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Kevin Schmidt, Author at Kevin Ian Schmidt - Page 10 of 26

Author: Kevin Schmidt

  • Loading Dock Safety Awareness

    Loading Dock Safety Awareness

    This form on loading dock safety awareness can be used as a quick training for dock employees during huddle meetings.

    This form is also good for employee orientation as part of the training process, to increase awareness of the dangers within the material transfer zone(MTZ).

    Finally this form can be used as part of a walk through program to identify hazards.

    Keeping the dock area clean and organized is the first part of this awareness training, as good housekeeping is the foundation of safety. Doing this will minimize slip/trip/fall potential injuries, which can be amplified in the dangerous MTZ, with the amount of powered equipment and material being moved within the area.

    This awareness form is only a small part of a total dock safety program, don’t forget to check out the other offerings for loading dock safety.

    Do you have other Loading Dock Safety needs? We also offer the following:

    3 Tips to Raise Safety Awareness of the Risks at Loading Docks

    1. Not every worker knows when trucks are arriving or leaving. This can be a serious hazard for powered equipment operators. Establish a communication model at the docks to raise this awareness.
    2. Sometimes workers fall off docks. They may get injured or left vulnerable where trucks move in. Drivers can’t always see well behind the truck. Being crushed by a truck on the drive approach is the most common dock-related cause of death. This can be corrected with properly guarding the dock edges.
    3. Ensuring there is a proper bridge from dock to trailer is a great way to reduce risk at the loading dock. This can be done with Dock Plates, Dock Boards and Loading dock levelers. They help ensure smooth, safe moving of goods between the two components, especially when using material handling equipment.

    Download the Loading Dock Safety Awareness form below

    View the Loading Dock Safety Awareness form below

  • Loading Dock Safety Policy

    Loading Dock Safety Policy

    The foundation of a safe loading dock is a quality policy that outlines expectations for safety.

    Partner this policy with all the other aspects of Loading dock safety offered here, and your company will have all the tools available for a safer loading dock.

    Do you have other Loading Dock Safety needs? I also offer the following:

    The policy here not only covers basics of loading dock safety but also covers physical security of the dock area, as that is an important aspect, that if neglected can create an unsafe working environment.

    This policy is not all inclusive, as it specifically covers safety and security, but nothing concerning operations. Your company will need a policy/procedure for loading dock operations, since every workplace is different. Pairing this safety policy with a quality operation policy will provide a safe and secure environment in which employee productivity is optimized.

    A quality loading dock safety policy should address the following risks employees face:

    • Trailer Separation: This problem is common enough that it goes by several nicknames: trailer walk, dock walk and — most commonly — trailer creep. The weight of forklifts entering and exiting the trailer can cause it to gradually drift away from the dock until there is a dangerous gap between the trailer and the dock.
    • Premature Departure: If a miscommunication occurs and a truck driver mistakenly pulls away from the dock prematurely, it could cause a forklift driver entering, exiting or inside of the trailer to be injured.
    • Landing Gear Collapse: Damaged or weak landing gear on a trailer can suddenly fail, allowing the trailer to move. It could either pitch forward or swing off to one side. This can injure employees who are entering, exiting or inside of the trailer.
    • Trailer Pop-Up and Up-Ending: Pop-up can occur when the weight of a loaded forklift entering the back end of the trailer causes the trailer to press down in the back and pop up in the front. Up-ending is the opposite, but equally dangerous, problem, where the trailer’s nose is forced down, causing the back to rise.
    • Dock Shock: Dock shock refers to the health and safety hazard that lift truck operators experience when they are jarred by a bumpy transition crossing over from the warehouse floor to the loading dock.
    • Unsecured Loads: When a load on a forklift or other powered truck isn’t properly secured, it can slide off, causing injury to the forklift driver or any other employees within close proximity.
    • Lifting: Though not unique to loading docks, lifting equipment is also a common source of warehouse injuries and often occurs when employees are loading and unloading goods at the loading dock. Though a back strain may seem less serious than a fall or other injury, a first-time back injury can cost $10,000 and can put an employee out of commission for some time.

