04/19/23 IENG 475: Computer-Controlled Manufacturing Systems

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IENG 475 - Lecture 04

Manufacturing Safety

04/19/23 IENG 475: Computer-Controlled Manufacturing Systems

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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

04/19/23 IENG 475: Computer-Controlled Manufacturing Systems

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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”.

04/19/23 IENG 475: Computer-Controlled Manufacturing Systems

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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”.

04/19/23 IENG 475: Computer-Controlled Manufacturing Systems

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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

04/19/23 IENG 475: Computer-Controlled Manufacturing Systems

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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 factors2. Fault of Person (character flaw) – poor choice made3. Unsafe Act and Physical Hazard – action taken in the

presence of a hazard4. Accident – unexpected result5. Injury – outcome of unexpected result

Removing any domino prevents the accident!

04/19/23 IENG 475: Computer-Controlled Manufacturing Systems

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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!

04/19/23 IENG 475: Computer-Controlled Manufacturing Systems

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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

04/19/23 IENG 475: Computer-Controlled Manufacturing Systems

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Four Tools for our Lab

Cause & Effect Diagrams Check Lists Supervised Training Practice

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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