If a worker is adversely affected by his or her work due to poor quality job design and working conditions or is injured on the job, there will be an adverse cost to the employer, as well as to the individual worker. Adverse costs can be divided into two categories: direct costs and impacts, and indirect costs and impacts.
Direct costs and impacts are the easiest to see and understand. These include medical expenses for emergency room and doctor visits, medical bills, medicines and rehabilitation; workers compensation; disruption to business activity; overtime to make up for lost productivity; repair or replacement of damaged materials and/or equipment; fines, penalties and legal liabilities
Indirect costs and impacts of an injury are more difficult to identify and are often overlooked. Research has shown this can be up to nearly 40 times the direct costs, depending on the industry and the occupation.
Indirect costs and impacts include administrative and supervisor/manager time dealing with the incident and accident investigation; increased insurance costs; reduced productivity; impact on company morale and customer service; remedial and compliance costs for any equipment safeguards or modifications; safety training and/or development; and creation of new workplace policies, procedures and monitoring.
GOOD HOUSEKEEPING
"Maintenance and repair orders don't stop because a technician is out with a work-related injury," says Karen D. Hamel, the technical education manager for New Pig Corporation. "What's worse is determining that the injury could have been prevented with something as simple as good housekeeping."
New Pig is a supplier of innovative liquid management solutions to industrial, institutional and government facilities in more than 40 countries. www.newpig.com.
Good workplace housekeeping - routine maintenance and upkeep - reduces injuries and accidents, improves morale, reduces fire potential and can even make operations more efficient, officials at W.W. Grainger add. Workplace housekeeping should be an integral part of every company's loss control program.
Grainger is North America's leading broad line supplier of maintenance, repair and operating products. www.grainger.com.
The officials note that the Occupational Safety and Health Administration (OSHA) makes reference to housekeeping in several health and safety standards contained in Title 29 of the Code of Federal Regulations (29 CFR). Per these regulations, all places of employment, passageways, store rooms and service rooms must be kept clean and orderly, and in a sanitary condition.
In order to ensure that proper workplace housekeeping is maintained, a continuous process of housekeeping should be incorporated into all processes, operations and tasks performed in the workplace advise the Grainger officials.
Furthermore, they say each worker needs to understand that workplace housekeeping is an integral part of his/her job and not merely a supplement to work he/she already performs. As workplace housekeeping becomes a standard part of operations, less time and effort are needed to maintain it at an appropriate level.
Workplace housekeeping levels are most easily maintained if they are completed throughout the day as needed, they say. At the end of the shift, all areas should be thoroughly cleaned in preparation for the next day or the following shift.
SLIP-AND-FALL INJURIES
Leaks and spills that aren't cleaned up promptly create slippery floors and track messes throughout the shop, leading to slips, trips and falls - the second leading cause of workplace injuries and lost work time, according to the Bureau of Labor and Statistics, says New Pig's Hamel.
The National Floor Safety Institute finds that slip and fall accidents account for more than one million hospital visits annually. It encourages workers to quickly report safety issues, such as a wet floor or equipment malfunctions, to a manager to prevent accidents and keep employees in the workplace.
Employers that proactively encourage safety have the potential to significantly reduce injuries.
"Identifying slip-and-fall hazards isn't complicated - just follow liquids through the shop and look for areas that are untidy," Hamel says. "Although every shop has unique hazards, fluid dispensing stations, work areas and waste collection sites are common locations for leaks, spills and clutter.
According to the National Floor Safety Institute (NFSI), creating and utilizing a floor safety plan that identifies hazards and includes good housekeeping practices, proper footwear, signage and cleaning materials can help reduce slip and fall injuries by up to 90 percent, she notes.
FLOOR SAFETY PLAN
Like most changes, it takes some time and effort for good housekeeping and safety changes to become habits, says Hamel, who recommends the following elements to help a floor safety plan succeed:
- Cleanup supplies and barriers. "Whether it is a dust pan and broom to sweep up metal shavings and dust, or absorbents to clean up spills near a waste oil tank, if clean up supplies are not readily available, people will not use them," she says. "Few people will take the time to go to the other end of the building to get the supplies that they need.
"Making them readily available where spills or messes happen encourages faster response.
"Likewise, having traffic cones or other barrier devices readily available can help divert traffic or people away from a hazardous area until it can be cleaned up or the hazard corrected."
- Signage. "Signs help to reinforce safety, identify hazards and help people know where to find things," says Hamel.
Signs can be as simple as a notice on the door that reminds every one of the need for safety glasses and proper footwear, or a sign on the wall that says "spill kit" and has an arrow pointing to its location.
