1. Dr. Georgi Popov, QEP, CMC gpopov@ucmo.edu
ANSI Z10 and Prevention through Design (PtD) Business Case: Manufacturing
Dr. Georgi Popov, QEP, CMC
Source: Dr. Popov’s Projects
Practical Projects

2. Why ANSI Z 10 AND PtD Risk Assessment Tools?
ANSI/ASSE Z Prevention through Design standard addresses occupational safety and health needs and RA methodologies
ANSI/ASSE/ISO (Z ) Risk Management Standards Package - This standard provides principles and generic guidelines on risk management.
ANSI/AIHA/ASSE Z : The standard defines minimum requirements for an OSHMS. It also includes risk assessment components not previously included.
ISO OSHMS also includes risk assessment components .

3. ANSI Z10 Requirements – Section 4.1

4. ANSI Z10 Requirements – Section 4.2

5. ANSI Z10 Section 4.2 Recommended Practices
Notice:
Multiple RA methods
Financial Impact
Regulatory compliance
Include:
Business Issues
Setting Priorities
High Severity

6. ANSI Z10 Section 4.2 Recommended practices
Establish priorities based on levels of risk (RAM)
Potential for system improvements (PtD HofC)
Business consequences (Bow – tie analysis).

7. ANSI Z10 & PtD
To demonstrate ANSI Z10 and PtD standards integration, the following case study is presented.

8. Silicone Wire Problem Statement
Silicone wire production involves variety of hazardous chemicals, and hazardous waste.
Requires repetitive movements
MSD’s, Lower back injuries, CTS
HR reported difficulties hiring new employees
High turnover rate
High cost of training and re-training

9. Silicone wire

10. Wire Production Process and Materials Step 1
The first step is to feed the raw silicone into the extruder. Talc powder is applied to the raw silicone to improve the process.

11. Step 2
The next step is to apply fiberglass tread on the basic silicone wire. Fiberglass tread is applied utilizing special treading machine.

12. Silicone wire extrusion process
Ovens
PIE

13. Steps 3 - 5
Third step is to apply another layer of silicone and heat it to 4800F in order to cure it.
The same silicone extruder like in step one is utilized.
Fourth step is to apply another layer of thicker reinforcement layer of fiberglass.
The same fiberglass-treading machine is utilized during this step.
Fifth step is to apply final layer of silicone and print ink.

14. Spark plug boots
The final step is to assemble the ignition wire and install spark plug boots.
The company utilizes spark plug boots made of silicone.

15. Crimping silicone wires
Manual Process

16. Next step
Once the insulation is stripped, it will expose the actual wire that conducts spark to the spark plugs

17. Folding
The workers are folding the wire over back onto the insulated part of the plug wire

18. Crimping
Employees put the end of the wire with the terminal on it into crimping tool.

19. Fitting Spark Plug Boots
Manual operation
Apply milk like lubricant
Test the wire

20. Project Cycle Efficiency Analysis
VAT - Work that customer would recognize as necessary to create the product or the service they are about to purchase.
TLT - How long the process takes from start to end.
FYI: Source: Wire Lean 2007 tab

21. Ergonomics
Repetitive motion is common for spark plug boots installation operations.
Unfortunately, the nature of the work requires a lot of repetitive movements. MSD’s are common.

22. Business Case Development

23. Business Case Development

24. Business Case Development

25. Business Case Development

30. Administrative Controls Personal Protective Equipment
PtD and ANSI Z 10 Hierarchy of controls
Potential Solutions by Hierarchy of Controls
Selection Barriers
Rank Order
Select Solution
Risk Avoidance
Enter Potential Solution 1
Eliminate
Full Automatic Terminal Crimping Machine
Multiple Barriers 4
Enter Potential Solution 2
Substitution
Engineering Controls
Semi-Automatic Crimping Machine
Technological Resources 1 X
Warning
Administrative Controls
Job rotation
Internal Staff 2
Personal Protective Equipment
Back belts
Other Barriers 3

35. PtD Hierarchy of Controls - Admin
The administrative control option
One possible option is to reassign the boots installation workers from the morning shift 7AM – 11AM to the packaging department.
The workers from the packaging department will be cross-trained to install spark plug wire boots in the afternoon.
Cost - $ 1250 training

36. PtD Hierarchy of Controls – Engineering: Semi-Automatic Crimping Machine
Initial investment – $17,500 per workstation
Engineering cost – $ 4700 per terminal
Utilities – $ 500 per year
Maintenance – $ 500 per year
Training – $ 2500 – 10 workers
Improved productivity
Employee morale

37. PtD Hierarchy of Controls – Engineering: Full Automatic Terminal Crimping Machine
Initial investment – $ 57,500 per workstation
Engineering cost – $ 5100 per terminal
Utilities – $ 500 per year
Maintenance – $ 650 per year
Training – $ 2700 – 10 workers
Improved productivity
Employee morale

44. Added NFB: Project Cycle Efficiency Analysis – Post Intervention
FYI: Source: Wire Lean PCM Lean tab

46. Results
The management selected Semi-Automatic Crimping Machine (SACM) option
3 SACM Total $ 70,100
Admin option was implemented for a short time – insufficient results
Reduced personnel from 90 to 47 (20% reduction due to current economic “difficulties”; 15% personnel reduction due to improved productivity; 12% other).
Production down only 11% from 2008

47. EHS INTERVENTION IS NOT AN EXPENSE --
IT IS AN INVESTMENT

48. Optional: Financial Analysis
FYI: Source: MS Excel Ergo Financial ROI

49. Optional: Financial Analysis 2
FYI: Source: MS Excel Financial: Financial tab

50. Optional: Financial Analysis – Compare Proposals
FYI: MS Excel Ergo Financial Compare proposals