JOB DESCRIPTIONS - safetyteam.com toolbox rev 5 05.doc · Web viewPowered Industrial Trucks...

TOOLBOX

TABLE OF CONTENTS

JOB DESCRIPTION......................................................................................................................1Driver.............................................................................................................................................. 1Service Technician.......................................................................................................................... 1Dispatcher....................................................................................................................................... 1Manager.......................................................................................................................................... 1Office Worker/Support Staff............................................................................................................2Bus Cleaner.................................................................................................................................... 2

DRIVER MANAGEMENT PROCEDURES....................................................................................3General information........................................................................................................................ 3Structured Telephone & Walk-in Interview Process........................................................................5Road Test..................................................................................................................................... 13Training Guidelines for New Drivers.............................................................................................20

Road Observations....................................................................................................................... 25

JOB HAZARD ANALYSIS..........................................................................................................27Maintenance Staff.........................................................................................................................27Apprentice/Preventive Maintenance Mechanic.............................................................................28Shop Labor er............................................................................................................................... 28General Maintenance Personnel...................................................................................................29Office Staff.................................................................................................................................... 29

OSHA COMPLIANCE PROCEDURES.......................................................................................30Hazard Communication Program & Procedures...........................................................................30Respiratory Protection Program & Procedures.............................................................................42Bloodborne Pathogens Exposure Control Program......................................................................54Lockout/Tagout Program & Procedures........................................................................................65Emergency Action and Fire Prevention Program & Procedures...................................................74Multi-Piece/Single-Piece Rim Wheels...........................................................................................81Work Environment........................................................................................................................86Personal Protective Equipment Program & Procedures................................................................94Powered Industrial Trucks (Forklifts)...........................................................................................109

BUS SPECIFIC PROCEDURES...............................................................................................123Bus Fuelling Procedures.............................................................................................................123Sewage Waste (Lavatory Holding Tank) Procedures.................................................................123“Mystery Bus Damage” Procedures............................................................................................124Passenger Assistance Procedures.............................................................................................125Baggage Handling Procedures...................................................................................................127Hour-of-Service Procedures........................................................................................................128

ACCIDENT/INCIDENT REPORTING AND INVESTATION REPORTING...............................130Requirements for Reporting and Responding to Accidents.........................................................130Definition..................................................................................................................................... 131Reporting.................................................................................................................................... 131Recording.................................................................................................................................... 132Investigation................................................................................................................................ 144

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TRAX Toolbox

MODIFIED RETURN-TO-WORK PROCEDURES....................................................................153Management’s Responsibilities...................................................................................................153Supervisor’s Responsibilities......................................................................................................154Types of Return-to-Work Programs............................................................................................157

GENERAL SAFETY RULES AND SUPERVISORY PROCEDURES.......................................158Driver Safety Rules.....................................................................................................................158Facility Safety Rules...................................................................................................................159Supervisor Safety Procedures....................................................................................................162

2001 Daecher Consulting Group, Inc. rev. 6/05

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JOB DESCRIPTIONS

DRIVER :Drives bus to transport passengers over specified or irregular routes to local or distant points according to time schedule. Assists passengers and collects tickets or cash fares. Regulates heating, lighting, and ventilating systems for passenger comfort. Complies with local traffic regulations and applicable state and federal regulations. Reports delays or accidents. Records cash receipts and fares. Inspects bus as required per company policy and regulations. Loads and unloads baggage in baggage compartment. Fuels vehicle when necessary. May make repairs and change tires. Reads schedules and itineraries, interprets maps, processes accident and incident reports, prepares reports requiring basic math skills.

SERVICE TECHNICIAN :Inspects, repairs and overhauls vehicles. Examines vehicle and determines nature and extent of any damage or malfunction. Plans work procedure, using charts, technical manuals, and experience. Follows manufacturer's recommended service procedures. Raises vehicle, using hydraulic jack or hoist, to gain access to mechanical units bolted to underside of vehicle. Removes units, such as engine, transmission, or differential, using wrenches and hoist. Disassembles a unit and inspects parts for wear, using it appropriate tools. Replaces or repairs parts, using mechanics hand tools. Overhauls, replaces, or rebuilds parts using lathes, shapers, drill presses, and welding equipment. Rewires ignition system, lights, an instrument panel. Relines and adjusts breaks, aligns wheels, repairs or replaces shock absorbers, and repairs system fluid and air leaks. Mends damage to body and fenders by hammering out or filling in dents and welding broken parts. Replaces and adjusts headlights, and installs and repairs accessories, such as radios, heaters, mirrors, and windshield wipers. May drive repaired vehicles to verify repairs.

DISPATCHER :Assigns motor vehicles and drivers for conveyance of passengers. Compiles a list of available vehicles. Assigns vehicles according to factors, such as length and purpose of trip, passenger requirements, and preference of user. Issues keys, record sheets, and credentials to drivers. Records time of departure, destination, and expected time of return. Investigates overdue vehicles. Directs activities of drivers, using two-way radio, or alternate method of communication. May maintain record of mileage, fuel used, repairs made, and other expenses. Dispatches buses according to schedule and oversees bus drivers. Issues orders for departure of buses at specified hours, according to schedule. Arranges for extra buses and drivers in case of accidents or other emergencies. May inspects drivers appearance and physical condition prior to dispatch. May record movement and location of vehicles subsequent to dispatch. Receives telephone or radio reports of accidents, delays, equipment breakdowns, and other operating or maintenance difficulties. Maintains a lot of schedule runs, numbers of vehicles, and names of drivers. Makes report of all accidents.

MANAGER :Directs and coordinates activities of company to provide fast, efficient, and safe transportation, either performing following duties personally or through subordinate supervisory personnel: Recommends rate revisions, extension of routes, or changes in schedules in order to improve services and increase revenues. Coordinates terminal and dispatching activities, communication operations, and assignment of driving personnel to obtain optimal use of facilities, equipment, and human resources. Inspects physical facilities of terminal and trucks/trailers for such factors as cleanliness, safety, and appearance, and takes required actions in order to meet prescribed standards. Processes customer complaints and initiates corrective actions into causes of accidents, interviews operators concerned to determine responsibility, and takes actions on findings or submits reports to management. Directs preparation and issuance of new schedules to terminals and operating personnel. Dispatches replacement vehicles and personnel for vehicles involved in accidents, mechanical breakdowns, or other emergencies. Directs and participates in training all personnel and issues manuals, bulletins, and technical guides to improve services and operational activities. Checks trip and dispatch logs for conformance with schedules. Verifies freight

deliveries with operator reports and reviews problems with personnel concerned. Directs preparation of and keeping of dispatch in vehicle operations records and reports.

OFFICE WORKER/SUPPORT STAFF :May perform any combination of the following and similar clerical duties requiring limited or detailed knowledge of systems and procedures: Writes, types, or enters information into computer, using keyboard, to prepare correspondence, bills, statements, receipts, checks, or other documents. Proofreads records or forms. Counts, weighs, or measures materials. Sorts, files, and maintains records and documents. Receives money from customers and deposits monies as stipulated. Addresses envelopes or packages by hand. Stuffs envelopes, answers telephones, conveys messages, and runs errands. Prepares various report for review by management or designees. Stamps, sorts, distributes mail. Photocopies documents.

BUS CLEANER :Cleans interiors and exteriors of vehicles. Cleans the interior of vehicle, using broom, cloth, mop, vacuum cleaner, and other cleaning accessories. Cleans windows with cleansing compounds, water, and cloth. Replenishes sanitary supplies in vehicle compartments. Removes dust, grease, and oil from exterior surfaces of vehicles by spraying or washing vehicles, using spraying equipment, brush or sponge. May polish exterior of vehicle. May fumigate interior of vehicle, using fumigating gases or sprays.

DRIVER MANAGEMENT PROCEDURES

ScopeProper selection and training of new employees is a key element in any safety program, but it is especially important when selecting new drivers. The following procedures will be followed in the selection of new drivers.

GENERAL INFORMATION

Hiring Procedures

The Company will perform the following procedures when hiring drivers:

Pre-Offer/Pre-Employment

• Advertise/Post position-describing essential job functions, physical requirements, minimum qualifications, etc.;

• Screen respondents using walk-in/telephone structured interview (use attached form as a guide);

• All applicants must completely fill-out an application form and authorizations;

• Motor Vehicle Driver's Certification of Violation Form must be completed (if not part of application) (form attached);

• A thorough formal interview of each candidate will be conducted;

• Experience reference checks of previous employers for at least the past 3 years will be conducted;

• Checks for positive drug tests for at least the past two years from previous employers must be performed (if CDL drivers);

• Background check of criminal activities must be performed;

• Obtain and review MVR of applicant. Applicant should not be considered for employment if the MVR contains:

2 or more moving violations in last 3 years; More than 1 accident in last 3 years; Any DUI/DWI conviction.

Post-Offer/Pre-Employment

• Require medical qualification through a DOT or other appropriate physical exam. If candidate does not pass physical, do not employ. If applicant has mild or severe hypertension, insulin-treated diabetes, blindness in any eye, or non-use of any limb, do not employ.

• Require pre-employment drug test, using appropriate specimen collection and testing facilities. If candidate does not pass drug test, do not employ.

• Require physical fitness test, if defined for job. If candidate does not pass test, do not employ.

• If commercial vehicle driver, conduct driver qualification review. If candidate is not qualified to drive, do not employ.

• Conduct road test, using type of vehicle to be used for job. If candidate does not pass road test, do not hire. (See attached form for testing/assessment.)

Post-Offer/Post-Employment

• Prepare driver qualification file for CDL drivers containing:

Application; Complete Motor Vehicle Driver's Certification of Violations form (if not part of application); Evidence of employment reference checks; Evidence of positive drug test checks; Copy of MVR reviewed for hire; Copy of medical qualification card or physical exam; Copy of CDL (if applicable); Copy of road test results.

• Review all applicable employment, job-specific and safety policies and procedures with employee. Obtain evidence of review and understanding of policies and procedures from employee.

• Provide initial minimum training as follows:

Pre-trip/post-trip inspection procedures; Basic defensive driving; Trip planning and preparation; Emergency and accident procedures; Compliance with regulations; Comprehensive knowledge of equipment; Alcohol and controlled substances effects and consequences; Specific equipment use training; Passenger assistance (including "special needs" passengers); Customer relations; Baggage handling; Employee health and safety (personal wellness and fatigue management, PPE, Hazard

Communication, etc.).

STRUCTURED TELEPHONE & WALK-IN INTERVIEW PROCESS

Drivers who will be applying for jobs with your company due to advertising, referrals, etc. will either apply over the phone or walk in. There are a lot of similarities in the way these contacts should be handled. There are also enough differences so that they will be handled separately in this manual, however, the objectives of the processes are the same:

1. To hire safe drivers who will remain with the company.

2. To sell this applicant on the company.

The Structured Telephone Interview Process

The structured telephone interview is your first personal contact with the applicant. The applicant has already started to form some ideas about your organization and the available job as a result of reading the advertisement. But now there is an opportunity to have an exchange of ideas, facts, and philosophies.

The applicant will be calling to find out more about the job and your company. The information you give to the applicant will be important. However, the way you communicate that information w ill be much more important than the actual words you choose. The applicant will begin to develop a “feeling” about your company based on what you say and how you say it. Generally, they will follow your emotional lead. If you are upbeat about the position and the company, the applicant will soon be upbeat as well. However, if you are cross or abrupt, he/she will quickly lose interest in your company.

The communication process begins the moment you answer the phone. Remember, the person answering the phone is probably the only employee of the company with whom the applicant has come in to contact. You are communicating a “first impression” about the company to the applicant just as much as they are communicating information.

No matter how well your advertisements are written, you will still have individuals who have questions about qualifications, pay, etc. or who are not qualified. Be certain to take the time to address the applicant’s questions first. Until the applicant has these answers, his/her attention will not be on what you are asking. Then, ask him/her specific questions of importance to determine if they meet the qualifications you have defined for the job. If the applicant turns out to be unqualified, the time is still well spent from a public relations standpoint. A properly structured telephone interview will quickly identify those who are unqualified.

When you identify, through your questioning, that an individual does not meet your minimum requirements, tell him so immediately, but don’t be rude. Explain the reason(s) why you are terminating the call and bring the conversation to a close.

If it isn’t possible to fill out the application in the office, an application should be sent through the mail along with information on your company and a number of reference check forms for the applicant to sign. Make clear to the applicant that only applications that are completely filled out will be considered. Stress the prompt return of the application; define a time limit for its return. Establish a diary to follow up with applicants who have been sent applications through the mail to be certain they were received.

Walk-in Interview Process

The process that is used for the structured telephone interview can be used for the walk-in applicant. Remember, you represent the company to this applicant and their “first impressions” of the company will be based on your initial greeting. A cheerful, upbeat, friendly greeting will go a long way towards putting the applicant at ease.

Your representative should re-verify that the applicant meets the basic hiring criteria for the job. The criteria should be posted in the reception room and potential drivers should affirm that they meet these before being given an application. If a driver states that he/she meets these qualifications, and once any additional questions on pay, benefits, etc. are answered; the applicant should be provided with an application and the following instructions:

1. Complete application fully.

2. It is vital that information on the application be verified - therefore, be sure to pay special attention to make certain that the authorization statement o n the back of the application has been signed. Reference check form(s) must be filled out for each of the former employers listed.

3. Application must be signed and dated by applicant.

Once the application is finished, it should be reviewed for completeness. Make the next steps in the process clear to the applicant. Establish times and locations where the applicant can be contacted. Give them a time frame within which they will be contacted.

At the conclusion of this visit, thank the applicant for their interest in your company. They should be provided with materials that describe your company so the applicant can review these during the application verification process.

