Inspections 1. Required prior to each shift

2. Must be documented


Never add additional weight to lift a load


Operating speed

Should equal your average walking speed or about 5 MPH.


No riders One seat means only one person allowed on lift while moving.


Seat belts are required to be worn during all operations.

Seat Belts


See a hazard?

Never allow anyone to walk under a load.

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HAZARD ASSESSMENT


Workplace Hazard Assessment

Employers shall complete a Hazard Assessment of the workplace to determine Employers shall complete a Hazard Assessment of the workplace to determine hazards which jobs require the use of Personnel Protective Equipment (PPE) and hazards which jobs require the use of Personnel Protective Equipment (PPE) and

enforce the use of PPE for all employees.enforce the use of PPE for all employees.


Hazard Assessment

Determines Personnel Protective Equipment (PPE) required to perform specific jobs.

Companies must documented that a hazard assessment has been conducted.

Determines engineering requirements to ensure specific hazards are resolved.


TYPES of HAZARDS

Pinch-points

Impacts

Compressed Air

Hydraulics

Slip and Fall areas

Penetration

Chemical

Harmful Dust

Thermal

Radiation

Electrical

Pneumatic

Solvents

Welding gases

Elevated work areas

Chain/sprockets

Belt/pulleys

Cutting

Noise


DATE:

JSA #

JOB TITLE:

DEPARTMENT: SUPERVISOR:

ANALYSIS BY:

APPROVED BY:

REQUIRED PERSONAL PROTECTIVE EQUIPMENT:

SEQUENCE OF JOB STEPS

POTENTIAL HAZARDS RECOMMENDED ACTION

Hazard Assessment Form


Five Key Components of Job Safety Analysis

Determine which steps to analyze.

Break the task into steps.

Identify the hazards.

Identify solutions and control of hazard(s).

Personal Protective Equipment requirements.

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Electrical Hazards


Electrical Hazards

Wiring strain relief requirementsCover Plate


Electrical boxes must have panels reinstalled


Roll Conveyors are chain & sprocket

driven


Most Planers are located in a separate room to lower noise hazard.

Noise Hazard


Ladder hazard


Fuel Storage requirements

Contents mustbe labeled

“No Smoking”sign

FireExtinguisherwithin 75 feet


What’s missing?


Blade guardmissing


"Toeboard.”

A vertical barrier at floor level erected along exposed edges of a floor opening, wall opening, platform, run- way, or

ramp.1910.21(a)(9)


Scrag Saw sharpening See any hazards ?Proper

PPE

Electrical wire


See any hazards?


See a hazard?

The employer shall ensure that each affectedemployee uses appropriate eye or face protection

when exposed to eye hazards from flying particles

1910.133(a)(1)


Green Chainoperations getcold during theWinter months !

Wore TennisShoes

Looks like the new guydid it again.

Did What ?

The employer shall ensure that each affected employee uses protective footwear

when working in areas where there is a danger of foot injuries due to falling or rolling objects.

1910.136(a) *


Personal Protective Equipment (PPE) Special equipment or clothing worn for occupational Protection against biological, chemical or physical hazards.

PPE shall be provided to employees at the employers expense.

Occupational hazards shall be controlled through engineering or administrative controls.

PPE shall be the last choice for control of a hazard.


Personal Protective Equipment (continued)

Hand Protection

Eye Protection

Hearing Protection

Respiratory Protection

Clothing Safety Shoes

Hard Hats

Chain Saw Chaps

Fall Protection


Enforce the wear of appropriate PPE.

Know PPE required for each task.

Train employees on proper wear.

Supervisor Responsibilities

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Hearing Conservation Program

Most machinery used in the lumber industry ranges from 90 - 110 decibels.

Allowable noise exposure for employees is 85 decibels per eight-hour period.


Determine if program is required

Program requirements:

Audiometric Testing

Record-keeping

Audiometric test will determine noise levels.

Sets baseline, determines employee's hearing threshold. Used annually to determine hearing loss.

Hearing Protection

Employer must provide hearing protection and train on proper wear.

OSHA standards require written documentation. Keep employee test results, sound level measurements and training records. Medical records must be kept for 30 years.

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Confined Space Entry Program


Confined space permit policy and procedure is designed to provide a method of protection from the hazards

associated with confined spaces.

Employer responsible to develop program and train employees to the position they will be

assigned.

“Extremely important that the employee be competent as another’s life is at stake when entering and working in confined spaces”

Purpose


An enclosed space which is large enough and so configured that an employee can bodily enter and perform assigned work.

Definition of Confined Space

Has limited or restricted means for entry or exit (tanks, vessels, silos, storage bins, hoppers, vaults, pits and diked areas).

Is not designed for continuous employee occupancy and has one or more of the following characteristics:

contains or has a known potential to contain a hazardous atmosphere.

contains a material with the potential for engulfment of an employee.

an internal configuration that could trap employee.


Key Personnel

Entry Supervisor Supervisor responsible for overseeing entry operations.

