Module 2: Occupational Safety

Occupational Safety vs. Process Safety

Occupational safety focuses mainly on preventing injuries to personnel that can result
from incidents associated with the job they perform in the workplace.Occupational
incidents tend to cause injuries to a small number of people. Common causes of:

Nonfatal occupational incidents include the following:

 Slipping, tripping, or falling incidents

 Being struck or compressed with an object or equipment (including motor
vehicles)
 Motorized vehicle accidents
 Overexertion

Fatal injuries based on US DOL statistics show similar causes,

 Violence and other injuries by persons or animals

 Transportation incidents
 Fires and explosions
 Falls, slips, and trips
 Exposure to harmful substances or environments
 Contact with objects and equipment

Process safety on the other hand focuses on preventing incidents related to the
process that can mainly lead to loss-of-containment events. In other words, process
safety for pipelines focuses on preventing leaks of hazardous material from pipelines
that can cause catastrophic accidents and could potentially impact a large number of
people. Process safety incidents typically cause a large number of fatalities and injuries
compared with occupational safety events.

What is Occupational Safety Hazard?

Occupational Safety Hazards are unsafe working conditions that that can cause injury,
illness, and death as a consequence of a particular occupation. Safety hazards are the
most common workplace risks.

5 Elements of an Effective Safety Culture

1. Responsibility – each individual is morally and ethically bound to act

responsibly for the good of his fellow employees, his company, and society as a
whole.
2. Accountability – managers must be accountable to lead by example each and
every day.
 3. Clear Expectations – safety expectations need to be set and communicated to
everyone in the organization.
4. Ethics – ethically driven management systems are important in developing a
strong safety culture.
5. Next Steps – a safety perception survey can help to evaluate company’s safety
culture to determine areas for improvement.

Housekeeping

The basic concept of housekeeping has started from keeping a domestic house clean
and has gradually come to maintaining high standards of cleanliness and maintenance
at commercial levels. Besides this, housekeeping should also contribute to the saving in
costs of labor, cleaning material and equipment, furnishings and the like in every type of
establishments.

Housekeeping means performing all the duties towards cleaning, maintaining

orderliness, and running a house or a business property. Housekeeping may also
defined as the provision of a clean, comfortable and safe environment.

Objectives of Hotel Housekeeping

The main objectives of housekeeping are:

 To maintain overall cleanliness of the entire hotel, establishments and plant

industries at all times.
 To perform cleanliness duties most efficiently and effectively.
 To use good quality, safe cleaning equipment and chemicals.

Workplace Housekeeping

Effective housekeeping can help control or eliminate workplace hazards. Poor

housekeeping practices frequently contribute to incidents. If the sight of paper, debris,
clutter and spills is accepted as normal, then other more serious hazards may be taken
for granted.
Housekeeping is not just cleanliness. It includes keeping work areas neat and orderly,
maintaining halls and floors free of slip and trip hazards, and removing of waste
materials (e.g., paper, cardboard) and other fire hazards from work areas. It also
requires paying attention to important details such as the layout of the whole workplace,
aisle marking, the adequacy of storage facilities, and maintenance. Good housekeeping
is also a basic part of incident and fire prevention.
Effective housekeeping is an ongoing operation: it is not a one-time or hit-and-miss
cleanup done occasionally. Periodic "panic" cleanups are costly and ineffective in
reducing incidents.

Purpose of Workplace Housekeeping

Poor housekeeping can be a cause of incidents, such as:

 tripping over loose objects on floors, stairs and platforms

 being hit by falling objects
 slipping on greasy, wet or dirty surfaces
 striking against projecting, poorly stacked items or misplaced material
 cutting, puncturing, or tearing the skin of hands or other parts of the body on
projecting nails, wire or steel strapping

To avoid these hazards, a workplace must "maintain" order throughout a workday.

Although this effort requires a great deal of management and planning, the benefits are
many.

Benefits of Good Housekeeping Practices

Effective housekeeping results in:

 reduced handling to ease the flow of materials

 fewer tripping and slipping incidents in clutter-free and spill-free work areas
 decreased fire hazards
 lower worker exposures to hazardous products (e.g. dusts, vapours)
 better control of tools and materials, including inventory and supplies
 more efficient equipment cleanup and maintenance
 better hygienic conditions leading to improved health
 more effective use of space
 reduced property damage by improving preventive maintenance
 less janitorial work
 improved morale
 improved productivity (tools and materials will be easy to find)
Plan a Good Housekeeping Program