    The following recommendations can improve safety on loading docks:

    • Use portable jack stands when loading and unloading trailers to prevent potential tipping of lift trucks.
    • Have all equipment maintained in accordance with manufacturer’s recommendations – this includes lift trucks, dock levelers, vehicle restraining devices, dock doors, and automatic signaling devices.
    • Purchase forklifts with side shifting capability – they help to prevent product damage and promote safety by allowing the lift truck operator to perform the task with fewer movements and eliminating the need for the forklift to be right up against the wall of a trailer.
    • To prevent injuries from lifting heavy materials, make sure all employees follow best practices for lifting.
    • Make sure the dock area is well-lit and that lift trucks are equipped with spotlights so drivers can see everything in front of them, whether on the warehouse floor or in a semitrailer.
    • Whenever possible, avoid having workers in trailers while a lift truck is loading or unloading.
    • Perform a visual inspection of the trailer prior to driving a lift truck into it – damaged and rotting floorboards are common in older trailers.

    Download the Loading Dock Safety Policy below

    View the Loading Dock Safety Policy below

  • Loading Dock Safety Checklist

    Loading Dock Safety Checklist

    When you think of a loading dock, does a flurry of activity and the classic “beep, beep, beep” noise come to mind? A company’s loading dock is a hub of activity for shipping and receiving functions that keeps the businesses flowing. Unfortunately, about 25 percent of reported warehouse injuries occur on loading docks.

    With the use of forklifts, pallet jacks, and other manual means in these critical transition areas, it’s important to review the hazards associated with loading docks and safety practices to help prevent injuries and incidents.

     

    Have you completed a loading dock safety assessment?

    This Loading Dock Audit Checklist is a great tool to assess the hazards present within the material transfer zone(MTZ) and provides a clear picture of where you can improve your safety.

    This checklist for dock safety should be completed, at minimum, every quarter to ensure your loading dock remains a highly functional safe working environment.

    The loading dock safety checklist covers important aspects such as:

    • Training – This is a review of the relevant training needed for safe work within the MTZ
    • Housekeeping – a clean and orderly work environment is the foundation of a safe workplace
    • Material handling equipment(MHE) – a solid check of all MHE will ensure employees are only using the safest equipment possible.
    • Loading zone – Is the loading zone properly setup for safe operation
    • General safety – many of the questions here are applicable for total warehouse safety, but with the fast moving work within the MTZ it should be checked regularly.

     

    A great way to perform a loading dock safety assessment is by bringing together your site safety committee and using this checklist, so there are multiple perspectives in helping to identify hazards at the loading dock.

    Check Out: Safe Lifting and Carrying Training as proper lifting will help reduce injuries, and employees need proper training on how to lift and carry safely.

     

    Do you have other safety needs for your loading dock?

     

    Download the Loading Dock Safety Checklist below

    View the Loading Dock Safety Checklist below

  • Loading Dock Safety Training

    Loading Dock Safety Training

    The loading dock in a business is a high hazard area, with many different risks. With freight and powered equipment moving through the area, injuries can be significant, an easy way to reduce risk of injury is by providing employees with this loading dock safety training.

    Loading dock injuries reviewed

    • Every 3 days someone is killed in a forklift related accident at a loading dock.
    • An additional 94,750 forklift related injuries are reported each year.
    • $135,000,000 in immediate costs are incurred due to forklift accidents.
    • 7% of forklift accidents occur when a lift truck is driven off a loading dock.
    • 12% of all loading dock fatalities involving power equipment result from trailer/dock separation.
    • 70% of all reported accidents could have been avoided with proper safety precautions
      *nist.gov, “Performance Metrics for Intelligence Systems Workshop” 2009

    Training employees to identify the hazards in a loading dock area, examples include:

    • Inspecting loads received to make sure they are stable and undamaged
    • Destroying damaged pallets
    • Inspecting loads before movement to ensure proper shrink-wrapping or banding
    • Securing dockplates or bridges
    • Chocking trailer wheels before accessing a trailer
    • Engaging locking devices before entering trailers
    • Guarding dock edges when trailers are absent

    This loading dock training will provide employees with the proper knowledge to identify risks and also the foundations of a quality loading dock safety program.

    Requirements and Recommended Practices:

    • Maintain a safe distance from the edge of loading dock.
    • Watch out for tail swing.
    • Keep working surfaces clear and clean.
    • Paint the edges of the loading dock to improve visibility.

    From OSHA.gov

    Do you have other Loading Dock Safety needs? I offer the following:

    This safety training can be conducted in a classroom training environment or as part of a quality self learning training program.

