RICHARD BRIAN MCLAUGHLIN, CSP360.731.7612 • rbmclaughlin1@gmail.com • Pt. Orchard, WA 98367

Career Accomplishments

A federal contract employer was awarded a warehouse/logistics contract for Air Force Base. This was a new venture for them. The project manager came from an IT background. When base OSHA came by requesting to review their written safety program did not have one. They had 14 days to put a program together or risk losing their multimillion dollar contract.

They came to me requesting a warehouse based written safety program. The program manager had no expertise in this area. We identify the specific tasks performed in the warehouse written program was developed for them in three business days. This included identifying individuals responsible for the program, employee training, hazard assessment and control, accident investigation, hazard communication, OSHA recordkeeping, material handling, forklift operations including how to get on site operator certification training, vehicle operations and clerical staff.

The program provided was reviewed on site management and senior management corporate office and approved for submission to base OSHA. The submitted program was approved of the client maintain their five-year, multimillion dollar contract.

A union construction client sustained a sharp increase in fall related injuries over a one-year period at various projects. This led to fractures and strains. This was an increase of 50% from one year to the next and claim costs increased 40% or $68,000 compared to the previous year. Their OSHA recordable injuries increased sharply that year.

Union members were falling off ladders. A thorough loss analysis was performed to identify causal factors. Accident investigation reports were analyzed looking for causes and corrective measures. Interviews were conducted the injured workers, shop steward and construction competent project manager to obtain their feedback on the accident and solicit their suggestions for improvement. The shop steward and project manager were unaware of the trend. Workers were using the closet ladder they could find, rather than obtaining the correct height ladder. Additionally, other trades were working in the same area reducing the work area space.

Through collaborative discussions between the union & employer and input recommendations included creating job specific hazard analysis, requiring workers use the correct height ladders, providing additional ladders to improve availability, discussing ladder safety during tool box meetings, proposing a training plan targeting proper ladder use for new employees and conducting daily jobsite discussions with all trades to ensure jobsite safety; resulted in 35% decrease in claims frequency and $45K savings in two years. It also contributed to reducing their experience modification 12% over a two-year period. The number of OSHA recordables the next year decreased by 40%.

Employees of a fish canning facility in Alaska were sustained back injury claims in the tail-off section where the product is packed and sorted for shipment. Their experience modification increased over two years by 15 points due to claim frequency and costs. This affected the profitability of the canning operation.

I teamed with their production manager to conduct an on-site visit determining what was contributing to the claims out to mitigate the exposures. Solutions included updating some of the packaging equipment to reduce manual material handling, developing job hazard analyses including pictures to show proper body mechanics to reduce repetitive motion strains, rotating employees to reduce exposure time, and updating their training plan for newer employees. The combined efforts resulted in a 55% decrease in claim frequency & $45,000 savings in two years. The client's experience modification decreased over three years by 18 points. The new packaging equipment also increased productivity 6%.

A temp staffing company was experiencing significant back injuries at one of their client's manufacturing operations in the Midwest. Our employer’s associates were performing heavy manual lifting and push/pull tasks. We arranged for a conference call with their client and the employer's on-site safety manager to identify the root causes. I convinced the employer's client it was in everyone's best interests to conduct an ergonomic assessment of the tasks.

Results of the assessment identified recommendations including a capital expenditure to install mechanical lift equipment, develop JHA’s with pictures and revise associate training. The employer was receptive to the expenditure we were able to demonstrate a return on their investment would take about 8.5 months. Strain claims decreased 35%, $45K in claim costs and an 8% Ex-mod decrease. Additionally, as a result of success, the client agreed to additional ergonomic assessments in two other plants.

 

Housekeepers from a regional hotel chain were sustaining knee and back injuries associated with cleaning rooms. The employer's experience modification increased to 115%. This meant the employer was paying 15% more for workers’ comp coverage than similar hotels. It was difficult to be competitive. He considered raising rates and/or laying off housekeepers.

Instead I suggested we meet with housekeepers from a number of properties to obtain their input on what was contributing to their knee and back problems. Among them included repetitive bending and stooping as they got on their knees to clean toilets, showers and tubs. Pushing the heavy metal carts put stress on their knees and back. Mattresses were heavy making it difficult to put on the fitted sheets and to flip each quarter.

Next, we solicited their suggestions on how to improve the work environment. This encouraged them to be a part of the solution process. We took pictures of them performing their tasks to get a better understanding of the physical demands of the position. Pictures were used to show correct body posture during new hire training and reinforced during safety meetings.

Solutions included purchasing new, lighter weight fiberglass carts with larger wheels making them easier to move. Additionally, the carts did not take up as much room the always making it safer for guests as well. A wedge-like device was purchased for each housekeeper to help raise the mattresses making it easier to put on the fitted sheets. The hotel chain also switched to mattresses that did not require to be flipped. Self-propelled vacuums were purchased to reduce repetitive pushing and pulling. Cleaning tools with handles were purchased allowing the housekeepers to clean tubs and showers in an upright position.

Over a period of three years the number of knee and back related claims from housekeeping dropped 30%, claim costs decreased 20% of their experience modification decreased 18 points.

Employees of a national metals recycler was incurring a significant increase in repetitive motion injuries to their hands, elbows and shoulders. Low back strains also incurred. A thorough loss analysis was completed.

I met with safety committee comprised of management and union employees to review the loss analysis. The analysis determined most of the injuries were occurring on the sorting lines. We teamed together brainstorming on the exposures and the most effective way to reduce the exposures.

I offered to take a video of the tasks to observe body mechanics, postures, reaching distances & exposure time. A certified industrial ergonomist was brought in to evaluate body posture, measure reach distances and conduct testing on the pinch/grip force needed to pull and sort materials.

Recommendations included installing a foot rest allowing employees to change body posture, install anti-fatigue matting reduce back and leg pressure, narrow the sorting line to reduce reaching distances, using tong-like devices to grab and grip recycled material and create sorting teams so employees can alternate between sorting and other recycling tasks. Employees rotated three times a day. This helped reduce exposure time. Provided additional cross training resulting in less lost productivity due to illness or injury.

Recommendations were implemented across all of their plants resulting in a net decrease of RMI -related claims attributed to the sorting line 20% the first year and 25% the year after.