A good housekeeping program plans and manages the orderly storage and movement
of materials from point of entry to exit. It includes a material flow plan to ensure minimal
handling. The plan also makes sure that work areas are not used as storage areas by
having workers move materials to and from work areas as needed. Part of the plan
could include investing in extra bins and more frequent disposal.
The costs of this investment could be offset by the elimination of repeated handling of
the same material and more effective use of the workers' time. Often, ineffective or
insufficient storage planning results in materials being handled many times and being
stored in hazardous ways. Knowing the workplace layout and the movement of
materials throughout it will help when planning work procedures.
Worker training is an essential part of any good housekeeping program. Workers need
to know how to work safely with the products they use. They also need to know how to
protect other workers such as by posting signs (e.g., "Wet - Slippery Floor") and
reporting any unusual conditions.
Housekeeping order is "maintained" not "achieved." Cleaning and organization must be
done regularly, not just at the end of the shift. Integrating housekeeping into jobs can
help ensure this is done. A good housekeeping program identifies and assigns
responsibilities for the following:

 clean up during the shift

 day-to-day cleanup
 waste disposal
 removal of unused materials
 inspection to ensure cleanup is complete

Do not forget out-of-the-way places such as shelves, basements, sheds, and boiler
rooms that would otherwise be overlooked.
The final step to any housekeeping program is inspection. It is the only way to check for
deficiencies in the program so that changes can be made. Examples of checklists
include inspecting offices and manufacturing facilities.

9 Elements of an Effective Housekeeping Program

1. Maintenance

The maintenance of buildings and equipment may be the most important element of
good housekeeping. Maintenance involves keeping buildings, equipment and machinery
in safe, efficient working order and in good repair. It includes maintaining sanitary
facilities and regularly painting and cleaning walls. Broken windows, damaged doors,
defective plumbing and broken floor surfaces can make a workplace look neglected;
these conditions can cause incidents and affect work practices. So it is important to
replace or fix broken or damaged items as quickly as possible. A good maintenance
program provides for the inspection, maintenance, upkeep and repair of tools,
equipment, machines and processes.

2. Employee Facilities

Employee facilities need to be adequate, clean and well maintained. Lockers may be
necessary for storing employees' personal belongings. Washroom facilities require
cleaning once or more each shift. They also need to have a good supply of soap, towels
plus disinfectants, if needed.
If workers are using hazardous products, employee facilities should provide special
precautions as needed such as showers, washing facilities and change rooms. Some
facilities may require two locker rooms with showers between. Using such double locker
rooms allows workers to shower off workplace contaminants and reduces the chance of
contaminating their "street clothes" by keeping their work clothes separated from the
clothing that they wear home.
Smoking, eating or drinking in the work area should be prohibited where hazardous
products are handled. The eating area should be separate from the work area and
should be cleaned properly each shift.
3. Surfaces
Floors: Poor floor conditions are a leading cause of incidents so cleaning up spilled oil
and other liquids at once is important. Allowing chips, shavings and dust to accumulate
can also cause incidents. Trapping chips, shavings and dust before they reach the floor
or cleaning them up regularly can prevent their accumulation. Areas that cannot be
cleaned continuously, such as entrance ways, should have anti-slip flooring. Keeping
floors in good order also means replacing any worn, ripped, or damaged flooring that
poses a tripping hazard.
Walls: Light-coloured walls reflect light while dirty or dark-coloured walls absorb light.
Contrasting colours warn of physical hazards and mark obstructions such as pillars.
Paint can highlight railings, guards and other safety equipment, but should never be
used as a substitute for guarding. The program should outline the regulations and
standards for colours.
4. Maintain Light Fixtures
Dirty light fixtures reduce essential light levels. Clean light fixtures can improve lighting
efficiency significantly.
5. Aisles and Stairways
Aisles should be wide enough to accommodate people and vehicles comfortably and
safely. Aisle space allows for the movement of people, products and materials. Warning
signs and mirrors can improve sight-lines in blind corners. Arranging aisles properly
encourages people to use them so that they do not take shortcuts through hazardous
areas.
Keeping aisles and stairways clear is important. They should not be used for temporary
"overflow" or "bottleneck" storage. Stairways and aisles also require adequate lighting.
6. Spill Control
The best way to control spills is to stop them before they happen. Regularly cleaning
and maintaining machines and equipment is one way. Another is to use drip pans and
guards where possible spills might occur. When spills do occur, it is important to clean
them up immediately. Absorbent materials are useful for wiping up greasy, oily or other
liquid spills. Used absorbents must be disposed of properly and safely.
7. Tools and Equipment
Tool housekeeping is very important, whether in the tool room, on the rack, in the yard,
or on the bench. Tools require suitable fixtures with marked locations to provide an
orderly arrangement. Returning tools promptly after use reduces the chance of it being
misplaced or lost. Workers should regularly inspect, clean and repair all tools and take
any damaged or worn tools out of service.
8. Waste Disposal
The regular collection, grading and sorting of scrap contribute to good housekeeping
practices. It also makes it possible to separate materials that can be recycled from
those going to waste disposal facilities.
Allowing material to build up on the floor wastes time and energy since additional time is
required for cleaning it up. Placing scrap containers near where the waste is produced
encourages orderly waste disposal and makes collection easier. All waste receptacles
should be clearly labelled (e.g., recyclable glass, plastic, scrap metal, etc.).
9. Storage
Good organization of stored materials is essential for overcoming material storage
problems whether on a temporary or permanent basis. There will also be fewer strain
injuries if the amount of handling is reduced, especially if less manual material handling
is required. The location of the stockpiles should not interfere with work but they should
still be readily available when required. Stored materials should allow at least one metre
(or about three feet) of clear space under sprinkler heads.
Stacking cartons and drums on a firm foundation and cross tying them, where
necessary, reduces the chance of their movement. Stored materials should not obstruct
aisles, stairs, exits, fire equipment, emergency eyewash fountains, emergency showers,
or first aid stations. All storage areas should be clearly marked.
Flammable, combustible, toxic and other hazardous materials should be stored in
approved containers in designated areas that are appropriate for the different hazards
that they pose. Storage of materials should meet all requirements specified in the fire
codes and the regulations of environmental and occupational health and safety
agencies in your jurisdiction.
5S Method of Housekeeping

