Material Handling Events Performance Analysis Group June 30, 2014

Material Handling Event Review FY 2012 – June 12, 2014  Review Material Handling Events at BNL How are we doing? What types of events have we had?  Review Material Handling Incidents in ORPS Database across the DOE Complexes Are BNL events similar? Can we learn something to prevent events here at BNL?  Review the DOE Lessons Learned Database Based upon our events and DOE events which Lessons Learned might be most beneficial to share. 2

Material Handling Events at BNL FY 2012 – June 12, 2014  Review material handling incident rates  Look at injury rates related to material handling event types 3

Material Handling Incidents at BNL  During this time period there were 56 material handling related events  3 became ORPS  While Q4 FY13 was the highest quarter; overall our rate is low in FY 2014 Bracket Falls from Overhead Crane Trolley (SC3) Cylinder Strikes Employee (SC2) Bucket of Ice Melt Falls nearly Striking Employee(SC3) 4

BNL Material Handling Event Type & Injury Rate  Strains & Overexertion is the most frequent outcome for material handling incidents  Overall injury rate for material handling incidents is 63%  This rate may be inflated as low level incidents without injury may not be reported 5

Material Handling Events ORPS Analysis FY 2012 – June 12, 2014  Looking for common themes across DOE sites  Provide general recommendations for consideration 6

Method Developed trending codes and evaluated DOE Complex Events:  General Equipment Type Forklift, dolly/cart/rolling equipment stand/skate, manual, hand truck, hydraulic lift/lift table, truck/trailer, vice…  Injury/No Injury  General Activity Transport, lifting/lowering, loading/unloading, positioning, manual lifting, inspection  Consequence Load slipped/dropped, Equipment tipped, Mechanical failure, Strains & overexertion, Contact with overhead item, Work delay  Initiation Load shifted/unbalance/not secured, load shifted/unbalanced, material not secure, unaware of surface/surroundings, mechanical failure, manual lift, overload, design change, removal of engineering control  Theme Inadequate procedure/work planning, General equipment knowledge, Exceeding equipment load capacity, Mechanical failure, Failure or missing engineering controls, Ergonomics, Underestimating weight of materials 7

What are the consequences of material handling events in the DOE Complex? Are there Injuries?  21 or about 66% of material handling issues involved a slipped/dropped load  17 or 53% resulted in injuries 8

What equipment is being used when a slipped/dropped event occurs and are there related injuries?  Many different types of equipment are involved with slipped/dropped loads  Likelihood of injury appears to increase if equipment requires manual involvement. 9

What activity is occurring when a load is slipped/dropped?  Happened most frequently during load transport (57%)  About 58% of drops during transport were initiated by issues with surfaces/surroundings 10

Common Themes Noted in the DOE Complex  During manual and machine assisted lifts it is important to accurately determine the weight, positioning and ergonomics of the load in order to select the proper equipment/method for movement.  Ensure that personnel utilizing machinery (forklifts, cranes, hoists, lifts, etc.) are trained and qualified in the use of such equipment and limitations.  Activities involving transport and machinery which involve manual assistance should require additional precautions and work planning especially relating to working surfaces and surroundings since the likelihood of injury is higher.  During work planning additional attention should be directed toward working surfaces and obstacles and its impact on equipment stability.  When possible items should always be properly secured during transport and care should be taken to observe any changes in load stability before any attempt to release the load.  Special care should be given to engage engineering controls when available and ensure they are working as intended. Work planning should consider consequences if engineering controls fail or mechanical failure occurs. 11

Comparison of DOE Complex Events and BNL ORPS Events  All three BNL ORPS events involved a slipped/dropped load Two of the three ORPS events involved unloading One involved lifting Surfaces and surroundings played a role in the most severe material handling event – Cylinder Strikes Employee (SC-2)  Manual lifting increases the likelihood of strains and overexertion. 12

Lessons Learned Review  DOE Complex Lessons Learned ( ) 34 related to material handling - 2 contributed by BNL  BNL Lessons Learned Database ( ) 13 related to material handling - 8 authored by BNL - 5 shared from the DOE Complex  Many Lessons Learned reviewed shared the same themes and issues revealed in the event analysis 13

Recommendations  Communicate to employees the common themes identified and engage them for their experiences, perspectives and possible solutions  Combine LL materials and generate 2- 4 targeted LL to cover themes identified Use a sub-team to review material from both LL sources relevant to these themes Sub-team should include personnel who perform material handling  Review current practices using work observations and procedure validation 14

Questions or Comments? 15