    Download the Loading Dock Safety Training below

    View the Loading Dock Safety Training below

  • Glad Hand Lock Training

    Glad Hand Lock Training

    Loading dock fatalities and serious injuries occur when there is unwanted separation between the trailer or truck being loaded and the loading dock. A glad hand lock can be used to secure a trucks air lines from connecting to the trailer, which means they won’t be pressurized, therefore they will be engaged.

    Trailer Air Brake Lock for Trailers and Containers

    Trailers and containers hold precious cargo, so keeping them secure is critical. That’s where Trailer air brake locks step in, acting as security ninjas for your glad hand mounting bolts. They cover those little guys like a knight’s shield, stopping unauthorized tampering with brake lines and preventing trailer takeoffs by surprise.

    Think Fort Knox for your fleet: This isn’t some flimsy padlock. We’re talking a high-security, push-button locking cylinder that makes unauthorized access about as easy as cracking a bank vault. Installation’s a breeze too, so you can get these guardians on duty in no time.

    But wait, there’s more! These locks aren’t just security superstars, they’re also safety chameleons. They seamlessly integrate with your lockout/tagout procedures, adding an extra layer of protection during maintenance and repairs. It’s like a two-in-one deal for ultimate peace of mind.

    So, whether you’re a big rig boss or a warehouse whiz, Trailer Air Brake Locks are your secret weapon for shielding your assets and safeguarding your crew. They’re a must-have in any comprehensive security strategy, ensuring your cargo and equipment stay put while your team works safely and efficiently.

    Remember: Security isn’t an option, it’s an investment. Invest in Trailer Air Brake Locks and watch your worries disappear faster than a truck down the highway.

    Glad Hand Lock Common Questions

    Can a glad hand lock be used in place of wheel chocks?

    • No. The lock should be used in addition to wheel chocks or dock locks. They are an additional layer of security.

    Can a glad hand lock be used in place of a king pin?

    • Yes. While a king pin prevents the truck from connecting to the trailer, a glad hand lock prevents the brakes from being energized. Best practice is to use both, whenever possible.

    Can a trailer move with a glad hand lock in place?

    • Yes. Trucks can connect to the trailer and pull it, but with the brakes engaged, the wheels won’t turn.

    Is glad hand lock usage required by OSHA?

    • General industry regulations relative to truck loading docks are largely embedded in requirements for Powered Industrial Trucks (1910.178). Specific requirements aimed at preventing trailer/dock separation incidents appear below:1910.178(k)(1): The brakes of highway trucks shall be set and wheel chocks placed under the rear wheels to prevent the trucks from rolling while they are boarded with powered industrial trucks.1910.178(m)(7): Brakes shall be set and wheel blocks shall be in place to prevent movement of trucks, trailers, or railroad cars while loading or unloading.OSHA has issued directives and interpretations that allow alternatives to chocking to prevent trailer/dock separation. Verbiage from a September 14, 2005 letter of interpretation summarizes the Agency’s most current position:“. . . in light of the changes in technology since the promulgation of 29 CFR 1910.178(k)(1) and (m)(7), OSHA as a matter of policy will regard failure to use wheel chocks or blocks as a de minimis violation and no citation will be issued if alternative methods of preventing truck movement are used. These alternatives may include the use of dock lock mechanisms, dock monitoring systems, or other systems which will prevent the unintentional movement of trucks and trailers while being boarded with powered industrial trucks.”

    This training will teach employees how to put on and take off a glad hand lock. Besides making this part of an employee’s dock safety training, this sheet can be laminated and placed at the glad hand lock station to remind employees how to use them.


    Do you have other Loading Dock Safety needs? We also offer the following:

    Download the Glad Hand Lock Training below

    View the Glad Hand Lock Training below

     

     

     

  • How Accurate is Your Company’s Incident Reporting?

    How Accurate is Your Company’s Incident Reporting?

    In any organization with a system for reporting accidents and incidents, there is always the risk of underreporting or overreporting. This discrepancy can significantly reduce the effectiveness and reliability of the reporting process. Accurate reporting is crucial because you can’t address issues that you aren’t aware of, and often, “near misses” serve as early warnings for potential serious injuries or accidents.

    When there is a suspicion of underreporting, it’s essential to ask several critical questions to ensure that all relevant information about accidents and no-harm incidents is captured. This is necessary so that appropriate preventive measures can be implemented. To address the issue, it is important to take a step back and examine the organization’s culture. Understanding what behaviors and actions are being rewarded or punished is key to identifying the root causes of underreporting.

