Findings From the National Machine Guarding Program: A Small Business Intervention: Lockout/Tagout

Career readiness: Finding a place for health and safety education

BACKGROUND

Studies have identified gaps in health and safety knowledge and work practices of vocational students in the United States and abroad. Little is known about what, how, when, or if health and safety are taught and if the teaching that takes place is effective. Faculty skilled in their technical area may lack knowledge related to health and safety and pedagogy. This knowledge gap is compounded by a deficiency or absence of high-quality safety and health resources for vocational and technical college faculty, the use of outdated and often inaccurate information, and lack of any standardized assessment of knowledge and skills.

METHODS

To identify these knowledge gaps, we conducted group interviews with auto body collision technology and machine tool technology faculty at two colleges.

RESULTS

Most instructors reported a rapid transition from technical trade worker or business owner into their faculty role, with little support or education related to teaching. No instructor used a defined health and safety curriculum and materials or could describe the breadth safety skills required for their profession. Instructors tested and evaluated health- and safety-related skills on an ad hoc basis and said that workers and employers were ultimately responsible for job health and safety.

CONCLUSIONS

Standardized health and safety training is needed nationally and should be progressive and integrated with career-specific educational programs. It should ensure that students obtain knowledge and understanding of how to apply the principles of safety and health and communicate with employers about health- and safety-related issues.

Self-audit of lockout/tagout in manufacturing workplaces: A pilot study

BACKGROUND

Occupational health and safety (OHS) self-auditing is a common practice in industrial workplaces. However, few audit instruments have been tested for inter-rater reliability and accuracy.

METHODS

A lockout/tagout (LOTO) self-audit checklist was developed for use in manufacturing enterprises. It was tested for inter-rater reliability and accuracy using responses of business self-auditors and external auditors.

RESULTS

Inter-rater reliability at ten businesses was excellent (κ = 0.84). Business self-auditors had high (100%) accuracy in identifying elements of LOTO practice that were present as well those that were absent (81% accuracy). Reliability and accuracy increased further when problematic checklist questions were removed from the analysis.

CONCLUSIONS

Results indicate that the LOTO self-audit checklist would be useful in manufacturing firms' efforts to assess and improve their LOTO programs. In addition, a reliable self-audit instrument removes the need for external auditors to visit worksites, thereby expanding capacity for outreach and intervention while minimizing costs.

Analysis of workers' compensation claims data for machine-related injuries in metal fabrication businesses

BACKGROUND

Metal fabrication workers are at high risk for machine-related injury. Apart from amputations, data on factors contributing to this problem are generally absent.

METHODS

Narrative text analysis was performed on workers' compensation claims in order to identify machine-related injuries and determine work tasks involved. Data were further evaluated on the basis of cost per claim, nature of injury, and part of body.

RESULTS

From an initial set of 4,268 claims, 1,053 were classified as machine-related. Frequently identified tasks included machine operation (31%), workpiece handling (20%), setup/adjustment (15%), and removing chips (12%). Lacerations to finger(s), hand, or thumb comprised 38% of machine-related injuries; foreign body in the eye accounted for 20%. Amputations were relatively rare but had highest costs per claim (mean $21,059; median $11,998).

CONCLUSIONS

Despite limitations, workers' compensation data were useful in characterizing machine-related injuries. Improving the quality of data collected by insurers would enhance occupational injury surveillance and prevention efforts. Am. J. Ind. Med. 59:656-664, 2016. © 2016 Wiley Periodicals, Inc.

Findings From the National Machine Guarding Program-A Small Business Intervention: Machine Safety

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Objectives:

The purpose of this nationwide intervention was to improve machine safety in small metal fabrication businesses (3 to 150 employees). The failure to implement machine safety programs related to guarding and lockout/tagout (LOTO) are frequent causes of Occupational Safety and Health Administration (OSHA) citations and may result in serious traumatic injury.

Methods:

Insurance safety consultants conducted a standardized evaluation of machine guarding, safety programs, and LOTO. Businesses received a baseline evaluation, two intervention visits, and a 12-month follow-up evaluation.

Results:

The intervention was completed by 160 businesses. Adding a safety committee was associated with a 10% point increase in business-level machine scores (P < 0.0001) and a 33% point increase in LOTO program scores (P < 0.0001).

Conclusions:

Insurance safety consultants proved effective at disseminating a machine safety and LOTO intervention via management-employee safety committees.

Findings From the National Machine Guarding Program: A Small Business Intervention: Lockout/Tagout

OBJECTIVE

Failure to implement lockout/tagout (LOTO) procedures adversely affects the rate of work-related fatalities and serious traumatic injury and is one of the most frequently cited Occupational Safety and Health Administration standards. This study assesses the impact of a nationwide intervention to improve LOTO in small metal fabrication businesses.

METHODS

Insurance safety consultants conducted a standardized and validated evaluation of LOTO programs and procedures. Businesses received a baseline evaluation, two intervention visits, and a 12-month follow-up evaluation.

RESULTS

The intervention was completed by 160 businesses. The mean LOTO procedure score improved from 8% to 33% (P < 0.0001), the mean program score went from 55% to 76% (P < 0.0001), and the presence of lockable disconnects went from 88% to 92% (P < 0.0001).

CONCLUSIONS

This nationwide intervention showed substantial improvements in LOTO. It provides a framework for assessing and improving LOTO.