STRUCTURED TELEPHONE/WALK-IN INTERVIEW

Hi, thanks for calling! My name is____________________. I'm sure you'd like to hear all about our organization and the job we have to offer. Let me give you a little general information, ask you some questions and then we can discuss the job in detail. How does that sound to you?

(Tell them a few things about your company, equipment, and service area - do not go into great detail, as they might not be qualified. Try to keep this sales pitch under 30 seconds.) (Construct a set of items your company representative will ask each applicant. Should include pay, benefits, time away from home, etc.)

NAME ________________________________________________ TELEPHONE #_________________

ADDRESS __________________________________________________________________________

ARE YOU OVER 25 YEARS OF AGE? [ ] YES [ ] NO SOCIAL SECURITY # ____________________

ARE YOU AN EXPERIENCED COMMERCIAL DRIVER? [ ] YES [ ] NO

A.) IF YES, PLEASE DESCRIBE YOUR DRIVING EXPERIENCE:_______________________________

Employer & Address Employment Dates

Miles Driven Contact States

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

DRIVER'S LICENSE NUMBER __________________ STATE LICENSED IN_________________

B.) IF NO, HAVE YOU GRADUATED FROM A PROFESSIONAL DRIVING SCHOOL? [ ] YES [ ] NO IF YES, WHERE?__________________________________________________________________

(NAME, ADDRESS & CONTACT) WHEN?__________________________________________________________________________

HAVE YOU EVER BEEN DENIED A LICENSE, PERMIT, OR PRIVILEGE TO OPERATE A MOTORVEHICLE? [ ]YES [ ] NO

HAVE YOU EVER HAD YOUR DRIVER'S LICENSE, PERMIT OR DRIVING PRIVILEGES SUSPENDED OR REVOKED? [ ] YES [ ] NO

HAVE YOU EVER BEEN DISQUALIFIED TO DRIVE A COMMERCIAL VEHICLE IN ACCORDANCE WITH SECTION 391.15 OF THE FEDERAL MOTOR CARRIER SAFETY REGULATIONS? [ ] YES [ ] NO

DO YOU POSSES A VALID COMMERCIAL DRIVER'S LICENSE ISSUED BY THE STATE, IN WHICH YOU RESIDE? [ ] YES [ ] NO

ARE YOU CURRENTLY EMPLOYED AS A COMMERCIAL DRIVER? [ ] YES [ ] NO

IF YES, WHY DO YOU WANT TO LEAVE YOUR CURRENT EMPLOYER?_______________________

____________________________________________________________________________________

HOW MANY DIFFERENT COMPANIES HAVE YOU WORKED FOR DURING THE PAST FIVE YEARS? ____________________________

HOW MANY ACCIDENTS HAVE YOU BEEN INVOLVED IN DURING THE PAST THREE YEARS? (ALL OF THEM, REGARDLESS OF FAULT OR PREVENTABILITY)____________________________

HOW MANY TICKETS HAVE YOU HAD? ____________________________

BEFORE WE HIRE AN APPLICANT, WE REVIEW THEIR STATE MOTOR VEHICLE REPORT, WHAT WILL WE FIND LISTED ON YOURS?_____________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

BEFORE WE HIRE AN APPLICANT, WE REQUIRE A PHYSICAL AND A DRUG TEST IN ACCORDANCE WITH D.O.T. REGULATIONS. ARE YOU WILLING TO TAKE, AND CAN YOU PASS THESE TESTS? [ ] YES [ ] NO

DO YOU CONSIDER YOURSELF TO BE A SAFE DRIVER? [ ] YES [ ] NO

WHY?______________________________________________________________________________

____________________________________________________________________________________

OK, I've asked enough questions for now. Let's give you a turn. What can I tell you about our organization?

(After further discussion about the company and the job, make a decision to either invite the applicant in for the next steps in the hiring process or explain why you won't be inviting him/her in. Remember be honest, but don't be rude.)

MOTOR VEHICLE DRIVER’SCERTIFICATION OF VIOLATIONS

I certify that the following is a true and complete list of traffic violation (other than parking violations) for which I have been convicted or forfeited bond or collateral during the past 12 months.

Date Offense Location Type of Vehicle Operated

If no Violations are listed above, I certify that I have not been convicted or forfeited bond or collateral onaccount of any violation required to be listed during the past 12 months.

________________________________________________________________________________________________________(Date of Certification) (Driver’s Signature)

_____________________________________________________________________________________________(Motor Carrier’s Name) (Motor Carrier’s Address)

_____________________________________________________________________________________________(Reviewed by Signature) (Title)© 1998, The Daecher Consulting Group, Inc.

REQUEST FOR INFORMATION FROM PREVIOUS EMPLOYER

From:______________________________________________________________________ File:______________

To:_________________________________________________________________________ Date:_____________Social Security No.___________________________________

_____________________________________________________________ has made application to this company for a position as________________________________________________________________ and states that he or she was employed by you as ______________________________________ from _______________________________ to ____________________________. Will you kindly reply to the inquiry below respecting this applicant. Your reply will be held in strict confidence and will in no way involve you in any responsibility.For your convenience in replying by return mail, we enclose a stamped, self-addressed envelope.

Very truly yours,Department of Safety

1. Is employment record with your company correct as stated above? ________________________________________________2. What kind(s) of work did applicant do? ______________________________________________________________________3. Did applicant have custody of money or valuables? ____________________________________________________________4. Were applicant’s accounts properly kept? ____________________________________________________________________5. Did applicant drive motor vehicles for you? Passenger car ____________? Straight truck____________? Bus ____________?6. Was applicant a safe and efficient driver? ____________________________________________________________________7. Give dates of vehicle accidents in which applicant was involved.__________________________________________________8. Does applicant have any physical or mental limitations or injuries that would prohibit him/her from performing the position sought?_______________________________________________________________________________________________9. Reason for leaving your employ: Discharged _____________; Laid Off _____________; Resigned _____________; Remarks: _____________________________________________________________________________________________10. Did applicant receive a verbal or written reprimand as a part of a formal company disciplinary procedure within the last five years?_______________________________________________________________________________________________11. Did applicant receive a citation for driving under the influence during the past five years? _______________________________12. Did applicant drink any alcoholic beverages while on duty? ______________________________________________________13. Did applicant receive a written or verbal reprimand for substance abuse, either alcohol or other drug, during the last five years? _____________________________________________________________________________________________________14. Is applicant eligible for rehire? Yes _________ No _________ If no, explain _________________________________________ _____________________________________________________________________________________________________ _____________________________________________________________________________________________________

Excellent Good Fair Poor Very Poor

Quality of Work ___________ ___________ ___________ ___________ ___________

Cooperation with others ___________ ___________ ___________ ___________ ___________

Safety habits ___________ ___________ ___________ ___________ ___________

Person al habits ___________ ___________ ___________ ___________ ___________

Driving skill ___________ ___________ ___________ ___________ ___________

Attitude ___________ ___________ ___________ ___________ ___________

Any other remarks _________________________________________________________________________________________ _________________________________________________________________________________________

Date: _____________________________ For:___________________________________________________________________ Name of Company

By: ______________________________________________ (Signature of person supplying information)

---------------------------------------------------------------(DETACH HERE FOR YOUR FILES)---------------------------------------------------------------

______________________________________________________________________________ Date ______________________You are hereby authorized to give to the ________________________________________________________________________all information regarding my services, character and conduct while in your employ, and you are released from any and allliability which may result from furnishing such information to the above named company.

_________________________________________________

REQUEST FOR PRIOR EMPLOYER TEST RESULTS

MEMORANDUM

TO:

FROM:

SUBJECT: Request to obtain past drug and alcohol test results

DATE:

____________________________ has advised us that he/she ____ worked for your company as a driver, or that he/she ____ applied to your company for work as a driver, during the pat two (2) years.

_____________________ _____________________(Social Security #) (Date of Birth)

Regulations of the Federal Highway Administration (FWHA) (49 C.F.R. 382.413) require us to obtain from your company and require your company to provide us, information concerning the above-named driver's past drug and alcohol test results (including refusals to be tested).

In accordance with FHWA's regulations, therefore, we are providing you with the driver's written authorization directing your company to provide us with the following information concerning this driver:

• all positive drug test results during the past two (2) years;

• all alcohol test results of 0.04 or greater during the past two (2) years;

• all alcohol test results of 0.02 or greater but less than 0.04 during the past two (2) years;

• all instances in which the driver refused to submit to a DOT-required drug and/or alcohol test during the past two (2) years.

Please send this information to __________________________, _________________________,___________________________, ___________________________, ___________________________, Attention: ______________________ as soon as possible either by facsimile (FAX #____-____-______) or by mail. As required by the FHWA, the information, which you furnish, will be treated as strictly confidential.

Thank you for your cooperation.

© 1999 The Daecher Consulting Group, Inc.

APPLICANT'S AUTHORIZATIONTO OBTAIN PAST CONTROLLED SUBSTANCES AND ALCOHOL TEST RESULTS

I, ___________________, understand that as a condition of hire with _________________I must give them written authorization to receive the results of all DOT-required controlled substances and/or alcohol tests (including any refusals to be tested) from ALL companies for which I have worked as a driver, or for which I took a pre-employment controlled substances and/or alcohol test, during the past two (2) years. I also authorize _________________to contact and receive results from any consortium that represents the companies I worked for or applied to. I understand that my signing of this authorization does not guarantee me a job or guarantee that I will be offered a position with _________________.

Listed below are ALL of the companies for which I worked as a driver, or to which I applied as a driver during the past two (2) years. I authorize _________________to obtain from those companies, and I authorize those companies to furnish _________________, the following information concerning my controlled substances and alcohol tests: (I.) all positive controlled substances test results during the past two (2) years; (II.) all alcohol test results of 0.04 or greater during the past two (2) years; (III.) all alcohol test results of 0.02 or greater but less than 0.04 during the past two (2) years; (IV.) all instances in which I refused to submit to a DOT-required controlled substances and/or alcohol test during the past two (2) years.

The following is a list of ALL of the companies for which I worked as a driver, or to which I applied for work as a driver, during the past two (2) years:

Company name & address Dates worked for/applied to

______________________________________ __________________________

______________________________________ __________________________

______________________________________ __________________________

______________________________________ __________________________

______________________________________ __________________________

APPLICANT CERTIFICATION:

I have read and understood this authorization to release my past controlled substances and alcohol test results. I certify that all of the information, which I have furnished on this form, is true and complete, and that I have identified ALL of the companies for which I have either worked, or applied for work, as a driver during the past two years.

__________________________ __________________________ _______________Signature of applicant Print name Date

_____________________ __________________________Social Security # Date of BirthROAD TEST

The road test is near the end of the hiring process. It is required by Federal regulation. But, as we have stated throughout this manual, the fact that it is required is far less important to you than what you may learn about the applicant while administering the road test. It should be treated as a serious part of your screening process; regardless of whether or not you are required to administer one.

The well-administered road test should address two factors:

• An applicant’s technical, mechanical and physical skills associated with driving a commercial vehicle.

• An applicant’s attitude while driving a commercial vehicle.

All too often, recruiters treat the road test as a formality - “something required by the D.O.T.” Even in the best situations, only the hard skills (technical competence) are measured. This is shortsighted. A driver’s responses to vehicle defects, weather, other drivers and traffic conditions can tell you a lot. And, while one could argue any driver can “ act the part” for the duration of a road test, a properly administered road test will produce some indications of potential problems if they exist. A road test should begin with a full pre-trip inspection. Special attention should be given to the manner in which the driver completes the pre-trip inspection. Early results of the Commercial Driver’s License testing indicate the highest failures in thisarea. Have the applicant explain every step of the process as he/she observes and checks the vehicle. It is not enough for them to look and/or touch the various safety sensitive parts - they should explain what they are looking for and what they have found.

If the pre-trip inspection is completed to your satisfaction, the driver should demonstrate their maneuvering skills. This should include steering, stopping, shifting and backing exercises. The driver’s proficiency at the maneuvering skills should be sound enough to give you confidence that you will be safe during the on-the-road test. Establishment of a road test range on the premises could pay dividends in the long run.

The actual road test should be similar to the required road test for your state’s CDL exam. It should be over a predetermined route of approximately 45 minutes of in-traffic driving. It should include the following if at all possible:

1. Four (4) left-hand and four (4) right-hand turns;2. A straight section of road in a business district;3. Three (3) or more intersections with various controls and rights-o f-way.4. A railroad crossing;5. At least one (1) fairly tight curve;6. A five (5) mile section of limited access highway or expressway and if this is not available, a

similar length of rural two-lane highway. The driver should demonstrate lane changing at least once during this part of the test;

7. A downgrade, preferably long enough to allow the driver to demonstrate downshifting;8. An upgrade to demonstrate shifting to maintain speed;9. A downgrade to show stopping without rolling;10. An upgrade to show stopping without rolling backward;11. An underpass;12. A bridge with a posted weight limit or some other hazard, which the driver should see and

identify.

Another source of road test layout is the one used by your state for CDL skills testing. Throughout the road test, the applicant’s specific driving skills should be assessed. However, take care to observe how the applicant interacts with the vehicle, the environment and other motorists. Is the applicant patient, considerate and accepting of less-than-professional abilities of automobile drivers? Remember, this road test is probably the best performance the applicant can muster. When they are on their own, their performance will either be equal to or less than what you are observing. Ask yourself, “Am I comfortable entrusting this applicant with the lives of others, the assets of the company and my reputation as a good judge of professionalism”?

