7/3/2015IENG 475: Computer-Controlled Manufacturing Systems 1 IENG Lecture 04 Manufacturing Safety

7/3/2015 IENG 475: Computer-Controlled Manufacturing Systems 2 Agenda Questions & Issues Safety Regulation NIOSH OSHA Liability Accident Theory Domino Theory Human Factors Theory Multiple Causation Theory Four Tools

7/3/2015 IENG 475: Computer-Controlled Manufacturing Systems 3 Safety Regulation The Occupational Safety & Health Act of 1970 created: NIOSH (National Institute for Occupational Safety and Health) which develops standards, performs research, and conducts education and training OSHA (Occupational Safety & Health Administration) which enforces standards to ensure safe and healthy working conditions

7/3/2015 IENG 475: Computer-Controlled Manufacturing Systems 4 OSHA Requirements for Employers “Each employer shall furnish to each of his or her employees employment and a place of employment free from recognized hazards that are causing or likely to cause death or serious harm to his employees and shall comply with occupational safety and health standards under this Act”.

7/3/2015 IENG 475: Computer-Controlled Manufacturing Systems 5 OSHA Requirements for Employees Employees have the responsibility to “…comply with occupational safety and health standards and all rules, regulations and orders issued pursuant to this Act that are applicable to his or her own actions and conduct”.

7/3/2015 IENG 475: Computer-Controlled Manufacturing Systems 6 Liability Employers ARE strictly liable for compliance with OSHA regulations Employees ARE NOT strictly liable for OSHA regulations BOTH employers and employees may be held to account for safety under general liability Know or could have reasonably foreseen of a problem and did not take appropriate action “Deep Pockets” legal theory applies Professional censure for engineers applies

7/3/2015 IENG 475: Computer-Controlled Manufacturing Systems 7 Safety Theory – Domino Theory Herbert Heinrich Study (1920s & 1930s): 88% caused by unsafe acts 10% caused by unsafe conditions 2% caused by unavoidable “acts of God” Sequence of Factors (dominos): 1. Ancestry & Social Environment – predisposing factors 2. Fault of Person (character flaw) – poor choice made 3. Unsafe Act and Physical Hazard – action taken in the presence of a hazard 4. Accident – unexpected result 5. Injury – outcome of unexpected result Removing any domino prevents the accident!

7/3/2015 IENG 475: Computer-Controlled Manufacturing Systems 8 Safety Theory – Human Factors Theory Humans are error prone – accident is a chain of events that lead to a human error Three factors that lead to the error: Overload – limitations on amount of stress that individuals can handle Working environment Health & physical condition Personal commitments & problems Job responsibilities Inappropriate Response – (lack of) experience, training, proper demeanor Inappropriate Activities – action taken based on incorrect judgement Prevent all three to avoid the accident!

7/3/2015 IENG 475: Computer-Controlled Manufacturing Systems 9 Safety Theory – Multiple Causation Theory Extension of Domino Theory – accidents may have multiple causes (more than one domino) but eliminating either one of two categories of causes will prevent an accident Behavioral – human elements contrary to safe operations, such as: Inadequate skill or training Fatigue or inattentiveness Environmental – physical elements contrary to safe operations, such as: Inadequate lighting, housekeeping, noise control Inadequate safeguards, personal protective equipment

7/3/2015 IENG 475: Computer-Controlled Manufacturing Systems 10 Four Tools for our Lab Cause & Effect Diagrams Check Lists Supervised Training Practice

7/3/2015 IENG 475: Computer-Controlled Manufacturing Systems 11 Questions Be ON TIME to lab next week For THIS lab, EP paper & instructions will be provided Activities: Safety Equipment Safety Analysis (individual & team) Capacity Analysis