Authorized EntrantEmployee authorized to enter a permit space.

AttendantEmployee stationed outside who monitors the authorized entrant in the confined space.


Verifies that appropriate tests specified by the permit are conducted.

Supervisors Duties

Know the hazards that may be faced during entry.

Terminates the entry and cancels the permit as required.

Ensures all procedures and equipment specified are in place.

Verifies rescue services are available.

Ensures entry operations remain consistent with terms of the entry permit.

Removes unauthorized personnel who attempt to enter the permit space.


Know the hazards that may be faced during entry.

Authorized Entrant duties

Properly use equipment (i.e. testing, ventilating, PPE, lighting, barriers).

Alert attendant when:

Recognizes any warning sign or symptom of exposure.Detects a prohibited condition.

Exit from the permit space as quickly as possible whenever:

An order to evacuate is given. Recognizes any warning sign or symptom of exposure. Detects a prohibited condition. An evacuation alarm is activated.


Know hazards that may be faced during entry.

Attendants duties

Continuously maintains an accurate count of authorized entrants.

Aware of possible behavioral effects of exposure in authorized entrants.

Alert entrants of the need to evacuate space if needed.

Remains outside the permit space during entry operations.

Communicates with authorized entrants to monitor entrant status.


One copy must be posted at the primary entrance to the

space.

One copy must be posted at all other entry points which are

open and accessible to personnel.

Confined Space Permit


Confined Space Entry Permit

Date:__________________

Confined Space Location: ___________________________________________________

Supervisor _____________________________

Entrant Attendant ______________________

Entrant(s) _____________________________ _________________________________

PPE requirements:

Goggles Gloves Boots Respirator Clothing Hardhat Hearing Other ___________________________

Potential Hazards: Oxygen Flammable Mechanical Engulfment Skin contact Other _______________

Preparation (check): Lockout / Tagout Atmospheric Testing Rescue team Other___________________

Equipment needed: Ladder Rope Welding Equipment Other __________________________________

Supervisor:________________ Attendant:_____________________ Entrant___________________

MUST BE POSTED DURING CONFINED SPACE OPERATION

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Welding Operations


Welding Requirements

Company must establish safety procedures for welding, brazing, cutting or other hot work operations performed in areas other than permanent welding shops or booths.

Pertains to all company locations. Outside contractors, as well as employees, must adhere to these procedures in order to guard against fire and other hazards normally present by welding and cutting operations.


Each “hot work” job must have a permit, which must remain at the site throughout the job.

An authorized supervisor must sign the permit.

Retaining records of permits is optional.

Hot Works Permit requirements


Date:___/___/___ Welding Location: ______________________________________________________________________________.

Work being accomplished: _______________________________________________________________________________________.

Start Time: ___________ Completion Time : ____________

____________________________________________ Signed Welder

____________________________________________ Signed Fire Guard

____________________________________________ Signed Authorizing Official

This permit expire on: ___/____/____ (Date)In case of fire call _______ or sound fire alarm located ______________.

PERMIT MUST BE MAINTAINED AT SITE OF WELDING OPERATIONS


Authorizing Supervisor

Signs permit only after completion of the following:

Inspection of immediate area involved for hazards.

Certification: ensure welding personnel have been properly trained to operate welding equipment.

Fire watch is required whenever welding is performed outside of a fixed welding shop.

Fire watch must be maintained for 30 minutes after welding or cutting operations cease at all locations.

Combustible materials must be at least 35 feet away from welding operations.


Welding Safety Precautions

Check for hazardous/explosive materials that may be present at welding site.

Insure fire protection equipment is available and operational:

sprinklersfire extinguisherswater hoses

Adequate ventilation is required.

Place signs, ropes, or warning devices to protect other employees in the area.

Barriers, screens or equivalent protection shall be provided to protect other employees from eye injury due to welding.


Be aware of flammable or explosive conditions prior to performing operations

Check out all welding equipment (hoses, cables, etc.) for any damage or leaks.

Clean the area up and remove combustibles and trash at least 35 feet away.

Thoroughly wet the area up to 35 feet for combustible materials such as saw dust and wood chips.

Have a water hose or adequate fire extinguisher nearby in case of fire.

Do not weld standing in standing water or rain – danger of electrical shock. Check walls, crevices, hidden areas, under equipment, or any other place where sparks could roll.

Properly dispose of spent welding rods.

Keep a Fire Watch for 30 minutes after welding ceases.

Notify your Supervisor once you complete all the above items.

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Stand alone cylinders must be chained in up-right position or stored in authorized storage fixture.


Welding is serious business

Glove caught on fireWelding near combustibles

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Chainsaw Operations


Operators must wear leg protection constructed with cut-resistant material.

Leg protection must extend from the upper thigh down to the boot

top and adequately cover the leg.

Must wear hard hat with facescreen protection.

Must wear cut resistantfootware.

Should wear proper hearing protection.

Operating Requirements


Chainsaw safety rules:

Inspect chainsaw prior to performing cutting operations.