Accompanying with this manual are several examples of road test forms and scoring methods. Remember, the individual who is giving the road test must b e instructed in the proper method evaluation for each phase of the road test. As the applicant performs the driving function, specific skill sets should be evaluated so that weaknesses can be identified. If an applicant is deemed to be sufficiently competent to pass the road test but weak in some specific areas, this should be noted. There should be a plan discussed with the applicant that they will follow to improve their skills in a weak area if they are hired. Remember, one of the most damaging things to you is not to do the road test. Just as damaging in the event of an accident, if not more so, is to identify a weakness in a driver and do nothing to improve the skill the driver is weak in. A signed copy of the road test and certificate of completion must be kept in the qualification file. A certificate of road test completion should also be given to the applicant.

ROAD TEST – DRIVER PERFORMANCE EVALUATION (Motorcoaches – Buses)

Driver Name____________________________________________________________________________________License #__________________________State__________________Exp. Date_________________________

Equipment Unit Type_________________________________________________________________________________Miles Tested________________________From__________________To______________________________

Check appropriate column: S = Satisfactory; U = UnsatisfactoryS U S U

PRE-TRIP INSECTION (Checks by the driver) VEHICLE CONTROLS AND EMERGENCY EQUIPMENT

General condition approaching unit Knows proper use of parking brake

Oil, water, and fuel leaks Knows proper use of hand valve

Fuel, oil, and water levels Understands lo air warning

Tires, lights, and reflectors Understands use of 4-way flashers

Air hoses and electrical connections Uses proper headlight beam

Suspension points and steering linkage Dims lights when following others

Service and parking brakes; hand valve Dims lights when meeting others

Wipers, mirrors, horn, and gauges Adjusts speed to range of lights

Emergency equipment Knows how to replace fuses

Cleans windshield, windows, mirrors, lights, Knows how to use fire extinguisher and reflectors

Knows placement of warning devices Other________________________________

Knows placement position of chocks

PLACING VEHICLE IN MOTION Knows operation of engine brake (if equipped)

Uses seat belt Other________________________________

Checks mirror adjustment OPERATING IN TRAFFIC

Puts transmission in neutral Intersection and Turning

Starts motor without difficulty Enters intersections prepared to stop

Allows proper warm-up Checks for cross traffic

Builds full air pressure before starting Yields to others

Checks brakes within 100 ft. of starting Signals intentions proper distance in advance

Checks and understands instruments Gets in proper lane well in advance of turn

Uses clutch properly Turns only when way is clear

Maintains proper engine RPM Blocks traffic from curb side of turn

Times gearshift properly Other________________________________

Uses proper gear sequence Signs and Signals

Shifts gears smoothly Looks ahead for signs and signals

Other________________________________ Approaches signs and signals prepared to stop

S U S U

Comes to a complete stop at stop signs Frequent use of mirrors

Starts slowly from stopped position Avoids being boxed in

Other________________________________ Makes eye contact with others

R.R. Grade Crossings Alert to live parking

Adjusts speed to crossing conditions Makes good driving decisions

If required, comes to a complete stop Other________________________________

Stops required distance from crossing BRAKING AND SLOWING

Avoids shifting gears while crossing Brakes as soon as need is recognized

Other________________________________ Avoids sudden stops

PassingStops smoothly without rolling back

Allows sufficient space for passing Tests brakes at to of hills

Passes only when there is long-term advantage Gears down to descend grades

Passes only in safe location Uses brake properly on grades

Signals when changing lanes Keeps check on air gauges

Signals before passing Other________________________________

Proceeds in proper lane

Other________________________________ BACKING AND PARKING

Speed Backing

Observes posted speed limit Avoids unnecessary backing

Uses times interval following distance Checks area before backing

Observes speed limit consistent with conditions Avoids backing from blind side

Maintains steady speed on open road Warns others when backing

Adjusts speed for curves, other danger zones Proper backing maneuvers

Other________________________________ Uses mirrors to advantage

General If in doubt, gets out and looks

Grips steering wheel properly Other________________________________

Good driving posture City Parking

Centers vehicle in driving lane Selects safe area to park

Reads traffic lights in advance Parks to avoid backing when leaving

Evaluates traffic patterns early Parks correct distance from curb

Aware of traffic around unit Keeps pull-ups to a minimum

S U S U

Secures units: Secures units:

Turns wheels to curb Sets brakes

Sets brakes Puts in gear

Puts in gear Shuts off engine

Shuts off engine Uses chocks

Uses chocks Locks unit

Locks unit Checks traffic and signals when pulling ontoroadway

Road ParkingOther________________________________

Selects safe area for parking

Parks well off roadway

Turns on warning flashers

Properly places warning devices

General performance: Satisfactory Needs Training Unsatisfactory

Explain additional training planned______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Qualified for: Motorcoach Other (specify)________________________________________________________________

Signature of examiner____________________________________________________________Date___________________________

The illustrations, instructions and principals contained in the material are general in scope and, to the best of our knowledge, are current at the time of publication. No attempt has been made to interpret any reference codes, standards, or regulations. Please refer to the appropriate

code, standard, or regulation-making authority for interpretation or clarification.

RECORD OF ROAD TEST

Instructions to Evaluator: Check () items, which the driver performs satisfactorily, use an “” where performance is unsatisfactory. Any item not evaluated, leave blank.

Driver’s Name _______________________ Home Address____________________________________

Social Security No. _____-___-______ License No. ________________ State ________Class ________

Equipment Driven: ___________________________________________________________________(Make & Model) (Body Type & Length of Each)

Length of Test ____________ Mi. From/In _______________________ To _______________________

Start Time _____________ Finish Time _____________ Weather Conditions ______________________

PART 1—PRE-TRIP INSPECTION AND EMERGENCY EQUIPMENT D. STEERING

Fights Steering Allows vehicle to wander

Poor driving posture or poor grip on wheel

E. LIGHTS Knows lighting regulations Uses proper headlight beam Dims lights when meeting or following traffic Adjusts speed to range of headlights Proper use of auxiliary lights

Checks general condition approaching unitLooks for leakage of coolants, fuel, lubricantsChecks under hood – oil, water, general

condition of engine compartment, steering

Checks around—tires, lights, trailer hook-up, brake and light lines, body, doors, horn, windshield wipers

Test brake action and parking (hand) brakeKnows use of jacks, tools, emergency

warning devices, tire chains, fire extinguisher, spare fuse and four-way flashers

Checks instrumentsCleans windshield, windows, mirrors, lights,

reflectors

PART 3— BACKING AND PARKING

A. BACKINGGets out and checks before backingLooks back as well as uses mirrorGets out and rechecks conditions on long backAvoids backing from blindsideSignals when backing

Controls speed and direction properly while backing

B. PARKING (City)Takes too many pull-upsHits nearby vehicles or stationary objectsHits curbParks too far from curbFails to secure unit-set parking brake, put in

gear, block wheels, shut off motorFails to check traffic conditions and signal when

pulling out from parked positionParks in illegal or unsafe location

C. PARKING (Rear)Parks off pavementAvoids parking on soft shoulderUses emergency warning signals when requiredSecures unit properly

PART 2—PLACING VEHICLE IN MOTION AND USE OF CONTROLS

A. MOTORStarts motor without difficulty

Allows proper warm-up Understands gauges and instrument panel Maintains proper speed while driving Basic knowledge of motors – gas, diesel Abuse of motor

B. CLUTCH AND TRANSMISSIONUses clutch properly

Times gearshift properly Shifts gears smoothly

Uses proper gear sequence

C. BRAKES Understands operating principals of air

brakes Understands low air warning Uses proper gear sequence

PART 4—SLOWING AND STOPPINGG. COURTESY AND SAFETY

Depends on others for safetyYields right-of-way for safetyFails to go ahead when given the right-of-wayTends to crowd other drivers or force way

through trafficFails to allow faster traffic to passFails to keep right in own laneUnnecessary use of hornOther discourtesy or improper conduct

Uses gears properly ascending Gears down properly descendingStops and restarts without rolling backTests brakes at top of hillsUses brakes properly on gradesSignals following trafficAvoids sudden stopsStops smoothly without excessive fanningStops before crossing sidewalk when coming

out of driveway or alley Stops clear of pedestrian walkways PART 6—MISCELLANEOUS

PART 5—OPERATING IN TRAFFIC, PASSING AND TURNING

A.G

B.R

C.U

REMARKS:

A. TURNINGGets in proper lane well in advanceSignals well in advanceChecks traffic conditions and turns only

when way is clearDoes not swing wide or cut short when

turningB. TRAFFIC SIGNS AND SIGNALS

Does not approach sign prepared to stop if necessary

Violates traffic signalRuns yellow lightStarts up too fast or too slow on greenFails to notice or heed traffic signsRuns “stop” signs

C. INTERSECTIONSAdjusts speed to permit stopping if

necessaryChecks for cross traffic regardless of

traffic controlsYields right-of-way for safety

D. GRADE CROSSINGSAdjusts speed to conditionsMakes safe stop, if requiredSelects proper gear

E. PASSINGPasses with insufficient clear space aheadPasses in unsafe location; hill, curve,

intersectionFails to signal changes of lanesFails to warn driver being passedTailgates waiting chance to passBlocks traffic with slow passCuts in too short returning to right lane

F. SPEEDSpeed consistent with basic abilityAdjusts speed properly to road, weather,

traffic conditions, legal limitsSlows down for rough roadsSlows down in advance of curves,

intersections, etc. Maintains Consistent speed

GENERAL PERFORMANCE: Satisfactory _______; Needs Training ________; Unsatisfactory_______QUALIFIED FOR:_______________________________________________________________________________ ______________________________________________________ Date:_______________________________ Signature of Examiner

TRAINING GUIDELINES FOR NEW DRIVERS

TRAINING GUIDELINES FOR NEW ENTRANT DRIVERS

The following guidelines should be used for providing consistent training to all new drivers:

• All topics identified in the Driver Management Policy must be presented during classroom presentations and, where appropriate, demonstrated in practice during "hands-on/behind the wheel" training.

• The minimum amount of time needed to fully present, demonstrate, and practice all topics identified in the policy is 4 weeks. Additional time for training should be provided as needed for each student.

• For every one-hour of classroom time, 3 hours of "hands-on/behind the wheel" training should be provided. At a minimum, one week of classroom time and 3 weeks of "hands- on/behind the wheel" training must be provided.

• Each topic covered should be presented in the classroom then demonstrated or practiced during "hands-on/behind the wheel" sessions. This is the most effective way to learn and remember by the student.

• Behind the wheel training comprises off-road practice as well as roadway driving. Off roadway practice should be utilized until sufficient comfort and the student demonstrates proficiency before roadway driving begins. A student should be able to successfully negotiate all skill problems established on an off roadway course before moving onto a roadway. Furthermore, as many road surface conditions as possible should be experienced by the student before operating a bus on a roadway. Therefore, during rain, snow, sleet, etc. off roadway practice behind the wheel should be provided when conditions present themselves.

• Driver trainers should demonstrate proper driving behaviors with all students onboard at the beginning of off roadway sessions and during an initial roadway driving session. All of this should be treated as "hands-on/behind the wheel" training for students.

• Initial driving by students on roadways should be done "one-on-one" or in the smallest possible groups. This will insure quality advice and guidance by the driver trainer and will minimize anxieties on the part of the student.

• After the student has received at least the minimum amount of required training and is proficient in driving, someone other than the driver instructor should administer a road test. Successful completion of this road test is necessary before the student can continue to receive behind the wheel training.

• After successful completion of a road test, the student should be paired with an experienced driver on actual routes with passengers. The experienced driver should drive the outbound portion of the route; the student should drive the inbound portion of the route during the initial run; then reverse this order. The experienced driver should fill out a road test form, with comments for both runs. If the experienced driver feels that the student is capable to operate a coach alone, the student should be assigned full driver status. If the experienced driver believes that more training is needed, the student should be returned to the driver instructor for additional instruction and training.

• All training must be documented. Classroom time as well as "hands-on/behind the wheel time" should be segmented. Topics addressed should be identified. And all road tests should be documented. These forms are attached for your use. These forms should be maintained in the driver's personnel file for reference as needed. The instructor or the person administering a road test should sign all completed forms.

TRAINING GUIDELINES FOR EXPERIENCED DRIVERS

The following are minimum eligibility criteria and training guidelines for experienced motorcoach drivers hired by the Company.

In order to be considered for the experienced driver-training program, the applicant in addition to all other existing hiring criteria must meet the following qualification criteria:

• Experience for the most current five previous years must be as a motorcoach driver for a bonafide company;

• Confirmation of this experience must be acquired and documented as part of the driver performance history check;

• The applicant cannot have any convictions for moving violations in any vehicle on his/her MVR for the past five years, and cannot have more than 2 moving violation convictions in the past seven years;

• The applicant cannot have any known preventable accidents in the past three years.

If these criteria are met, then no less than 56 hours of training will be provided as follows:

• At least 24 hours of classroom training;

• At least 6 hours of vehicle equipment familiarity, vehicle inspection, and mirror adjustment training;

• At least 8 hours of off-roadway training;

• A 2 hour road test;

• At least 16 hours of pairing with existing drivers on at least 2 routes

The classroom training will provide necessary company information, insurance of regulatory knowledge, reparation of log, OSHA required training, emergency and security procedures, and customer assistance training. See the attached form for all items suggested for classroom training for experienced drivers.

Vehicle familiarity training is designed to ensure the driver’s familiarity with all vehicle controls and equipment, proper pre- and post-trip inspection procedures, and proper mirror adjustment.

The off-roadway training is designed to ensure that the driver can operate company equipment effectively. If any difficulty is experienced in maneuvering the off-roadway skill problems, more than 8 hours of off-roadway training will be required.

After the off-roadway training is provided, a driver trainer will conduct a comprehensive road test of the applicant. If any behavioral deficiencies are observed, additional classroom time will be required to discuss these behaviors and present the materials, which describe acceptable behaviors.