- Cleaning chemicals. It is not uncommon for the wrong cleaning chemical to cause slippery floor problems, Hamel observes. Check with cleaning chemical suppliers to determine how much of a cleaning chemical should be used when cleaning a floor, and how often cleaning is recommended.
"Two very common problems are using too much of a cleaning chemical - more isn't always better, or not using it often enough."
- Footwear. "Consider footwear as a tool," advises Hamel. "Like an impact wrench or a pad sander, it needs to be taken care of, and it needs to be replaced from time to time.
"Unfortunately, the lifespan on a pair of work boots is probably a lot shorter than other tools. Establish a change-out policy for footwear that encourages replacement at proper intervals.
INCENTIVE PROGRAMS
In most cases, on-the-job accidents and the accompanying loss of productivity and efficiency can be avoided by establishing manager/employee safety committees, instituting regular training programs and inspections, and creating safety incentive programs. Such programs have become a commonplace approach used by all types of vehicle maintenance operations to improve safety and reduce workers' compensation claims and other worker injury-related costs.
For these types of programs to be effective, they must be properly developed, implemented and maintained.
Officials at Grainger, offer the following advice for crafting an effective safety incentive program.
1. Define objectives.
First, concentrate attention where incidents are occurring, stress the officials. Then, gather the appropriate personnel and analyze your company's incident/injury rates and subsequent lost-work times.
"This will help identify the areas that need to be focused on and give the background necessary to set reasonable goals," they note.
"Involve everyone, especially management. Management's involvement and support is vital to set the tone for employees."
Furthermore, they say employees should be encouraged to become involved by submitting safety ideas and be rewarded for pointing out safety hazards.
2. Choose a format.
Get to know the needs of supervisors and employees, then select activities for the safety incentive program that will yield results.
One way to get information from workers is to take an inventory or a survey of opinions, the Grainger officials say. A safety suggestion box is another tool to use to solicit ideas.
Employees need to understand why the program is being implemented. The program's goals, rules, how it works and how progress is measured must be clearly defined and easily understood. The awards/rewards should be tailored to fit the workforce.
3. Maintain interest.
The supervisor plays an important role in creating and maintaining interest in a safety awareness program, Grainger officials say. A supervisor is responsible for translating management's policies into action and for promoting safety activities directly among the employees.
It is the responsibility of management that the safety director and supervisors receive adequate safety training. Essentially, supervisors are directly accountable for the safety of their employees.
The supervisor's attitude toward safety is a significant factor in the success not only of specific promotional activities, but of the entire safety program as well.
4. Create safety committees.
Safety committees play a key role in any safety program as they can help share the responsibilities of implementing and monitoring the program, plus maintain interest in safety and health, all of which helps to reduce accidents.
Safety committee membership should be rotated periodically, suggest the Grainger officials. "Rotation allows for new viewpoints while it increases the number of employees to look at operations through the eyes of safety."
Biobased solutions for the safety of shop workers and the environment
By Mike Guggenheimer, Vice President, Business Development, RSC Bio Solutions
Safety considerations are just as important in the shop as they are out in the field. In fact, the confined environment of the shop can make small incidents turn into bigger problems.
Conventional chemical products often have ingredients that are irritating to the skin, and in some cases can result in a serious burn. Even inhaling the products' vapors in a tight space can be a health concern that requires the use of protective equipment.
The hazards of conventional chemical products extend beyond contact with the fleet worker, as they can be highly flammable or combustible. These products often require special storage and handling and present additional risks to the vehicle maintenance operation.
Biobased solutions offer options for the workers using them that reduce the hazards associated with many conventional products. Despite the persistent myth that there is a trade-off in performance when using non-hazardous chemicals, advanced biobased products are engineered to work effectively for even the toughest applications.
SPECIAL FORMULATIONS
There are a variety of cleaners, degreasers and lubricants formulated for high performance applications and designed to work alongside traditional, petroleum-based products without compromise. These products are often readily-biodegradable, limiting the impact on the environment if there is a spill and do not contain any harsh ingredients that would irritate the skin or damage sensitive surfaces.
The products have low or no volatile organic content (VOC) so there's little or no impact on ground level air quality, and high flashpoints make them safer to store and handle.
Using a non-hazardous cleaner like Gunk powered by SafeCare Truck and Equipment Wash, for example, will clean a fleet as well as conventional cleaners while mitigating the risk of fines from a spill or exposure in the environment.
Many facilities are finding that municipalities are scrutinizing waste water content more closely and these products create new, efficient options for compliance.
Biobased lubricants have also been improved to the point that they can go head-to-head with conventional products in terms of performance. Some lubricants, like the Liquid Wrench powered by EnviroLogic brand biobased penetrating oil delivers industry-leading performance loosening rusted and stuck nuts and bolts with the enhanced safety benefits of a non-hazardous and readily-biodegradable formula.