    According to a basic principle of human behavior, “Things that get rewarded or recognized, get done.” In the context of accident and incident reporting, this means that employees are more likely to report incidents if they are positively acknowledged for doing so, and less likely if they fear negative consequences. Therefore, two fundamental questions must be asked: “Are employees being punished or blamed for reporting incidents?” and “Are employees being rewarded, either implicitly or explicitly, for not reporting?”

    If the answer to either question is yes, it becomes clear how these conditions can influence human behavior and lead to underreporting. For example, if employees feel that reporting an incident will result in punishment or blame, they may choose not to report it. Conversely, if they believe that not reporting incidents will help them avoid trouble or gain rewards, they may be incentivized to keep issues under wraps. In both scenarios, the organization’s culture and policies play a significant role in shaping reporting behaviors.

    To address these issues, organizations must foster a culture that encourages open and honest reporting without fear of repercussions. This involves creating a safe and supportive environment where employees feel comfortable sharing information about incidents and near misses. Recognizing and rewarding accurate and timely reporting can also help promote a culture of transparency and continuous improvement. By doing so, organizations can ensure that they have a complete understanding of workplace hazards and can take proactive steps to prevent accidents and injuries, ultimately creating a safer work environment for everyone.

    Does your company need more components of an incident reporting program? I have many posts to help you here

    Human behavior is often shaped by the outcomes that individuals and groups experience as a result of their actions. If employees are rewarded for not reporting accidents, they are likely to continue withholding this information because the consequences reinforce that behavior. Conversely, if reporting accidents leads to punishment or blame, employees will naturally try to avoid these negative outcomes by not reporting incidents. In both scenarios, underreporting becomes a common practice, which can create a false sense of security within the organization. Management may mistakenly believe that their workplaces are becoming safer when, in reality, crucial information about potential hazards is being suppressed.

    Unfortunately, many organizations implement incentive programs aimed at improving safety, but these initiatives often have the unintended consequence of merely altering the reported statistics rather than enhancing actual safety. In these cases, safety statistics can become highly unreliable, as they may not accurately reflect the true state of workplace safety. It is entirely possible for unsafe practices to occur without being captured in the statistics, thereby weakening the connection between reported data and the actual level of safe behavior within the organization.

    In some organizations, particularly those with multiple sites or divisions, a competitive element is introduced into safety reporting. This approach often exacerbates the problem of underreporting. When safety performance is turned into a competition, managers may feel pressured to avoid appearing at the bottom of safety rankings. The fear of being scrutinized or criticized for poor safety records can lead to deliberate underreporting of incidents. Managers may choose not to report accidents or near misses to avoid raising questions about their leadership or facing demands to “get your people to work safely.”

    This competitive atmosphere creates an environment where the focus shifts from genuinely improving safety to simply maintaining appearances. As a result, the organization may continue to operate under the illusion that safety is improving when, in fact, serious risks are being overlooked. This can have dangerous consequences, as the true state of safety within the workplace remains hidden, and opportunities to address and mitigate hazards are missed.

    To cultivate a truly safe working environment, organizations must prioritize accurate and honest reporting over superficial improvements in safety statistics. This requires a cultural shift away from punitive or reward-based systems that inadvertently encourage underreporting. Instead, organizations should foster an environment where reporting is seen as a positive and essential component of workplace safety. By doing so, they can gain a realistic understanding of safety conditions and take meaningful steps to protect their employees, rather than relying on misleading data that only serves to mask underlying problems.

     

    The solution to this issue is 2 fold:

    The first step in addressing the issue of accurate incident and accident reporting is to foster a deeper understanding of human behavior among managers and executives. Far too often, organizations invest substantial time, money, and effort in training leaders on the financial and operational aspects of the business, yet they overlook the importance of equipping these individuals with knowledge about the science of human behavior. This oversight leads to the implementation of initiatives that fail to address the underlying reasons behind why people act the way they do, especially in the context of safety reporting.

    When managers and executives lack an understanding of human behavior, they may inadvertently create environments that discourage honest reporting. For instance, if leaders are not aware of how fear of punishment or desire for rewards can influence employees’ decisions to report—or not report—incidents, they might unintentionally reinforce behaviors that lead to underreporting. Without this foundational knowledge, even well-intentioned safety programs can miss the mark, resulting in a false sense of security and a failure to address real safety issues.