After this is accomplished, the driver will be retested. After the driver performs all required behaviors satisfactorily during a road test, they can continue to be provided on-road training with an experienced driver on at least two different routes. The same procedures as described in the Training Guidelines for New Drivers will be used for this phase of training of experienced drivers. Once the driver has satisfactorily completed all of these elements, they can be placed in revenue service.

_______________________________________________________________________________

Driver Training School – Record of Topics

Student ______________________________

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*New Entrant Training Requirements

©2002 Daecher Consulting Group, Inc. rev. 6/28/04

Page 2

_______________________________________________________________________________

Driver Training School – Record of Topics

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©2002 Daecher Consulting Group, Inc. rev. 6/28/04

Page No. ________________________________________________________________________

Driver Training School - Record of Training Hours

Student ________________________________

Date Page Totals

Instructor

Classroom Hours

Cumulative Hours

Bus Number

Skill Course Hours

Highway Hours

City Hours

Night Hours

Total Daily Hands-on/Behind the Wheel

Cumulative Hours

Daily Miles

Cumulative Miles

ROAD OBSERVATIONS

ROAD OBSERVATIONS GUIDELINES

Spot speed checks can be performed as often as desired, but do not replace shadow vehicle observations.

Shadow vehicle observations should be performed as follows:

• At least 10/month of drivers on a random basis;• For each driver who has received a verified passenger or motorist complaint;• Every new driver within the first 60 days of revenue service;• Every new driver who had a moving conviction on his/her MVR when hired, within each month for

the first 3 months of revenue service;• Each driver who has received a traffic citation within 30 days after you have been informed of the

citation.

Shadow vehicle observation should be performed for at least 10 miles on interstate and at least 20 minutes on city streets. While both types of observations may not be performed at the same time, both should be used regularly.

All road observations must be documented and signed by observer. These documents should be kept in a "Road Observation" file or individual driver's file.

Each road observation should be discussed with the driver. Acceptable behaviors should be commended; unacceptable behaviors must be discussed.

Any retraining or discipline associated with unacceptable road observations must be documented and maintained in a "Training" and/or "Discipline" file or the driver's file.

A monthly summary of all road observations detailing date, driver, result (acceptable/unacceptable) and dates of follow-up retraining or discipline must be prepared. A form to be used is attached.


SHADOW VEHICLE DRIVING OBSERVATION FORM

Date: Time: Unit #: Driver

# Miles Observed # Minutes Observed

Location of Observation: Weather/Road Surface Conditions:

OBSERVED BEHAVIOR Acceptable Unacceptable N/A CommentsMaintained proper following distanceObeyed posted speed limitsMaintained appropriate speed for conditionsUsed turn signals properlyChanged lanes properlyApproached construction zone carefullyUsed flashers when expected and requiredApproached sharp curves and steep hills properlyUsed headlights properly (rain, fog, darkness, etc.)Used high beams appropriatelyStopped and accelerated smoothlyStopped appropriate distance behind vehicle aheadPositioned vehicle correctly for right and left turnsResponded to presence of pedestrians appropriatelyBacked only when necessaryUsed proper backing proceduresParking brake applied when boarding and deboarding

Observer:___________________________________________ Signature:_______________________________________

Actions to be taken if observed behaviors are unacceptable:

JOB HAZARD ANALYSIS

Scope

Applies to maintenance and office employees.

Definition

Job Hazard is any duty, tool, machine, material or supply encountered by an employee during the performance of their job duties which could cause harm or injury to the employee.

MAINTENANCE STAFF

Job or Task Steps: Equipment Operation

Hazard: General Operational HazardsProtection: Equipment Operation and Driving Familiarization and Training

Job or Task Steps: Equipment Repair

Hazard: Back StrainProtection: Awareness Training Proper Techniques, Use of Mechanical Lifting Equipment

Hazard: Foot / Ankle InjuryProtection: Safety Shoes

Hazard: Eye InjuryProtection: Safety Glasses, Goggles, Face Shields

Hazard: Hand InjuryProtection: Latex / Leather Gloves

Hazard: Skin IrritationProtection: Coveralls, Raingear, Boots, Gloves

Hazard: NoiseProtection: Hearing Protection, Training

Hazard: Oil Spill SlippageProtection: Catch Basins, Absorbent Materials

Hazard: BurnsProtection: Gloves, Boots

Hazard: Chemical ContactProtection: Gloves, Coveralls, Eye Protection, MSDS Information

Hazard: Injury While Working on any EquipmentProtection: Lockout / Tagout


APPRENTICE/PREVENTIVE MAINTENANCE MECHANIC

Job or Task Steps: Equipment Operation

Hazard: Typical Operational HazardsProtection: Equipment Operation and Driving Familiarization and Training

Job or Task Steps: P.M./Service

Hazard: Chemical ContactProtection: Gloves, Coveralls, Eye Protection, MSDS Information

Hazard: Oil Spill SlippageProtection: Catch Basins, Absorbent Materials

Hazard: Eye InjuryProtection: Safety Glasses, Goggles, Face Shields


Hazard: Injury While Working on any EquipmentProtection: Lockout / Tagout

Job or Task Steps: Vehicle Washing

Hazard: Waste Water ExposureProtection: Gloves, Raingear, Boots

Hazard: Eye Contaminants / InjuryProtection: Eye Protection

SHOP LABORER

Job or Task Steps: Vehicle Washing

Hazard: Waste Water ExposureProtection: Gloves, Raingear, Boots

Hazard: Eye Contaminants / InjuryProtection: Eye Protection

Job or Task Steps: Shop / Yard Clean-up

Hazard: Oil Spill SlippageProtection: Oil Absorbent Materials

Hazard: Waste ContactProtection: Gloves, Overalls

Hazard: Chemical ContactProtection: MSDS Information, Gloves, Coveralls, Eye Protection


Hazard: Foot / Ankle InjuryProtection: Safety Shoes / Foot Protection

Job or Task Steps: Equipment Operation within Yard

Hazard: General Operational HazardsProtection: Equipment Operation and Driving Familiarization and Training

GENERAL MAINTENANCE PERSONNEL

Hazard: Slips, Trips & FallsProtection: Foot Protection, Awareness Training, Inspection of Work Areas

Hazard: Cuts & InfectionsProtection: Gloves, Foot Protection, Proper Clothing, Vaccinations

Hazard: Back StrainProtection: Proper Lifting Techniques, Awareness Training

Hazard: Cross TrafficProtection: Reflective Clothing, Traffic Awareness

Hazard: Tight Quarter DrivingProtection: Route Familiarization, Mirror

Hazard: Injury While Working on any Part of a VehicleProtection: Lockout / Tagout of Vehicle

OFFICE STAFF

Job or Task Steps: Answering Phone, Typing, Bookkeeping, Photocopying, Data Entry

Hazard: Slips, Trips, FallsProtection: Preventative Devices, Awareness Training, Floor and Stair Maintenance,

Proper Storage Practices, Keep Aisles Clear

Hazard: Repetitive Motion InjuryProtection: Preventative Devices, Administrative and Engineering measures

Hazard: LiftingProtection: Proper Lifting Techniques

Hazard: Unstable Filing CabinetsProtection: Avoid Overloading, Keep Drawers Closed


OSHA COMPLIANCE PROCEDURES

HAZARD COMMUNICATION PROGRAM & PROCEDURES OSHA COMPLIANCE REF: 29 CFR 1910.1200

Scope

It is the intent and commitment of the Company to provide a safe and healthy environment for its employees. It is important that employees be aware of chemicals or hazardous substances that can affect their health or create hazards. The Hazard Communication Program has been established to insure a safe and healthy environment for all employees.

All departments of the company are included within the Program. The Written Program will be available in the operations department for review by any interested employee.

General Information

• The Hazard Communication Program establishes a comprehensive strategy of chemical information dissemination flowing from the manufacturer to the Company and ultimately to the end users (employees). The Program is intended to cover health hazards and physical hazards. Employees who are potentially exposed to such hazards are covered under the Program and the policies of the Company.

• The Written Program is part of a comprehensive program of chemical information to provide necessary information to employees for their protection and well-being. The program requires the ongoing cooperation and understanding of all employees for its continued success.

• The information about hazardous chemicals and substances is provided to all exposed, and potentially exposed employees through a variety of measures, including Material Safety Data Sheets (MSDSs), chemical lists, container labels, placards, signs, training and education. They are all available to employees while they work at the Company. Employees are instructed that questions or concerns about the program be brought to the attention of their supervisor.

• The program contains specific provisions regarding the MSDS program, the labeling program, the information and training program, and non-routine task hazard warning and training. Methods are established which will be used to inform contractors and their employees of hazardous chemicals they may be exposed to while they are in the facility. The program details the information that is available to employees and where such information is stored. The Manager or designee will insure that all containers are labeled with either an extra copy of the original manufacturer's label or with generic labels. All labels shall have a block for identity and blocks for the hazard warning. For help with labeling, employees should contact the Maintenance Manager or designee.

• Maintenance Managers or their designee will review the labeling systems annually and will update as required.

Requirements for Chemical Manufacturers and Importers

Chemical Manufacturers and Importers Are Required to:

• Evaluate chemicals, that they manufacture or import, to determine if they are hazardous. Our Company will use the information developed by the manufacturers.

• Develop and provide an MSDS with the first shipment of a chemical.

• Update the MSDS within three months of learning new information about a chemical and provide the updated MSDS with the next shipment of the material.

• Insure written procedures used to evaluate chemical hazards are available to employees or their representatives upon request.

• Label each container of the chemical with the following information:

Identity of the hazardous chemical;

Hazard warnings;

Name and address of manufacturer or importer.

Requirements for Employers

Employers Are Required to:

• Develop and maintain a written hazard communication program. The program must be available to employees and their representatives upon request.

• Develop and maintain a list of hazardous chemicals in the work place.

• Obtain and maintain MSDSs for all hazardous material used. MSDSs must be readily available to employees during their work shift.

• Provide Container Labeling:

Insure that chemical labels are not removed or defaced from incoming containers;

Insure that labels are affixed to any secondary container the chemical is transferred or poured in to;

May affix signs, labels, placards, batch tickets and/or process sheets to stationary process containers;

Not required to label portable containers, If the chemical is immediately used by the employee who did the transfer;

• Provide employees with Hazard Communication training at the time of their initial assignment and when a new hazard is introduced, which includes:

Requirements of the Hazard Communication Standard;


Details of the written Hazard Communication program including location and availability;

Provide information to contractors on hazards of chemicals they may encounter;

Operations in their work area where hazardous chemicals are used;

A list of chemicals used in the facility;

Methods and observations used to detect the presence or release of hazardous chemicals;

Physical and health hazards of chemicals in their work place;

Protective measures employees can use to reduce exposures such as: work practices, emergency procedures, and personal protective equipment;

Procedures to follow when performing non-routine tasks such as confined space entry;

Workplace Chemical Inventory List

The Operations Manager, or Maintenance Manager, is responsible for maintaining a Workplace Chemical Inventory List of all hazardous materials used at their District's facilities. A separate form will be used for each facility. The Workplace Chemical Inventory List will be available for review by employees of the facility, upon request.

The Workplace Chemical Inventory List constitutes the official list of all hazardous materials approved for use in the named facility. The Maintenance Manager must approve materials not on the list before being received.

Once each year, all departments will conduct a physical inventory of chemicals and materials in use in its area. The results will be compared with the Workplace Chemical List to insure it is complete and accurate.

Note: An Example Chemical Inventory List follows this page. A Chemical Inventory Form (Form-HCCI) is included at the end of this written program.

Material Safety Data Sheets (MSDS)

In an effort to have a Material Safety Data Sheet for every hazardous material or product used in Company operations, the following procedures must be followed:

• Maintenance Manager or designee will be responsible for creating and maintaining the Material Safety Data Sheet System for the Company;

• Maintenance Manager will review incoming sheets for new and significant health/safety information. They will insure that any new information is passed on to the affected personnel;

• Copies of MSDSs for all hazardous chemicals to which employees of the Company may be exposed will be kept in the Hazard Communication Manual located in the maintenance shop, and in other appropriate locations;

• MSDSs will be available for review by all employees during each work shift. If MSDSs are not available or new chemicals in use do not have MSDSs, employees should immediately contact their supervisor. The supervisor will contact the Maintenance Manager who will insure anMSDS sheet is obtained;

• In the event of an occupational exposure to a chemical hazard, employees should immediately notify their supervisor. If an employee is in a position to administer emergency first aid procedures, he/she should always consult the Material Safety Data Sheets(s) on the chemical(s) or material(s) involved in exposure;

• If a customer (or anyone else) requires a copy of a particular MSDS, the Maintenance Manager or designee will review the request. He/she may make and furnish a copy and return the original to the manual.

Information Contained in the Material Safety Data Sheets

Material Safety Data Sheets are divided into sections. Each section deals with different, but pertinent information on the hazardous chemical or material. Each section should be carefully reviewed. It is important to have a thorough understanding on how to read and interpret these sections.

MSDSs must be shipped with or prior to the first shipment of a chemical and when the MSDS has been updated. Information may not be left blank. "Not Applicable" or "Not Available" may be used only when appropriate.

MSDSs may be kept in any form in the work place such as in operating procedures. These procedures may be designed to cover a group of chemicals; however, MSDSs for individual chemicals must always be kept on file.

MSDSs must be in English and include/use the information on the following page.

Note: The information on the following page identifies the nine (9) major sections of the MSDS. Within each section are the criteria to be addressed.


OUTLINE OF MSDS SECTIONS AND INFORMATION

SECTION ONE

PRODUCT OR MATERIAL IDENTIFICATION

Manufacturer’s Name and Address Emergency Telephone Number Chemical Name and Synonyms Trade Name and Synonyms Formulas

SECTION TWO

HAZARDOUS INGREDIENTS

List all the ingredients of the chemical used in the material or product.