5S is a method of work organized in 5 stages with the goal of significantly improving the
order and cleanliness.

5S are particularly effective because they want to improve the housekeeping of your
workshops and the rest of your premises in order to obtain the following advantages :

 Improve safety
 Improve the working atmosphere and environment
 Improve the quality of work and products
 Enable efficient maintenance
 Enhance your image and customer trust
 Prepare the launch of other methodologies

5S Principles (Japanese Management Techniques)

1. Seiri : sort means eliminating anything that is unnecessary for the equipment to
work properly.
2. Seiton : straightening is the best way of eliminating pointless searching and
having all the material necessary for functional production according to the
principle: “a place for everything and everything in its place.”
3. Seiso : shining means keeping everything so clean that it shines.
In a clean environment, any leak or other abnormality can be detected faster.
Working in a clean environment improves motivation and safety. This is a
prerequisite for quality maintenance.
4. Seiketsu : standardizing means respecting the previous 3S.
The 3S are actions to take; so that cleanliness and elimination of the causes of
untidiness become the norm, it is essential to write them down as ordinary rules,
as standards.
Seiketsu helps to overcome the natural tendency to slovenliness and a return to
old habits.
5. Shitsuke : sustain after a period of 3 to 6 months (depending on the size and
complexity of the workshop), the time has come to evaluate the situation by
means of an in-depth audit. The audit is based on a very precise questionnaire,
which assesses the previous 4S, and which leads, if successful – to the site
being certified.

Material Handling Safety

Material handling is one of the leading causes of work-related injuries. Each year
thousands of back injuries, hand injuries and arm strains are attributed to improper
lifting and carrying of heavy objects. An understanding of how to prevent injury to
yourself and others is necessary when your task involves material handling.
Materials handling is a form of logistics movement that includes any process that
involves the movement between vehicles, conveyors, store rooms, other forms of
logistics support where employees are involved to some extent.

Effective Material Handling Safety Policy

The foundation for a safe workplace starts with policies and procedures that senior
management must put in place. A comprehensive health and safety policy would
include the appropriate level of guidelines on material handling and the associated
employee training program.

A key portion of the policy would be the safety compliance activity that is essential for
the business to operate. Most importantly, the policy would inform on the shared
responsibilities of each employee in keeping the workplace safe.

Safety Training for Materials Handling

There are employee safety risks involved with materials handling in distribution centers,
warehouses, shop floors and loading docks. The mitigation of safety risks starts
with proper training in awareness, procedures and safety equipment.
Safety training should be mandated for any new employees involved with lifting,
carrying, loading or transporting materials in any form. In addition to new hire
training, the safety risks and potential safety compliance rules may require re-
certification on an annual or other regular time cycle.

Materials Handling Safety Procedures

The day to day handing of materials continues free of accident or injury when safety
procedures are consistently followed. Procedures start with awareness of the specific
materials handling risks involved and the proper safety equipment for the situation.
Procedures would cover the types of material, and the conditions of the work area.

List for safely lifting and moving materials:

 Maintain the correct posture: avoid bending over and keep lifts close to the
body
 Lift in a careful, deliberate manner and avoid any sudden lift movements
 Never lift materials from a sitting position, or twist to pick up a heavy object
 Use the correct grip on objects; lifts should be shoulder high and with full
grasp of the hands
 Get assistance from co-workers to avoid successive lifts of heavy objects
 Always make use of conveyors, slides or other devices, to avoid
unnecessary lifting or pushing of objects
 Always go around a blocked pathway, never step over an obstacle while
carrying material
 Maintain a clear line of site; objects should not block vision; lift only where
there is sufficient lighting
 Whenever possible; reduce load sizes, adjust bulky objects to ease
movement
 Regularly stretch back and leg muscles during the day and keep in good
physical shape