    To effectively promote a culture of safety, it is crucial that those in leadership positions understand the psychological factors that drive human behavior. This understanding allows them to create policies and practices that encourage transparency and honesty in reporting, rather than fostering environments where employees feel pressured to hide incidents to avoid negative consequences.

    The second solution to improving incident and accident reporting is to ensure that employees are thoroughly trained in incident reporting, incident investigations, and root cause analysis. It’s not enough to simply track the number of incidents that are reported; organizations must also delve deeper into understanding the root causes of these incidents and take corrective actions to address them. Many companies fall short by focusing solely on the incidents that are reported, without considering the underlying hazards that may have contributed to them. This narrow focus can lead to a reactive approach to safety, where issues are only addressed after an incident has occurred, rather than proactively identifying and mitigating risks before they result in harm.

    Proper training in incident reporting and investigation empowers employees to identify and report potential hazards, even if an incident hasn’t yet occurred. Root cause analysis, in particular, is a critical tool for uncovering the fundamental reasons behind accidents and near misses. By identifying these root causes, organizations can implement corrective measures that address the source of the problem, rather than just treating the symptoms. This approach not only helps to prevent future incidents but also contributes to the overall safety culture within the organization.

    In summary, the key to resolving the challenges of incident and accident reporting lies in two main strategies: first, educating managers and executives on the intricacies of human behavior, and second, providing employees with comprehensive training on incident reporting, investigations, and root cause analysis. By integrating these elements into the organizational culture, companies can create a more transparent, proactive, and effective approach to workplace safety. This not only protects employees but also strengthens the organization’s ability to maintain a safe and productive work environment.

    Download & View the Accident Investigation for Leaders Training below:

  • Improve Workplace Safety Culture 6 Steps

    Improve Workplace Safety Culture 6 Steps

    As a safety professional, your commitment to fostering a safe workplace is unwavering. You are well-versed in identifying potential hazards, implementing the latest safety protocols, and ensuring compliance with industry regulations. But while your expertise is crucial, it’s important to remember that not everyone in your organization has the same depth of understanding when it comes to workplace safety. The reality is, even the most advanced safety measures and equipment will fall short if the entire workforce isn’t aligned with the same commitment to safety.

    Understanding the True Essence of Safety Culture

    Many organizations make the mistake of equating a strong safety culture with the presence of top-tier personal protective equipment (PPE) or the existence of comprehensive safety programs. While these elements are undoubtedly important, they are only pieces of a much larger puzzle. A true safety culture goes beyond the tangible aspects of safety; it is rooted in the collective mindset and behaviors of every individual in the organization.

    Simply put, having the best PPE and the most well-designed safety programs means little if the people they are meant to protect aren’t fully engaged, aware, and motivated to use them correctly. Without a culture that genuinely values safety—where every employee feels a personal responsibility for their own safety and that of their colleagues—those efforts can become ineffective, even pointless.

    Check out the information I have available on PPE here

    The Heart of Safety Culture: Caring and Accountability

    At the core of a strong safety culture is a deep-seated care for the well-being of everyone in the organization. It’s not enough to have policies and procedures in place; what truly makes a difference is fostering an environment where employees inherently understand and appreciate the importance of safety.

    In a thriving safety culture, employees don’t just wear PPE because it’s mandated by policy; they do so because they care about their own safety and the safety of those around them. They recognize that every task, no matter how routine, carries potential risks, and they take proactive steps to mitigate those risks. This mindset doesn’t come from top-down directives alone—it comes from a shared understanding that safety is a fundamental value, integral to the way the organization operates.

    So, how do you go about establishing a safety culture?

    Traveler’s Insurance says there are 4 steps to starting a successful safety program, they are as follows:

    1. Evaluate risks. To understand how to create a safer workplace, you must first understand the risks you face every day. Each task and associated risk should be properly evaluated, and safety-based changes should be considered.

    • Analyze past incidents and near misses.Understand that past incidents can help you identify root causes and identify risks and exposures that threaten the safety of your employees and the success of your business.
    • Identify the risks before they result in loss. Review your work policies and procedures, buildings and equipment, employee work practices and behaviors and geographic location to determine if there are opportunities to prevent or mitigate loss. And hold people accountable to the practices.
    Check Out: How to Improve Your Safety Culture

    2. Design a plan to keep safe. A good plan is the best place to start, but it is only the beginning. Once you have a plan, you must act to eliminate or minimize risk.