SECTION THREE

PHYSICAL DATA AND CHEMICAL CHARACTERISTICS

Characteristics Boiling Point Specific Gravity Vapor Pressure Percent Volatile Evaporation Rate Solubility in Water Appearance and Odor

SECTION FOUR

FIRE AND EXPLOSION HAZARD DATA

Flash Point Flammable Limits Extinguishing Media Special Fire Fighting Procedures Unusual Fire and Explosion Hazards

SECTION FIVE

HEALTH HAZARD DATA

Threshold Limit Value Effects of Overexposure Emergency and First Aid Procedures

SECTION SIX

REACTIVITY DATA

Stability Incompatibility Hazardous Decomposition Products Hazardous Polymerization

SECTION SEVEN

SPILL OR LEAK PROCEDURES

Procedures for Spills Releases Waste Disposal Method

SECTION EIGHT

SPECIAL PROTECTION INFORMATION

Respiratory Protection Ventilation Protective Gloves and Eye Protection Other Protective Equipment Needed

SECTION NINE

SPECIAL PRECAUTIONS

Handling and Storing Precautions Other Precautions

CHEMICAL INVENTORY LIST

Date________________________ Location________________________________

Company_____________________________________________________________________________

Prepared by___________________________________________________________________________

Title_________________________________________________________________________________

PRODUCT NAME MANUFACTURER LOCATION USED AND STORED IN THE FACILITY

UTILIZED IN THE FOLLOWING PROCESS

Propane HD-5 Phillips 66 Shop Shop Fuel for Lift Truck

00449 Diesel #2 Texaco Shop Fuel for Coaches

01569 Rando Oil HD Texaco Shop Equipment Hydraulic Fluid

01935 Starplex Texaco Shop Equipment Bearing Grease

Brakleen CRC Chemicals Shop Cleaning

Copier Toner Xerox Office Area Office Corrections

Note: This list must be retained:

1. In the MSDS Binder

2. In the Written Program


Labels and Other Forms of Warning

Labels and similar forms of warning list any hazards associated with containerized materials. As a result, all hazardous materials must be placed in labeled containers. Labels may not be defaced or removed. Labeled containers must always be positioned with the labels clearly visible. If a container is without a label, it must be labeled immediately. Until the container is properly labeled, the material will not be used.

Labels are to include:

• Hazards associated with use;

• Identity of hazardous materials within the container;

• Appropriate hazard warnings;

• Name address and phone number of the manufacturer, distributor, or importer;

• Handling precautions.

Labels are to be in English, with other languages optional. Labels must contain the material's name. If the chemical name is used, the common name can be found by referring to the Workplace Chemical List.

Employees are to be trained not to rely solely on the information inscribed on a label, but also to read the MSDS for additional information.

Note: Employers must also label:

Waste Containers

Secondary Use Containers

Informing Contractors

It is the responsibility of the General Manager or designee to provide contractors with the following information:

• Hazardous chemicals to which they may be exposed while on the job site;

• Precautions the employees may take to lessen the possibility of exposure through the use of appropriate protective measures.

The General Manager or designee will be responsible for contacting each contractor before work is started on the company premises to obtain and disseminate any information concerning chemical hazards that the contractor is bringing to the workplace.

Purchasing Products That Contain Hazardous Chemicals

Written prior approval must be obtained from the Maintenance Manager before purchasing any products not listed in the program, which contain hazardous chemicals.Hazardous Non-Routine Tasks

Periodically, employees may be required to perform hazardous non-routine tasks. Prior to starting work on such projects, each affected employee must be given information by his or her supervisor about hazardous chemicals to which he or she may be exposed during such activity. This includes specific chemical hazards, protective/safety measures the employee can take and measures the company has taken to lessen the hazards, such as ventilation, respirators, presence of another employee, and emergency procedures.

Training and Location of Hazard Data

A program has been established to insure that all employees are trained prior to beginning work with hazardous materials. Procedures have also been established to train new hires and transferred employees. This training is to inform employees of any hazardous materials known to be present in the workplace.

This written program and copies of MSDSs covering hazardous materials in a specific work area are maintained by the General Manager, Maintenance Manager and Supervisors in appropriate places to permit ready access for employees at all times. (A location within a locked office or filing cabinet and not readily accessible is unacceptable).

Employee training includes, as a minimum:

• A briefing on the OSHA Hazard Communication Standard concerning employee and company rights and responsibilities;

• Identification of hazardous materials in the employee's work area, and potential dangers associated with them;

• Location of the written program and MSDSs appropriate to the employee's work area;

• How to use MSDSs (e.g., what information they contain, where to find the information, and how to use it);

• How to use labels and other forms of warning—what information they communicate, and how to use that information for protection;

Individual employee training must be documented on the Hazard Communication Training Acknowledgment form (Form-HCTA). An example is included at the end of this program.


Hazard Communication Training

Specific Training Appropriate to the Employee

Specific training must be provided in:

• Methods and observations that detect the presence or release of a hazardous material in the work area; periodic monitoring, monitoring devices, visual appearance and/or odor;

• Physical and health hazards of materials in the work area;

• Work practices, emergency procedures, and employee personal protective measures, such as protective equipment installed to limit exposure;

• What to do when in doubt—contact a supervisor.

Training Schedule

• All new employees must be trained prior to working with hazardous materials.

• All transferred employees must be trained prior to assignment in an area where hazardous materials are used.

• All employees must be trained on the hazards of materials at the time they are introduced into their work area.

• All employees, prior to being assigned to a non-routine task involving hazardous materials, must receive special training.

• All employees must be retrained annually.

• The Manager must schedule such annual training as a safety/training meeting topic. Ongoing responsibility for training employees in the situations described above rests with the supervisor of the applicable work area.

Key Concepts

Exposure (dose)

Acute Exposure

Chronic Exposure

Individual Susceptibility

Toxicity

Routes of Chemical Exposure

Inhalation

Absorption (through eyes or skin)

Ingestion

Injection

What is Chemical Exposure?

Exposure depends on:

Type of substance

Amount Absorbed

Susceptibility

Period of time of absorption

Methods Employees Can Use to Reduce Exposure to Chemicals:

Keep containers closed.

Wear protective equipment.

Read the MSDS before working with an unfamiliar chemical.

Follow the manufacturer's product use instructions.

Leave the area immediately if there is a significant chemical spill.

Do not transfer any chemical out of its original container without first labeling the new container.

HAZARD COMMUNICATIONTRAINING ACKNOWLEDGMENT

DISTRICT ___________________________________________________________________________

EMPLOYEE'S NAME___________________________________________________________________

SS NUMBER ________________________________________________________________________

JOB TITLE __________________________________________________________________________

DEPARTMENT _______________________________________________________________________

I have received Hazard Communication Training as described in the Hazard Communication Program. I have had the opportunity to ask questions and receive answers.

SUBJECT DATE ATTENDEE'S SIGNATURE

WRITTEN PROGRAM __________ _________________________

HOW TO READ MSDS's __________ _________________________

INVENTORY OF MATERIALS __________ _________________________(i.e. solvents)

_________________________________________________ __________________________EMPLOYEE SIGNATURE DATE

I hereby certify that the above employee has completed the entire Hazard Communication Training Program as of: __________

DATE

______________________________________ ______________________________________INSTRUCTORS NAME SIGNATURE

FORM HCTA

CHEMICAL INVENTORY LIST

DATE________________LOCATION__________________ COMPANY_________________________

PREPARED BY: __________________________________ TITLE:_____________________________

Product Name Manufacturer Location used and stored in facility

Utilized in the following process

Note - This list must be retained: (1) In the MSDS Binder(2) In written program

FORM HCCI

RESPIRATORY PROTECTION PROGRAM & PROCEDURES OSHA REF: 29 CFR 1910.134

Scope

Applies to Company operations in which potential employee exposure to an oxygen deficient atmosphere exists or to breathing air contaminated with harmful dusts, fogs, fumes, mists, gases, smoke or vapors.

In accordance with its Environmental Health and Safety Policy, the Company will establish procedures, which ensure employees maximum protection for potential respiratory exposures in which the levels of contaminants cannot be further reduced through engineering or administrative controls.

The Company will institute feasible engineering and/or work practice controls as the primary means of maintaining exposures within permissible limits. As an added measure of employee protection, certain operations and activities will require those employees to be medically qualified, fit-tested and trained for respirator use.

Operational activities, which fall in this category, may include spray painting, welding in confined spaces, sandblasting. Only those individuals determined by a physician to be medically able to wear respiratory protection equipment will be issued a respirator and be allowed to perform work requiring the use of a respirator. (See Form RP-B).

Selection and Use

Respirators used shall be selected from those approved by the National Institute for Occupational Safety and Health (NIOSH). The selection process shall include, among other considerations, the following items:

• The nature of the hazardous operation or process;

• The type of respiratory hazard (i.e., contaminant identity, physical state, exposure level);

• The location of the hazardous area in relation to available fresh air;

• The period of time respiratory protection must be worn;

• The work activity (i.e. metabolic work rate) in the hazardous area;

• The physical characteristics, limitations and capabilities of various types of respirators;

• Respirator protection factors.

Specific work activities and hazards encountered at the Company are identified in Appendix A-1, which describes the respiratory protection selected for each.

Training

Employees designated to use a respirator will be trained on the limitations, use and maintenance of the respirators assigned to them. An outline of the training program is included in Appendix B of this written program. The training includes an opportunity to wear and be fit-tested with the respirator(s) assigned to them. Upon satisfactory completion and understanding of this training, employees must read and sign the acknowledgment of training and respirator fit-testing form (Form RP-A).

Fit-Testing

Each employee will be instructed and required to demonstrate understanding of the methods for conducting a negative pressure and positive pressure fit test for the respirator(s) assigned to them. A negative and/or positive pressure fit test is a requirement of the employee each time their respirator is donned for use. The specific method for fit testing will follow the respirator manufacturer's recommendations.

At the time of initial assignment and at least annually thereafter, each employee will receive a qualitative fit-test using a test atmosphere. The Company will use one or more of the following agents for qualitative fit testing.

Agent Proper UseIsoamyl Acetate Can be used to test for proper fit of (Norton #7002 Ampoules) respirators equipped with cartridges,(Scott #802817 Ampoules) canisters, or otherwise designed to filter out organic

vapors.

The suggested procedures for carrying out qualitative respirator fit testing are in Appendix C. The Respirator Fit-Test Record will be completed following an employee's fit-test procedure (see Appendix D- Form RP-B).

Facial Hair Policy

Testing and research has shown that excessive facial hair prevents a good seal from forming between the skin and respirator-sealing surface. Employees required to use a respirator must be clean-shaven and have no hair in the facial areas where a specific respirator must seal. A properly trimmed and groomed mustache is acceptable but beards, extended sideburns and goatees are unacceptable.

Respirator Issuance

Where practical, respirators will be assigned to workers for their exclusive use by the Program Administrator or his trained designee. The specific respirators selected for use at this Company will be documented. Only the Program Administrator or an individual will make any changes or additions to this documented respirator listing with proper training in the selection and use of respiratory protective equipment.

Respirator Inspection and Maintenance

Employees must inspect the respirator(s) assigned to them prior to each day's use and during cleaning. The primary defects to look for in the inspection of the respirator and the corrective actions to take are itemized below:

1. Air purifying respirators (quarter-mask, half-mask and full-face piece)

a) Rubber face piece - check for: excessive dirt (clean all dirt from face piece); cracks, tears, or holes (obtain new face piece); distortion (allow face piece to “sit”—free from any constraints—and see if distortion

disappears (if not, obtain new face piece); cracked, scratched, or loose fitting lenses (contact respirator manufacturer to see if

replacement is possible; otherwise, obtain new face piece).

b) Headstraps - check for: breaks or tears (replace headstraps); loss of elasticity (replace headstraps);

broken or malfunctioning buckles or attachments (obtain new buckles); and face piece slippage (replace headstrap).

c) Inhalation valve, exhalation valve - check for: detergent residue, dust particles or dirt on valve or valve seat (clean residue with soap and

water); cracks, tears or distortion in the valve material or valve seat (contact manufacturer for

instructions); and missing or defective valve cover (obtain valve cover from manufacturer).

d) Filter element(s) - check for: proper filter for the hazard; approval designation; missing or worn gaskets (contact manufacturer for replacement); worn threads - both filter threads and face piece threads (replace filter or face piece,

whichever applies); cracks or dents in filter housing (replace filter); and missing or loose hose clamps (obtain new clamps).

2. Atmosphere Supplying Respirators

a) Check face piece headstraps, valves and breathing tube, as for air-purifying respirators.

b) Hood helmet, blouse or full suit, if applicable - check for: headgear suspension (adjusted properly for individual); cracks or breaks in face shield (replace face shield); and protective screen, to see that it is intact and fits correctly over the face shield, abrasive

blasting hoods and blouses (obtain new screen).

c) Air supply system - check for: breathing air quality; breaks or kinks in air supply hoses and end fitting attachments (replace hose and/or fitting); tightness of connections; proper setting of regulators and valves (consult manufacturer's recommendations); and correct operation of air-purifying elements and carbon monoxide or high temperature alarms.

Respirators will be cleaned and disinfected regularly. At a minimum, each employee will clean his/her own respirator after each day’s use. The cleaning procedure is described below:

1. Before leaving the work area, each user must "wipe down" the respirator with a wet cloth to remove any contamination, which may have settled on the equipment.

2. Respiratory equipment shall be washed with detergent in warm water using a brush. If possible, detergents containing a bactericide should be used. Organic solvents should not be used, as they deteriorate the rubber face piece. If bactericide detergent is not available, the detergent wash should be followed with a disinfecting rinse. Two types of disinfectants may be made from readily available household solutions. A hypochlorite solution (50ppm) can be made by adding two tablespoons of chlorine bleach to one gallon of water. An aqueous solution of iodine (50ppm) can be made by adding one-tablespoon tincture of iodine to one gallon of water. A two-minute immersion of the respirator into either solution would be sufficient to disinfect.