When you consider all of the ways biobased technology can reduce risk and eliminate hazards, it is like a cheap insurance policy.
Mike Guggenheimer is vice president of business development for RSC Bio Solutions, a company focused on providing high-performance chemistries that are safe, non-hazardous and environmentally responsible. www.rscbio.com.
Precautions for safe ladder use
Safety professionals recommend sharing the following ladder safety tips for all personnel that use ladders.
Straight ladders:
- Inspect ladders for potential dangers before using. Never use a damaged ladder. Have them placed out of service for repair or have them destroyed.
- Make sure the ladder has firm, solid, level footing to keep it from slipping or falling.
- Place the ladder so that its base is one foot away from what the ladder leans against for every four feet in height to the point where the ladder rests. This is referred to as the four-to-one rule. For example, if a 16-foot ladder leans against a trailer, its base should be placed four feet from the trailer.
- Always face the ladder and use both hands to grip the side rails when climbing or descending.
- Do not carry tools or materials in your hand. Use a rope to hoist them up and down, or wear a toolbelt or pouch.
- Always keep your body centered between the ladder rails. If your belt buckle goes outside of the side rails, you're reaching too far. Reposition the ladder.
- Do not stand on the top four rungs of the ladder.
- Only one person should be on a ladder at a time.
Step Ladders:
Some additional safety tips come into play for step ladders.
- Make sure the legs are fully extended and the spreader locked. The locking device on some ladders may present a pinching hazard, so keep fingers clear when setting up the ladder.
- Never use a folding step ladder in an unfolded position as a straight ladder.
- Do not stand on the top two steps of a step ladder.
- Never place a step ladder upon other objects, such as boxes, barrels, scaffolds or other unstable bases, in an effort to obtain additional height.
The impacts of flooring systems
When it comes to vehicle maintenance, the level of service customers receive and the labor rate they are charged is often times in direct correlation to the technician's skills and the aesthetics of the facility, says Alex Dittenhoffer, strategic accounts manager for Dur-A-Flex.
The company is a privately-held, leading manufacturer of epoxy, urethane, methyl methacrylate and colored aggregates, offering a complete line of high performance polymer flooring and wall systems that provide improved safety, minimal downtime and easy maintenance. www.dur-a-flex.com.
Customers want their vehicles maintained correctly, safely and ready on time, he goes on. The last thing that anyone needs is to have a critical item on a PM inspection overlooked or a bolt lost while working on a customer's rig in a dingy, poorly lit facility.
RESINOUS FLOORING
Resinous floor systems have been a necessary addition to a quality-focused, safe vehicle maintenance area, says Dittenhoffer.
Resinous flooring is typically comprised of epoxy, methyl methacrylate or urethane-based liquids that are formulated to bond to concrete, wood or other rigid substrates to provide a safe, clean, durable and aesthetically appealing flooring solution. These floor systems are smooth, seamless and non-porous, offering stain- and chemical-resistance, greater durability and slip-free safety.
"Resinous floor systems provide up to 200 percent reflectivity from overhead lighting, making it easy for technicians to see what needs to be done and to effortlessly retrieve a dropped bolt or tool that falls beneath the vehicle's chassis," he says.
"Bounce back" light reflectivity, along with a much easier to clean, professional looking facility, are among the reasons that companies like Ryder choose Dur-A-Flex resinous floor systems for many of their facilities.
Resinous flooring can also be used to identify safe pedestrian areas, truck drive-thru pathways, chemical storage, fire extinguishers, trash receptacles and access doorways, he notes. Plus, the flooring can easily handle a high level of activity.
SPECIAL ATTENTION
At first glance, a floor choice may seem as easy as opening a can of paint and getting started on your own. However, says Dittenhoffer, an oil-soaked concrete floor needs special attention before a resinous system can be installed.
Often, an analysis of the concrete must be performed to determine the extent of oil and lubricant penetration, he explains. Next, the type of concrete preparation must be considered.
"Expansion joints and floor drains can also derail a flooring project if not taken into account. Concrete moisture transmission is also a potential problem and, if not addressed properly, will result in water blisters on the floor, thus creating a safety hazard."
Lastly, the right floor system has to meet the needs of the service facility, says Dittenhoffer. Chemical abuse, dropped tools and the stress of slow moving tires that are often caked with sand from the outdoor staging area will quickly destroy a poorly installed floor system.
"A resinous floor system can enhance the performance of a shop's service team while providing a safe, world-class facility, including lubrication areas, tire installation and wash down bays. The secret to choosing the right floor is to start with a professional consultation from a flooring system provider to help you to understand the choices that are available."
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