    • Get commitment. Your management team should be committed to a safety culture from the beginning.
    • Stay focused. Keep focused on the risks and exposures identified during your evaluation.
    • Prioritize your efforts. Focus on the risks that pose the greatest threat. You should consider frequency and severity of the loss potential, and/or the opportunity to prevent or mitigate risks.
    • Identify solutions and resources.Your solutions can vary from implementing engineering controls to creating administrative policies and procedures. These can help create positive changes in safety attitude, commitment and culture.

    3. Implement your plan. Implementation entails communication of the plan and its details, training, regularly scheduled practice and drills, and ongoing review. A thorough plan will cover a number of potential risk areas, including buildings and equipment, the environment, employees, customers and vendors.

    • Communicate and train – the real test of a safety program and culture is not what is written down on paper, but rather how well it actually works. How well your plan works is often dependent on what your employees know and what they do at the time of an incident.
    Check Out: SMART Goals Guide

    4. Monitor, evaluate and improve your plan. As your business environment changes, so should your safety program. Regularly test your plan to determine if it fits the changing business environment and reflects changing accountabilities.

    • Monitor the plan and collect feedback to determine the effectiveness of the plan.
    • Regularly compare your safety performance against the plan’s expectations.
    • Make adjustments when necessary.
    • Recognize success. Be sure to communicate and celebrate your safety successes.

    Source

    As you see, the steps towards building a safety culture according to Traveler’s Insurance are simple, and should be followed in order.

    Once you’ve surpassed the basics of a safety culture in your workplace, consider building a sustainable safety culture. Do you know what steps to take concerning doing that, do you know the steps? The foundation of a sustainable workplace safety culture according to EHS Today:

    There are four cornerstones on which an effective safety culture can be built:

    • leading indicators,
    • accountability,
    • good relationships
    • and discretionary effort.

    Safety culture is not about compliance; it’s about commitment. It’s about creating a workplace where safety is ingrained in the fabric of the organization—where every employee, from the CEO to the newest hire, understands that safety is not just a policy but a shared value.

    When employees work towards their own safety, when they wear PPE not out of obligation but out of care, and when they approach each task with an understanding of the risks involved, that’s when a true safety culture is born. It’s not just about having the right equipment or the best programs; it’s about fostering a culture where safety is everyone’s responsibility and everyone’s priority.

    As a safety professional, your role is not only to implement safety measures but to inspire and cultivate this culture of care, awareness, and commitment. When this culture is fully realized, the impact is profound—reducing incidents, protecting lives, and creating a workplace where everyone can thrive.

    This pamphlet presents to you 6 Steps towards improving your safety culture, no matter where in the process you are. So start working towards a safer workplace today!

    Download the pamphlet 6 Steps to Improving Your Workplace Safety Culture

    View the pamphlet 6 Steps to Improving Your Workplace Safety Culture

     

  • Welding Safety Policy

    Welding Safety Policy

    The first consideration for safety in welding is the location and peculiarities of the space in which the welding operation is to be performed.

    Restrictions

    Weld or cut only in locations specifically designated for this purpose unless you have obtained approval of the job and have taken the necessary precautions to eliminate fire and explosion hazards.

    Do not weld in any location outside the shop unless you take the necessary precautions and get authorization. Before you weld in any compartment, room, tank, or adjacent space which contains or which has contained flammable or explosive materials, liquids, or vapors, make sure they are:

    • made safe,
    • tested, and
    • proclaimed safe.

    These restrictions also apply to closed drums, tanks, and similar containers.

    • Allow welding or cutting only in areas that are or have been made “fire safe.”
    • When you cannot move work practically, as in most construction work, the area must be made safe by removing combustibles or protecting combustibles from ignition sources.
    • If you cannot remove fire hazards, install suitable guards, or take special precautions as discussed below, then welding and cutting should not be performed.
    • If you cannot move the object to be welded or cut and if not all the fire hazards can be removed, use guards to confine the heat, sparks, and slag, and to protect the immovable fire hazards.

    Prohibited Areas

    Do not permit welding or cutting in the following situations:

    • in areas not authorized by management
    • in sprinklered buildings while such protection is impaired
    • in the presence of explosive atmospheres (mixtures of flammable gases, vapors, liquids, or dust with air)
    • inside uncleaned or improperly prepared tanks or equipment which have previously contained such explosive atmospheres or have the potential for explosive atmospheres
    • in areas with an accumulation of combustible dust
    • in areas near the storage of large quantities of exposed, readily ignitable materials such as bulk sulfur, baled paper, or cotton.