3. Respiratory equipment will be thoroughly rinsed in warm water (120 F maximum) to remove all traces of detergent, cleaner and sanitizer, and disinfectant.

4. Respiratory equipment will be allowed to air dry on a clean surface or hung from a horizontal wire.

Monitoring

Supervisors and Management will monitor the use of respirators to insure that respirators are being used; that the respirator in use is appropriate for the work conditions; that respirators are being worn properly; and, that the respirators in use are in good working condition.

Program Evaluation

This Respiratory Protection Program will be evaluated at least annually to determine the overall effectiveness of the program in assuring the proper selection and use of respiratory protective equipment. The Program Administrator will conduct this evaluation. Compliance with the aforementioned points of the program will be reviewed and where deficiencies are noted, appropriate action will be taken to correct them. Special attention will be given to proper record keeping which includes training, fit testing, and medical records.

APPENDIX ARESPIRATORY PROTECTION PROGRAM

APPROVED RESPIRATORS AND CARTRIDGES WILL BE WORN IN THE FOLLOWING AREAS WHEN RESPIRATORY HAZARDS ARE PRESENT:

OPERATION/HAZARD P.P.E. NEEDED TYPE OF EQUIPMENT

PAINTING / PAINT FUMES RESPIRATOR HALF MASK ORGANIC VAPOR CARTRIDGE

WELDING / FUMES IN ENCLOSED AREA

RESPIRATOR, HELMET, FLAME-RETARDANT CLOTHING

DEPENDS ON CHEMICAL HAZARD

APPENDIX BRESPIRATORY PROTECTION PROGRAM

SAMPLE RESPIRATOR TRAINING OUTLINE

A. Introduction

1. Why wear a respirator?a. Extra measure of protection

1. Potential exposures are evaluated/monitored2. Like a safety belt - provides extra protection

b. Building ventilation problems1. Belts on fan2. Power failure

2. Why train?a. Essential to obtain maximum protectionb. Understand respirator limitationsc. Understand proper care and maintenanced. Know when to change cartridges

B. Program Requirements

1. Required in certain areas / operations2. NIOSH approved respirators are used3. No Facial Hair4. Respirator selected for specific job5. Inspected & maintained daily6. Cartridge change7. Fit-test procedures8. Training9. Monitoring

C. Respirator Familiarization

1. Description of brand/model2. Valves3. Clean daily4. Describe cartridges5. Assembly

D. Fitting Instructions

1. Bottom strap below ears2. Top strap above ears3. Tighten straps

E. Fit Test

1. Negative pressure2. Positive pressure3. Test atmosphere

APPENDIX C

RESPIRATORY PROTECTION PROGRAM

Suggested Procedures for Qualitative Respiratory Fit-Testing

Irritant Smoke Test

The irritant smoke test can be used for both air-purifying respirators and atmosphere-supplying respirators. When an air-purifying respirator is tested, it should be equipped with a high efficiency filter. The respirator wearer should keep their eyes closed during the test, even if the respirator offers eye protection. If the respirator wearer detects the penetration of smoke during the test, they should be permitted to readjust the seal of the respirator. The test operator should direct smoke over the respirator, from about two feet away and watch the reactions of the respirator wearer. If the wearer does not detect penetration of smoke, the test operator should move the smoke tube closer to the respirator and observe the reactions of the wearer. When the smoke tube has been moved to within six inches of the respirator and the wearer still has not detected penetration of smoke, the smoke should be directed at potential points of leakage in the seal of the respirator. If the respirator wearer still does not detect penetration of the smoke, the wearer should then carry out a series of exercises such as deep breathing, turning head from side to side, nodding head up and down, and talking while smoke is directed at the respirator. If the respirator wearer is still unable to detect the penetration of smoke, the wearer has achieved a satisfactory fit with the respirator.

Odorous Vapor Test

An odorous vapor test can be used for both air-purifying respirators and atmosphere-supplying respirators. When an air-purifying respirator is tested, it should be equipped with a cartridge or canister, which removes the test vapor from the air. Isoamyl acetate is normally used for this test. The simplest way to carry out this test is to saturate a piece of fabric or sponge with liquid isoamyl acetate or to fill a stencil brush with liquid isoamyl acetate and then move the saturated item around the respirator worn by the person. The fabric, sponge or stencil brush should be passed close to the potential points of leakage in the seal of the respirator while the wearer carries out exercises as described previously. If the respirator wearer detects the odor of the test material during the test, the wearer should be permitted to readjust the seal of the respirator. If the respirator wearer is unable to detect the odor of the test material, the wearer has achieved a satisfactory fit with the respirator.

An improved qualitative respirator fitting test using isoamyl acetate vapor as the test agent may be carried out using a hood, chamber or room containing a known concentration of the agent in the air. The concentration of isoamyl acetate vapor in air commonly used is 100 parts per million (ppm) by volume. The respirator wearer enters the enclosure containing the test atmosphere and carries out a series of exercises as described previously. If the respirator wearer detects the odor of isoamyl acetate vapor during the test, the wearer should be permitted to readjust the seal of the respirator. If the respirator wearer is unable to detect the odor of isoamyl acetate vapor, the wearer has achieved a satisfactory fit with the respirator.

The use of isoamyl acetate vapor as a test agent has the following two major drawbacks: the odor threshold varies widely among persons; and olfactory fatigue may cause a person to fail to detect the odor of a low concentration of isoamyl acetate vapor in air. Before performing this test, all persons should be tested to determine their ability to sense the odor of isoamyl acetate vapor in air. Since the odorous vapor test is subjective, the validity of the test results depends on honest indication by the respirator wearer as to whether or not an odor was detected during the test.

APPENDIX C RESPIRATORY PROTECTION PROGRAM

Other Qualitative Respirator Fitting Tests

A stream of coal dust or talcum powder or a spray of fluorescein liquid may be directed at the interface of a respirator and the wearer's face. At the same time, the wearer should carry out the series of exercises as described on the following page. After removing the respirator, any coal dust, talcum powder, or fluorescein liquid noted on areas, which had been covered by the facepiece, will indicate that the wearer did not obtain a satisfactory fit. An ultraviolet light will have to be used to see the fluorescein spray.

Negative – Pressure Sealing Test

A negative air pressure-sealing test can be used on air-purifying respirators; however, this test may be difficult or impossible to carry out on valueless respirators. The inlet opening of the respirator's canister(s), cartridge(s), or filter(s) is closed off by covering with the palm of the hand(s), by replacing the inlet seal on a canister(s), or by squeezing a breathing tube or blocking its inlet so that it will not allow the passage of air. Then the wearer inhales gently and holds their breath for at least 10 seconds. If the facepiece collapses slightly and no inward leakage of air is detected, the fit of the respirator is considered satisfactory.

Positive – Pressure Sealing Test

A positive air pressure test can be used on respirators equipped with inhalation and exhalation valves. This test may be difficult or impossible to carry out on valveless respirators. The exhalation valve or breathing tube, or both, is closed off and then the wearer exhales gently. The fit of a respirator is considered to be satisfactory if a slight positive pressure can be built up inside the facepiece without the detection of any outward leakage of air between the sealing surface of the facepiece and the respirator wearer's face.

Negative pressure and positive pressure respirator sealing tests are not considered to be qualitative-type respirator fit-test, and these sealing tests should not be used as a basis for selecting specific makes and models of respirators for use by respirator wearers.

APPENDIX C RESPIRATORY PROTECTION PROGRAM

Exercises Carried Out by Respirator Wearers

A respirator wearer should carry out a series of exercises, which simulate work movements. The kinds of exercises carried out depend on the type of respirators.

The series of exercises for testing a respirator equipped with a facepiece should include but not be limited to:

Normal breathing Deep breathing Turning head from side to side Nodding up and down Talking (reading the 'Rainbow Passage' below)

The series of exercises for testing a respirator equipped with a helmet, hood or suit should include the following:

Standing still, arms hanging down, normal breathing Bending forward and touching toes Raising arms above head and looking upward Bending knees and squatting Standing while holding a tubular rod about 76cm in length with hands approx. 30cm

apart, twisting torso from side to side in an 180 degree arc, and slowly raising the arms from a downward direction to an upward direction having an angle of 45 degrees with the horizontal plane.

"RAINBOW PASSAGE"- When the sunlight strikes raindrops in the air, they act like a prism and form a rainbow. The rainbow is a division of white light into many beautiful colors. These take the shape of a long round arc, with its path high above, and its two ends apparently beyond the horizon. There is, according to legend, a boiling pot of gold at one end. People look, but no one ever finds it. When a man looks for something beyond his reach, his friends say he is looking for the pot of gold at the end of the rainbow.

APPENDIX D

RESPIRATORY PROTECTION PROGRAM

RESPIRATOR FIT-TEST RECORD

NAME:____________________________________________________ DATE:_______________________

ESPIRATOR TYPE:_______________________________________________________________________

TEST RESULTS

ISOAMYL ACETATE IRRITANT SMOKE OTHER

FIT: _________________ _________________ _________________

NO FIT: _________________ _________________ _________________

COMFORT: VERY COMFORTABLE_____ COMFORTABLE _____ TOLERABLE _____

UNCOMFORTABLE _____ VERY COMFORTABLE_____

COMMENTS: __________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

I, _______________________________________, acknowledge that the above respirator has been assigned to me and that I have been fit-tested in the manner described above.

____________________________________________________ ______________________Employee Signature Date

____________________________________________________ ______________________Employer Signature Date

APPENDIX ERESPIRATORY PROTECTION PROGRAM

REQUEST FOR MEDICAL CLEARANCE FOR RESPIRATOR USES

The Program Administrator must complete this section. The examining physician will complete the form and return to the Program Administrator.

_______________________________________ ___________________ ________________Employee Social Security No. DOB

_______________________________________ __________________________________________Supervisor Company

Type(s) of Respirator(s) to be used: (Circle)

1. Atmosphere Supplying Respirator 2. Open Circuit SCBA

3. Supplied-air Respirator 4. Air-purifying (non-powered)

5. Continuous Flow Respirator 6. Closed Circuit SCBA

7. Combination air-line & SCBA 8. Air-purifying (powered)

Level of Work Effort: (Circle)

Light Moderate Heavy Strenuous

Extent of Usage: (Circle)

1. Daily basis

2. Occasionally - but more than once a week

3. Rarely - or for emergency situations only

Length of time anticipated effort in hours: ________________

Special Work Considerations: (i.e., high places, temperature, hazardous materials, protective clothing, etc.)

________________________________________________________________________________________

________________________________________________________________________________________

Form RP-C

APPENDIX ERESPIRATORY PROTECTION PROGRAM

PHYSICIAN’S EVALUATION

Employee:_______________________________________________________________________________

Class: (Circle)

1. No restrictions on respirator use

2. Some specific restrictions

3. No respirator use permitted

Restrictions: _____________________________________________________________________________

________________________________________________________________________________________

________________________________________________________________________________________

Comments:_______________________________________________________________________________

________________________________________________________________________________________

________________________________________________________________________________________

____________________________________________________ ______________________Examining Physician Date

Note to Physician: Please return both pages to Company

Form RP-C

BLOODBORNE PATHOGENS EXPOSURE CONTROL PROGRAM

OSHA COMPLIANCE REF: 29 CFR 1910.1030

Scope

The Bloodborne Pathogens Standard requires employers, who meet specific criteria, to implement an exposure control plan, designed to protect employees from exposure to human blood, blood contaminated body fluids and potentially infectious materials.The standard is aimed at the prevention and reduction of diseases such as the Hepatitis B virus (HBV) and Human Immunodeficiency virus (HIV), both of which are transmitted through pathogens present in human blood.

The purpose of the Bloodbome Pathogens Program is to establish guidelines and the implementation of appropriate safety programs to assure that safety practices are in place to minimize human exposure to materials contaminated with blood or other potentially infectious substances within the work place. Exposure incidents would include, but are not limited to, exposure of eyes or mucous membranes through splashes, or the piercing of the skin by needle sticks.

All departments of the company are included within the Program. The Program will be available in the operations department for review by any interested employee.

Exposure Determination

This section presents a mechanism to determine which employees may be at increased risk for occupational exposure to bloodborne pathogens, as required by the OSHA Bloodborne Pathogens Standard. Such employees at increased risk need to be included in special programs designated by the standard, including special training, issuance of personal protective gear, and immunization for Hepatitis B.

Employees determined not to be at increased risk for exposure are not covered by the Standard. However all employees will receive limited information about certain aspects of the Standard, whether or not they are considered in the increased risk group. Such information should include availability of protective equipment at first aid stations and post-exposure treatment/monitoring procedures if a BBP exposure occurs.

Exposure Evaluation by Work Activity

1. First Aid Providers for Co-workers

Some employees may be part of groups, which are at times remote from emergency medical services. In such remote settings, it is not an expectation that these employees would serve as "first responders" in performing first aid to injured passengers or co-workers. In these instances, first aid training and the expectation of providing first aid to injured passengers or co-workers is not a required or expected part of job duties. For the purpose of the standard, such an expectation does not exist and is not a written part of the job description. These employees, therefore, are not in an increased risk group.

Employees, who receive first aid training primarily for their own benefit and are not expected to perform first aid as part of their job, are at low risk. Such employees may at times perform first aid on a voluntary basis as "Good Samaritans". Since they are not required to do this as part of their jobs, they would not be considered in the increased occupational risk group. However, if these employees should become exposed at work even through voluntary actions, they would still be covered by parts of the Standard dealing with exposure treatment and post-exposure monitoring. In addition, first aid training for all groups should cover the issue of BBP exposure and preventive measures.