Properly start chainsaw.

Inspection of starting site and cutting area.

Plan an escape route prior to cutting.

Never saw above shoulder level.

Proper carrying technique.

Proper open-faced cuts and back cuts.


Chainsaw chaps must extend

from the upper thigh down to

the boot top and adequately

cover the leg.


See any hazards ?

Eye Protection

Hearing Protection


Proper Open Face Cut ??


Chain Saw Accidents


The facts…………Chainsaws will cause bodily harm !!


Still not convinced………...


ACCIDENT REPORTING

& PREVENTION


If an injury or illness occurs at work:

“REPORT IT IMMEDIATELY”

Every job related injury or illness must be reported to supervisor as soon as possible.

Reporting Accidents


Updated recordkeeping forms OSHA Form 300: Log of Work-related Injuries and Illnesses

Replaces Form 200: Log and Summary of Occupational Injuries & Illnesses

Simplified reporting requirements

Printed on smaller legal sized paper

OSHA Form 301: Injury and Illness Incident Report Replaces Form 101: Supplementary Record of Occupational Injuries & Illnesses

Includes more data about how injury or illness occurred

OSHA Form 300A: Summary of Work-related Injuries and Illnesses


Accidents are investigated, not to find fault or to blame, but to find out the Root Cause.

Get the who, what, when, where &……... why.

Careless acts should be considered as preventable …implement safety precautions.

Develop a plan for preventing the accident in the future.



Preventing Accidents

Supervisors are responsible for Four things to ensure safety of workers:

PLAN - Each job or task assigned ORGANIZE - Each job or task assigned

DIRECT - Train the employees who will do the job or task.

CONTROL - Ensure that the job or task is conducted with the highest degree of quality, safety, & productivity.


Planning

Each job, task or operation must be planned. Planning includes:

What resources are needed to do the job.

How can hazards be eliminated or controlled?

What hazards are present in the task?

What training is required to do the job.



Organizing.

Organizing is the act of ensuring that all RESOURCES necessary to do the job safely are:

Available Proper (size, type) In good (safe) condition

Organization should be in written form, not “in your head.”

Organizing also means getting the cooperation you need from others to effectively implement your plan.



Directing

Directing the job or task is making sure your plan is going as designed.

Conduct safety meeting to bring safety concerns, new proceduresor policies to employees attention.

Assessing or reassessing tasks for safety and productivity.

Making sure all employees are properly trained to perform the task.



Controlling

Controlling you plan enables you make adjustments as required.

Reassess job resources. Have job requirements changed?

Continually observe for unsafe acts and conditions. Take immediate corrective action Take action to prevent recurrence Treat the causeLack of Training Lack of Resources Lack of Job Interest

Train others to over see and enforce set job standards.



Blade replacement operation

Bandsaw housings can create a serious crushing hazard.



AccidentInvestigation Photo


Scrag SawPreventing Accidents


Accident Investigation Photo


Guard placed in front of sawyers cab

After accident occurred !


Log SizerPreventing Accidents


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Safety Observation Report

SOR is a tool to identify and document unsafe acts and conditions.

Resources and training can be focused on area of deficiency.

Helps indicate the Indirect Cause of accidents.

Allows both supervisor and employee to document safety concerns.


Training Employee did not understand Safety Procedure. Employee not trained to do task Training was not frequent enough, employee had forgotten procedures Employee received no job specific training. Employee did not follow supervisor’s instructions.

Lack of Resources Task was not planned correctly. Equipment damaged or defective. Not enough people provided/available to carry the

task out safely.

Employee Work Habits

I. Employee too lazy.

J. Employee did not believe they could get hurt.

K. Employee had bad attitude towards safety.

L. Employee taking shortcuts.

Date: ____________ Time: ______________

Observation:

_________________________________________

_________________________________________

Observer: _______________________________

Action Taken:____________________________

Immediate Corrective Action: _______________

_________________________________________

Cause: __________________________________

Corrective Action: ________________________

_________________________________________

Signature:

______________________________________

Supervising for Safety

SAFETYOBSERVATIONREPORT

PRODUCTIVITY

SAFE

TY

QU

AL

ITY

Areas of Concern

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Job Engineering

Light duty jobs

Retrain

Part time

Returning a previously injured employee back to work consider the following:





OSHA Requirements

Accident Prevention

Hazardous Assessment

SUMMARY


7 Loss Control Field Reps Field reps also, carry variety of safety equipment that is readily available to our policyholders. 2 Specialized Trainers Chainsaw trainer for on-site and felling tree training. Sawmill / Manufacture trainer for on-site OSHA compliance assistance.

Visit their website at www.forestrymutual.com

Additional Services:On-Site Specialized Training

On-Site Job Layout Analysis

On-Site Loss Control Assistance

On-Site Safety Meetings

supervisor safety training page 1 sawmill industry

Documents

safety of employees

safety policies

daily safety

safety programs

specific safety rules

supervisor responsibilities

interests of health

osha training requirements