    An important component of welding safety is a Fire Prevention Plan, learn more here

    Basic Precautions for Fire Prevention

    Combustible material: Wherever there are floor openings or cracks in the flooring that you cannot close, you should take precautions so no readily combustible materials on the floor below is exposed to sparks that might drop through the floor. Use the same precautions for cracks or holes in walls, open doorways and open or broken windows.

    Combustible covers: Never weld on a metal partition, wall, ceiling or roof having a combustible covering nor on walls or partitions of combustible sandwich-type panel construction.

    Relocation of combustibles: If possible, relocate all combustibles at least 35 feet (10.7 m) from the work site. When relocation is not possible:

    • protect combustibles with flame-proofed covers, or
    • shield combustibles with metal or asbestos guards or curtains.

    Floors: Where combustible materials such as paper clippings, wood shavings, or textile fibers are on the floor, sweep the floor clean within a radius of 35 feet (10.7 m). In addition:

    • If floors are combustible, keep them wet, covered with damp sand, or protected by fire-resistant shields.
    • Protect workers operating arc welding or cutting equipment from shock where floors have been wet down.

    Ducts: Protect or shut down ducts and conveyor systems that might carry sparks to distant combustibles.

    Combustible walls: Where cutting or welding is done near walls, partitions, ceiling or roof of combustible construction, provide fire-resistant shields or guards to prevent ignition.

    Non-combustible walls: If you need to do welding on a metal wall, partition, ceiling or roof, prevent ignition of combustibles on the other side, preferably by relocating combustibles. Where you are not able to relocate the combustibles, be sure to provide a fire watch on the opposite side from the work.

    Pipes: Do not cut or weld on pipes or other metal in contact with combustible walls, partitions, ceilings or roofs if the work is close enough to cause ignition by conduction.

    Fire extinguishers: Position suitable fire extinguishing equipment and maintain it in a state of readiness for instant use. Depending on the nature and quantity of the combustible material, fire-extinguishing equipment may consist of:

    • pails of water,
    • buckets of sand,
    • hoses, or
    • portable extinguishers.

    Hot Work

    Hot work is any work that involves burning, welding, using fire- or spark-producing tools or that produces a source of ignition. Follow these general best practices below for hot work.

    • Do not perform hot work where flammable vapors or combustible materials exist.
    • Relocate work and equipment outside of the hazardous areas, when possible.
    • Make suitable fire-extinguishing equipment immediately available in a state of readiness. The equipment may consist of pails of water, buckets of sand, hose, or portable extinguishers dependent upon the nature and quantity of the combustible material exposed.
    • When performing hot work, assign a fire watch to guard.
    Check Out: Welding Safety Training

    Fire Watch

    A worker designated as the “Fire Watch” is required whenever welding or cutting is performed in locations where other than a minor fire might develop, or any of the following conditions exist:

    • Appreciable combustible material, in building construction or contents, closer than 35 feet (10.7 m) to the point of operation.
    • Appreciable combustibles are more than 35 feet (10.7 m) away but are easily ignited by sparks.
    • Wall or floor openings within a 35-foot (10.7 m) radius expose combustible material in adjacent areas including concealed spaces in walls or floors.
    • Combustible materials are adjacent to the opposite side of metal partitions, walls, ceilings, or roofs and are likely to be ignited by conduction or radiation.
    Test your knowledge on welding safely in the workplace with my quiz here

    The duties of a qualified fire watch include:

    • They must have fire-extinguishing equipment readily available.
    • Train them in how to use fire-extinguishing equipment.
    • They must be familiar with facilities for sounding an alarm in the event of fire.
    • They must watch for fires in all exposed areas, try to extinguish them only when obviously within the capacity of the equipment available, or otherwise sound the alarm.
    • They must maintain a fire watch for at least a half hour after completion of welding or cutting operations to detect and extinguish possible smoldering fires.

    View & Download the Welding Safety Policy below:

     

  • Near Miss Program

    Near Miss Program

    An employee is walking down a hallway, carrying a cup of coffee. While turning a sharp corner, they nearly collide with another employee, spilling coffee on the floor. Stepping into their office, the employee stumbles over an extension cord run across the doorway to power a printer, which pulls it to the floor.