2. Maintenance Employees

Employees responsible for building and coach or bus maintenance are considered low risk for encountering potentially infectious materials.

3. Drivers of Vehicles Equipped with Restrooms

Employees who are drivers or who operate vehicles equipped with restrooms and are required to service or "dump" the contents of the restroom are also considered to be at low risk for encountering potentially infectious materials.

As is seen under the definitions portion of this Program, tears, vomit, urine, feminine napkins and feces are not considered other potentially infectious materials unless they are visibly contaminated with blood.

4. Emergency Response Team Members

Some employees may be required, as part of their job description to clean up blood or bodily fluid spills. For the purpose of the standard it would be reasonable to assume that the potential for exposure to other infectious materials does exist. These employees are therefore considered to be in an increased risk group and are covered by parts of the standard dealing with universal precautions, exposure control, P.P.E., and the specific procedures to follow when performing a "clean-up" of potentially infectious materials. Specific steps are listed on Page 6.

5. Other Exposure Settings

In general most full time employees should be considered in the low risk group. Individual judgment may need to be used by the safety officer and Manager in designating which users should be considered in the increased risk group.

These will be determined on a case-by-case basis. General educational information on the risks of BBP will be given to all employees. Those employees who feel they are at increased risk for occupational exposure to BBP, are encouraged to discuss this with their supervisor or safety officer. In addition, managers and safety officers should be asked to identify increased risk worker groups or individuals not included in the above categories. These situations should be discussed with the Corporate Manager of Safety & Health and individual decisions made on whether such employees should be included in the increased risk group.

Definitions

Bloodborne Pathogens

Bloodborne pathogens are defined as pathogenic microorganisms present in human blood which can cause disease in humans. These bloodborne pathogens include, but are not limited to hepatitis B virus (HBV) and human immunodeficiency virus (HIV or AIDS virus).

Other Potentially Infectious Materials

Other Potentially infectious materials are defined as the other types of body fluids and tissues besides blood, which are potentially capable of causing disease. The OSHA Standard specifically defines these to include: semen, vaginal secretions, fluids from internal body spaces (such as spinal or synovial fluids), any body fluid visibly contaminated with blood, and all body fluids where it is difficult or impossible to differentiate between body fluids. Also included are any human tissues other than intact skin (unless the tissue has been fixed by histology procedures) and tissue cultures and potentially infected experimental animals used in medical research. The Standard does not specifically include tears, vomit, urine, or feces on this list unless visibly contaminated with blood. In disposing of tears, vomit, urine, and feces these need not be treated as

hazardous materials as long as they are not contaminated with blood. It should be mentioned here that a number of serious human diseases can be transmitted by urine, feces, etc. even in the absence of blood. While such transmissions are not covered by the Standard unless contaminated with blood, they should still be handled and disposed of in an appropriate manner.

Engineering Controls

Engineering Controls means control measures that isolate or remove the bloodborne pathogens from the workplace. These might include such things as special containers for disposal of contaminated needles or self-sheathing needles.

Exposure Incident

Exposure Incident is defined as a specific contact of blood or other potentially infectious material with a person's eye, mouth, other mucous membrane, non-intact skin, or by parenteral contact (i.e. by a puncture wound or cut with a contaminated object.

Personal Protective Gear

Personal Protective Gear includes items an individual employee may use to prevent contamination by potentially infectious material. In the case of bloodborne pathogens, such personal protective equipment might include gloves, eye protection or face shield, masks covering the mouth, and protective clothing.

Sharps

Sharps are defined as all sharp items which have become contaminated with potentially infectious materials. Sharps include all hypodermic needles, IV catheters, scalpel blades, and other sharp instruments considered as potentially infective and must be handled with extreme care to prevent accidental injuries.

Universal Precautions

Universal Precautions are defined as the standard precautions all persons should use to prevent contact with blood or other potentially infectious materials whenever these situations occur or are anticipated. These may involve standard work practices and the use of personal protective gear such as gloves.Occupational Exposure

Occupational Exposure means reasonably anticipated skin, eye, mucous membrane, or parenteral contact with blood or other potentially infectious materials that may result from the performance of an employee's duties. The determination of potential exposure is made without regard to whether the employee uses personal protective gear such as gloves.

Approved General Work Practices

Engineering and Work Practices

Engineering and work practice controls shall be used to eliminate or minimize employee exposure. Where occupational exposure remains after institution of these controls, personal protective equipment shall be used.

Universal Precautions

All employees should use Universal Precautions, whenever the potential for exposure to bloodborne pathogens exists. Employees should adhere rigorously to the infection control precautions noted in this

section in order to minimize the risk of exposure to blood and other body fluids. Other potentially infectious materials (as defined in Definitions #2) shall be considered potentially infectious materials. All protective equipment needed to protect workers will be supplied, cleaned, disposed of, repaired, or replaced by the Service.

Eating, drinking, smoking, applying cosmetics or lip balm, and handling contact lenses are prohibited in areas where there is a reasonable likelihood of occupational exposure to bloodborne pathogens. Food and drink shall not be kept in refrigerators, freezers, shelves, cabinets, or on counters where blood or other potentially infectious materials are present.

Use of Gloves

Gloves are to be worn when it can be reasonably anticipated that an employee's hands may be in contact with blood or other potentially infectious materials, including touching contaminated items or surfaces. Gloves should be located at appropriate locations for easy access. Hands should be washed immediately after possible contact with blood and/or body fluids as well as before putting on and after taking off the gloves when possible. Sinks should be available at all locations. Where sinks are not available, antiseptic wipes will be provided.

Gloves must be of appropriate material, latex or vinyl, if necessary, and appropriate size for worker. Anytime gloves are contaminated with blood and/or other body fluids, the gloves must be changed and disposed of as noted below.

Use of Masks, Eye Protection, and Face Shields

Masks, eye protection, and face shields shall be worn whenever splashes, spray, spatter, or droplets of blood may be generated and eye, nose, or mouth contamination can be reasonably anticipated.

Use of Resuscitation Equipment

Pocket masks are provided in designated first aid kits located around the facility. Designated first aid responders must acquaint themselves with such equipment and location. Most individual airway masks are not designed for re-use.Handling contaminated clothing and linens

Contaminated clothing and linens should be placed in a plastic bag and appropriately labeled. Gloves should always be worn when handling any biohazard container. If the employee has his or her own blood on themselves, they will be allowed to launder their clothing at home. Any other person's blood or other potentially infectious material on one's clothing will require the clothing to be disposed of as infectious waste.

Cleaning Blood and/or Body Fluid Spill

Note: Only those employees who have been trained to respond to these types of events will be allowed to perform such tasks.

The following procedures should be followed for cleaning up blood or body fluid spills:

1. Area of the spill shall be cordoned off to prevent the accidental spread of body fluids.

2. Vinyl or latex gloves must be worn.

3. An appropriate germicide or bleach solution should be prepared. A germicide solution is the cleaning solution of choice. If a bleach solution is used it can be prepared with 800 ppm NaC10 solution (i.e., standard household chlorine bleach) by mixing a quarter cup (60ml) with one gallon of water. The bleach solution should only be used on hard floors. Do not use this solution on carpet. Bleach should be made fresh; never hold more than one day's worth unless stored in an airtight container in a cool dark place.

4. Remove any large pieces of glass or other particulate material. Do not pick up material with hands. Use a plastic scoop to remove this matter. A tongue depressor, or some other type of disposable tool, may be used to maneuver pieces onto scoop. Particulate matter and tongue depressor/tool should be placed in a puncture proof and splatter proof container. The scoop should be cleaned after use.

5. Carefully remove the body fluids from the spill surface with gauze sponges. When a sponge becomes saturated, replace it with a new one. Do not wring out fluids. All soiled sponges are placed in a puncture resistant splatter proof container.

6. Once body fluids have been removed from the area, the bleach solution is used to decontaminate the area. Starting two (2) inches outside the spill and moving into the center of the spill by making a series of overlapping concentric circles with a sponge do this. The area is allowed to air dry and the process is repeated. The soiled sponges are placed in a biohazard container. Red bags displaying the biohazard symbol will be used to hold material other than sharps.

7. All materials used in the cleanup are placed in a holding area until they can be sterilized or disposed of. A qualified waste hauler should provide disposal services.

8. All material to be sterilized with usual procedures for sharps containers. The bleach solution may be disposed of in a sanitary sewer, although large quantities may be harmful to septic systems. The scoop should be cleaned with a bleach solution.

Exposure Incident

An exposure incident refers to a specific eye, mouth, other mucous membrane, non-intact skin, or parenteral contact with blood or other potentially infectious material resulting from the performance of an employee's duties.

1. Have the employee thoroughly wash the affected area. Supervisor will immediately notify the local medical clinic and the safety department. The employee should be taken to the clinic for post-exposure treatment.

2. All employees who have been identified as having been exposed to possible BBP will be offered Hepatitis B vaccine at no cost. The treating physician(s) will coordinate all counseling and post exposure monitoring. The Company will provide appropriate documentation to be made part of the employee’s permanent personnel records.

Training

Training Level I - All employees

All employees will receive some training in BBP risks and what the plan covers. Their supervisor will contact employees felt to be at increased risk. The training will also state gloves and masks should be used by anyone who voluntarily chooses to perform first aid. A brief description of the BBP exposure control plan will be presented at a safety meeting annually.

Training Level II - Increased Risk Employees

Increased risk employees will receive BBP exposure control training as a result of their advanced training. This will be provided through the company. These employees will also be provided personal protective gear to use as necessary.

Recordkeeping

The company is required to establish and maintain an accurate record for each employee with occupational exposure in accordance with the Standard. All medical records are to be kept confidential and not disclosed or reported to any person within or outside the workplace without the employee's expressed written consent except as required by law. Each record is to be maintained for at least the duration of employment, plus 30 years, in accordance with the Standard.

Supplemental Information

Q. What is the Bloodborne Pathogens Standard?

A. Regulations issued by OSHA aimed at reducing occupational exposure to bloodborne diseases.

Q. What are the provisions within the Standard?

A. Exposure Control Plan, methods of compliance (engineering and work practices), personal protective equipment, HBV vaccinations and post exposure evaluation, training and record keeping.

Q. What are the modes of transmission for bloodborne diseases?

A. Skin inoculation, needle sticks, or contact through open wounds. Non-intact skin or mucous membranes, with blood, body fluid or concentrated virus.

Q. What is an Exposure Control Plan?

A. The Exposure Control Plan includes step-by-step procedures on exposure determination, engineering and work practices, and communications of hazards to employees.

Q. How is PPE (Personal Protective Equipment) selected, where located, and how is it handled after use?

A. PPE is selected by the company according to what provides the greatest protection available and it is located within the first aid and emergency kit (spill prevention kit). Contaminated PPE must be packaged and disposed of as regulated waste.

Q. What work tasks are associated with potential exposure to BBPs and what controls are used to reduce this exposure?

A. Universal precautions are observed for all employees and appropriate personal protective equipment must be used.

Q. What is the HBV Vaccination Program?

A. Hepatitis B Vaccines will be provided at no cost to those employees considered at increased risk due to their current job. This also includes post exposure evaluation, follow-up, on-site response and medical facility response.

Q. What should employees do following an exposure incident?

A. 1. Dispose of the potentially infectious material and contaminated PPE.2. Thoroughly wash all contact skin.3. Report the incident immediately to their supervisor.4. Report to a recommended medical facility for evaluation.

Q. What types of signs or labels are used for Bloodborne Pathogens?

A. Universal precautions must be posted in appropriate locations. Regulated waste containers must contain a biohazard sign or be colored red.

EMPLOYEE DECISIONFOLLOW-UP TO OCCUPATIONAL EXPOSURE

(Occupational Exposure to Bloodborne Pathogens or other potentially Infectious Materials)

I, _________________________________ , experienced an occupational exposure in the course of my duties. I acknowledge that I may be examined by a physician and be tested for hepatitis B virus (HBV) and human immunodeficiency virus (HIV) at no charge.

The physician who is authorizing the testing should be informed of the latest CDC guidelines regarding the testing frequencies, which are six weeks, twelve weeks, and six months subsequent to exposure. A baseline sample may be requested for testing which will be drawn after the exposure.

The results will be forwarded to the physician in a confidential manner and will be communicated to me by the physician.

______ I hereby authorize the examination and testing for the presence of HBV and HIV.

______ I do not authorize the examination and testing for the presence of HBV and HIV.

______ I hereby authorize the examination and testing for HBV only.

____________________________________________________Employees Printed Name

____________________________________________________ ___________________Employees Signature Date

____________________________________________________Supervisor/Manager's Printed Name

____________________________________________________ ___________________Supervisor/Manager's Signature Date

FORM BBP-1

HEPATITIS B DECLINATION FORM

Company Name: _______________________________________________________________

Employee Name: _______________________________________________________________

Positions/Job Title: _______________________________________________________________

I understand that due to my occupational exposure to blood or other potentially infectious materials, i may be at risk of acquiring hepatitis B virus (HBV) infection.

I have been given the opportunity to be vaccinated with hepatitis B vaccine, at no charge to myself. However, I decline hepatitis B vaccination at this time. I understand that by declining this vaccine, I continue to be at risk of acquiring hepatitis B, a serious disease.

If in the future I continue to have occupational exposure to blood or other potentially infectious materials and I want to be vaccinated with hepatitis B vaccine, I can receive the vaccination series at no charge to me.