    No one is hurt in this scenario. However, the employees in it experience multiple near-miss situations – any one of which could have led to a serious injury.

    It is important to have employees know how to identify these incidents as potential injury situations, called near misses. Besides identifying them, it is equally important to report them, so hazards and risks can be mitigated before they lead to a serious incident.

    Workers should be trained on how to properly identify and recognize potential hazards. To help make it easy for employees to submit near misses and ensure good data, consider allowing them to turn in near-miss reports anonymously.

    Collecting near-miss reports helps create a workplace safety culture that seeks to identify and control hazards, which will reduce risks and the potential for injury, according to OSHA. A well-run program goes beyond the collection of reports, it treats every near miss as important as an accident and investigates them. Conducting a root cause of a near miss can lead to a corrective action, before an injury occurs.

    Need to learn more about how to conduct root cause analysis?
    Check out my book here, and also check out my posts about root cause analysis.

    Reporting near misses and conducting a root cause of them, is only valuable if you complete the final step and correct the issues, otherwise the hazards remain a risk to employees.

    Consider using an Action Plan tracking sheet, like this one to ensure identified issues are corrected.

    A well laid out near miss program that involves properly trained employees, will decrease total workplace accidents over time. Don’t expect it to happen tomorrow, it can take 1-2yrs to see the changes. Don’t allow the program to slip in that time, because it requires long commitment to the program to reap the rewards.

    Download the Near Miss Program below

    View the Near Miss Program below

     

    Additional Near Miss Program resources

    Near Miss Reporting Form

     

    Near Miss Tracking Form

  • Action Plan Template

    Action Plan Template

    It is important that action items are tracked and assigned or delegated to responsible parties. Unassigned action items are useless as they will most likely never be completed.

    This form will help you track, delegate, and follow-up on all corrective actions that result from an investigation.

    Steps to a quality corrective action plan


    State the Problem

    Stating the problem is the first step to be considered when writing an action plan to correct problems. Unless the problem is stated appropriately, finding the root cause and in turn, identifying the solution is not feasible.

    For stating the problem, ask yourself a couple of questions:

    1. What is the current situation?
    2. What should be the right situation?
    3. What is the reason behind the current situation?
    4. What is the impact of the current situation?
    5. How can the current situation be rectified or resolved?

    The answers to the above questions will help you to state or define the problem statement.


    Define the Plan

    Once you’ve stated the problem, what is the next step? Move on to define the action plan.

    Once the problem statement is prepared, now it is time to define the action plan. The action plan helps to design the implementation phases of the processes. Assessing the current problems and evaluating the root causes are the key elements highly used in defining the action plan.

    The following criteria must be included in the action plan:

    • Change in the policies, processes and procedures
    • Training for resources
    • Changes in management system and tools
    • Product redesigning or re-engineering
    • Resource analysis
    • Implementation processes

    Create Ownership

    Once the action plan is strategized, assigning tasks to the team is the third important step. Create ownership to take care of each step in the corrective action plan. Many times, the process implementation from the corrective action plan requires collaboration from various departments, practices and functions.


    Establish Deadlines

    As already articulated, creating ownership or resource allocation is a vital step when writing the corrective action plan. Establishing deadlines is the next step to be considered in your plan. A plan without a defined schedule will definitely fail. Ensure the deadline defined to complete each step is appropriate and adequate to comply with all the processes.

    Unfair deadlines also create chaotic situations during the implementation phase. Inadequate deadlines lead to quality issues and delays in the final deliverables.

    Check Out: SMART Goals Guide

    Track and Monitor the Progress

    Once the processes, resources and deadlines are defined, it is imperative to develop ways to manage the progress. You need to create procedures to track and monitor the progress when writing the plan, this form is ideal for simple action plan tracking.

    Tracking and monitoring the progress while implementing processes from the action plan is critical to business growth and success. Doing it right at the first time always helps to save quality time and energy.

    Check out my Project Management Planner on Amazon

    An additional tip for getting buy-in to your corrective actions:

    Link to Compliance Record

    Corrective actions don’t exist in a vacuum. Rather, they should connect to relevant areas of the compliance record to communicate the full context of the problem. Each corrective action should be linked to the appropriate source, such as:

    • Audit results.
    • Nonconforming Materials.
    • Safety incidents.
    • Customer complaints.

     

    Members view the corrective action plan template below


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