____________________________________________________Employees Printed Name

____________________________________________________ ___________________Employees Signature Date

____________________________________________________Supervisor/Manager's Printed Name

____________________________________________________ ___________________Supervisor/Manager's Signature Date

FORM BBP-2

EVALUATION OF EMPLOYEEAFTER OCCUPATIONAL EXPOSURE

Date: _____________________

Dear Physician: _________________________________________________________________

An employee of ____________________________________________________ (Company) experienced an occupational exposure on ___________________ (Date). This employee has presented himself/herself for medical evaluation regarding antibody testing for the presence of hepatitis B virus (HBV) and human immunodeficiency virus (HIV). CDC guidelines indicate antibody testing for HBV and HIV should be performed at six weeks, twelve weeks, and six months following the date of exposure. A blood sample has been drawn by ________________________________________ (Medical facility) from the employee after the exposure. The specimen will be tested at your discretion.

The source specimen status is as follows:

______ The source patient and/or patient specimen can be identified.______ The source patient and/or patient specimen cannot be identified.______ The medical facility can provide the name of the patient's physician to initiate

testing authorization, if needed.

The following information has been provided for your information:

• A copy of 29 CFR 1910.1030, 'Bloodborne Pathogens';• A complete description of the exposed employee's duties;• Documentation of the route(s) of exposure and the circumstances under which the exposure occurred on the

Incident/Accident Report;• Results of the source individual's HIV and HBV testing, if available;• All medical records relevant to the appropriate treatment of the employee, as well as vaccination status.

A copy of the medical evaluation and written opinion should be delivered to the employee within fifteen (15) working days of the injury.

The following areas should be addressed in your written opinion:

• If the hepatitis B vaccination is indicated;• If the employee has received the hepatitis B vaccination;• If the post-exposure evaluation results have been given to the employee;• If employee has been told of any medical conditions resulting from the exposure which may require further

evaluation or treatment;• All other findings and/or diagnosis will remain confidential and will not be included in this report.

Your assistance and cooperation is greatly appreciated.

Sincerely,

____________________________________________________ ________________________________________________Supervisor/Manager's Signature Phone

____________________________________________________ ________________________________________________Company Address

FORM BBP-3

SPILL INCIDENT REPORT

This form is to be used in the event of a significant discovery or spill. A spill in which two (2) or more gallons of medical waste is discharged from its container to the plant floor or equipment or any spill that occurs outside of confined spaces within the building.

DATE: ____________________________ TIME: ___________________________

LOCATION OF WASTE/SPILL LOCATION: _____________________________________________________________________

NATURE OF SPILL: (estimate quantity)

_____________________________________________________________________________________

PERSONNEL INVOLVED:

_____________________________________________________________________________________

EXPENDABLE MATERIALS USED FROM SPILL KIT:

_______________________________________ _______________________________________

_______________________________________ _______________________________________

_______________________________________ _______________________________________

I certify that the above spill has been remediated.

____________________________________________________ ___________________Signature Date

(Upon completion, forward this form to the Corporate and Regional Safety Departments.)

FORM BBP-4

LOCKOUT/TAGOUT PROGRAM & PROCEDURES OSHA COMPLIANCE: REF: 29 CFR 1910.147

Scope

This program applies to both Company employees and contract personnel. Contractors' tags and procedures may vary; however, the same level of control must be met by the contractor's program.

The purpose of this program is to establish the minimum requirements for the lockout/tagout of hazardous energy. It shall be used to insure that before an employee performs any servicing or maintenance activities where the unexpected start-up or release of any form of stored energy could occur and cause injury, all such potentially hazardous energy shall be isolated and locked out and/or tagged out. This program includes written energy control procedures, employee training and periodic inspections.

The forms of energy, which must be controlled, are: Electrical, Mechanical, Hydraulic, Pneumatic, Chemical, Thermal or Other Energy Sources (fluids and gases, water under pressure, gravity, etc.) This program does not apply to plug-in and cord type electrical equipment, for which exposure to the hazards of unexpected start-up or release of stored energy of the equipment is effectively controlled by unplugging equipment from the energy source and by the plug being under the exclusive control of the employee performing the service or maintenance.

General Program Provisions

1. A specific, written lockout/tagout (energy control) procedure is required for each type of equipment, machine or vehicle.

2. Only authorized employees who are performing servicing or maintenance shall perform lockout/tagout.

3. Whenever replacement or major repair, renovation or modification of a machine, equipment or vehicle is performed and whenever new machines or equipment are installed, energy-isolating devices for such machines or equipment shall be designed to accept a lockout device.

4. When only a tagout device is used, the tagout device shall be attached at the same location as the lockout device would have been attached in a position that will be immediately obvious to anyone attempting to operate the equipment.

5. The tagout attachment device shall be non-reusable, attached by hand, self-locking, have no less than 50 pounds of unlocking strength and have basic characteristics of being at least equivalent to a one-piece nylon cable tie.

6. Lockout/tagout devices shall:

a. Be standardized at the location;

b. Not be used for any other purpose;

c. Be readily identifiable by size, shape or color;

d. Be durable and capable of withstanding environmental effects (i.e., not paper);

e. Indicate the identity of authorizing employee applying device.

7. Specific procedures shall be utilized during shift or personnel changes to insure continuity of lockout/tagout protection. Only the authorized employee who applied the device may remove the device. Someone else should only remove the device after verifying that the individual who applied the device is not at the facility. Insure that he authorized employee has knowledge that the device has been removed before he/she resumes work at the facility.

8. If more than one authorized employee is performing service or maintenance, each authorized employee who is performing service or maintenance shall attach a personal lockout/tagout device before beginning work.

9. If there is a possibility of reaccumulation of stored energy to a hazardous level, verification of isolation shall continue until servicing is complete or until possibility of accumulation no longer exists.

Periodic Inspection/Evaluation

At least annually, the Maintenance or Operations Manager is required to audit the energy control procedures to insure that they are effective and being followed. Where only tagouts are being used, a review of the procedure between each affected and authorized employee shall occur; where only lockouts are being used, a review between the authorized employees needs to be performed.

The periodic inspection form must be used to certify the periodic inspection. Any deviations or inadequacies must be identified and corrected. This form must be retained.

Training and Communication

Each authorized employee shall receive training in the recognition of applicable hazardous energy sources, the type and magnitude of the energy available in the workplace, and the methods and means necessary for energy isolation and control.

Each affected employee shall be instructed in the purpose and use of the energy control procedure.

All other employees who work in an area where energy control procedures may be utilized shall be instructed in the purpose and use of the energy control procedures.

When tagout systems are used, employees shall also be trained in the following limitations of tags:

• Tags are essentially warning devices affixed to energy-isolating devices and do not provide the physical restraint on those devices that is provided by a lock.

• When a tag is attached to an energy-isolating device, it is not to be removed without authorization of the authorized person responsible for it, and it is never to be bypassed, ignored or otherwise defeated.

• Tags must be legible and understandable by all authorized employees, affected employees and all other employees whose work operations are or may be in the area, in order to be effective.

• Tags and their means of attachment must be made of materials that will withstand the environmental conditions encountered in the workplace.

• Tags may evoke a false sense of security, and their meaning needs to be understood as part of the overall energy control program.

• Tags must be securely attached to energy-isolating devices so they cannot be inadvertently or accidentally detached during use.

Retraining shall be provided for all authorized and affected employees whenever there is a change in their job assignments, a change in machines, equipment or processes that present a new hazard, or when there is a change in the energy control procedures. Retraining shall also be provided when the periodic inspection indicates inadequacies in the employee's knowledge or use of the energy control procedures.

The employer shall document all employees training and retraining. (See Lockout/Tagout Training Section.)

Lockout/Tagout Definitions

Affected Employees

An employee whose job requires him/her to operate or use a machine or equipment on which servicing or maintenance is being performed under lockout or tagout, or whose job requires him/her to work in an area in which such servicing or maintenance is being performed.

Authorized Employee

A person who locks out or tags out machines or equipment in order to perform servicing or maintenance on that machine or equipment. An affected employee becomes an authorized employee when that employee’s duties include performing servicing or maintenance covered under this section.

Capable of Being Locked Out

An energy-isolating device is capable of being locked out if it has a hasp or other means of attachment to which or through which, a lock can be affixed, or it has a locking mechanism built into it. Other energy-isolating devices are capable of being locked out, if lockout can be achieved without the need to dismantle, rebuild or replace the energy-isolating device or permanently alter its energy control capability.

Energized

Connected to an energy source or containing residual or stored energy.

Energy-Isolating Device

A mechanical device that physically prevents the transmission or release of energy, including but not limited to the following: a manually-operated switch by which the conductors of a circuit can be disconnected from all ungrounded supply conductors and, in addition, no pole can be operated independently; a line valve; a block; and any similar device used to block or isolate energy. Push buttons, selector switches and other control circuit type devices are not energy-isolating devices.

Energy Source

Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal or other energy. Other energy sources include fluids and gases, water under pressure, gravity, etc.

Lockout

The placement of a lockout device on an energy-isolating device, in accordance with an established procedure, ensuring that the energy-isolating device and the equipment being controlled cannot be operated until the device is removed.

Lockout Device

A device that utilizes a positive means such as a lock, either key-or combination-type, to hold an energy-isolating device in the safe position and prevent the energizing of a machine or equipment. Included are blank flanges and bolted slip blinds.

Normal Production Operations

The utilization of a machine or equipment to perform its intended production function.

Servicing and/or Maintenance

Workplace activities such as constructing, installing, setting up, adjusting, inspecting, modifying, and maintaining and/or servicing machines or equipment. These activities include lubrication, cleaning or unjamming machines or equipment and making adjustments or tool changes, where the employee may be exposed to the unexpected start-up of the equipment or a release of hazardous energy.

Tagout

The placement of a tagout device on an energy-isolating device, in accordance with an established procedure, to indicate that the energy-isolating device and the equipment being controlled may not be operated until the tagout device is removed.

Lockout/Tagout Training

Many industrial mishaps are experienced each year due to the uncontrolled release of hazardous energy. Many of those mishaps can be prevented by proper lockout/tagout procedures. In accordance with the Company Environmental Health and Safety Policy, this lockout/tagout program is designed to prevent needless fatalities and serious injuries to service and maintenance workers by controlling hazardous energy.

To perform service and maintenance work on industrial equipment safely, employees must understand the importance of energy control and OSHA’s lockout/tagout standard, and they must know how to apply energy isolation and lockout/tagout.

1. A lockout is a method of keeping equipment from being set in motion and endangering workers. In lockouts:

a. A disconnect switch, circuit breaker, valve or other energy isolation mechanism is put in the safe or off position;

b. A device is often placed over the energy-isolating mechanism to hold it in the safe position;

c. A lock is attached, so that the equipment cannot be energized or engaged.

2. In a tagout, the energy-isolating device is placed in the safe position and a written warning is attached to it. All lockout and tagout materials are supplied by the Company. Each device must be:

a. Durable, to withstand wear and tear;b. Substantial, so it will not come off easily;c. Capable of identifying the person who applied it.

3. The company will issue each employee authorized to apply lockout/tagout his/her own personal lock(s) and tags.

4. Lockout or tagout whenever performing service or maintenance around any machine where an injury could occur by:

a. Unexpected startup of the equipment;b. Release of stored energy.

5. Two situations are most likely to need lockout/tagout:

a. When an employee must place any part of his/her body where it could be caught by moving machinery or in contact with electric current;

b. When it becomes necessary to remove or by-pass a guard or other safety device.

6. Some jobs for which lockout/tagout should be used are:

a. Repairing electrical circuits;b. Cleaning or oiling machinery with moving parts;c. Clearing jammed mechanisms.

7. The OSHA Standard allows each employer to use either lockout or tagout, or both. It is the employee's responsibility to follow whichever system has been chosen for his/her workplace.

8. Locks and tags by themselves do not de-energize equipment. They should be attached only after the machinery has been isolated from its energy source.

9. Preparation for shutdown. Before turning off any equipment in order to lock or tag it out, employees must determine:

a. The types and amounts of energy that power it;b. The hazards of that energy;c. How the energy can be controlled.

10. Equipment shutdown:

a. Shut the system down by using its operating controls;b. Follow whatever procedure is right for that particular equipment, so as not to endanger

anyone during shutdown.

11. Equipment isolation; employees must:

a. Operate all energy-isolating devices so that the equipment is isolated from its energy sources;

b. Be sure to isolate all energy sources—secondary power supplies, as well as the main;c. Never pull an electrical switch while it is under load;d. Never remove a fuse instead of disconnecting.

12. Applying lockout/tagout devices:

a. All energy-isolating devices are to be locked, tagged or both according to the company's energy control policies;

b. Only the standardized devices supplied by the Company are to used for lockout/tagout, and they are not to be used for anything else;

c. Use a lockout device (C-clamp) if the lock cannot be placed directly on the energy control;

d. When lockout is used, every employee in the work crew must attach his/her own personal lock;

e. More than one employee can lock out a single energy-isolating device by using a multi-lock hasp;

f. For big jobs, a lockout box can be used to maintain control over a large number of keys;g. If tags are used instead of locks, attach them at the same point as the lock would be, or

as close to it as possible;h. Fill tags out completely and correctly.

13. Control of Stored Energy. Take any of the following steps that are necessary to guard against energy left in the equipment after it has been isolated from its energy sources:

a. Inspect the system to make sure all parts have stopped moving;b. Install ground wires;c. Relieve trapped pressure;d. Release the tension in springs, or block the movement of spring-driven parts;e. Block or brace parts that could fall because of gravity;f. Block parts in hydraulic and pneumatic systems that could move from loss of pressure.

Bleed the lines and leave vent valves open;g. Drain process piping systems and close valves to prevent the flow of hazardous

materials;h. If a line must be blocked where there is no valve, use a blank flange;i. Purge reactor tanks and process lines;j. Dissipate extreme cold or heat, or wear protective clothing;k. If stored energy can re-accumulate, monitor it to make sure it stays below hazardous

levels.

14. Verifying Isolation of Equipment. Take any of the following steps that apply to equipment described in the company's energy control policies:

a. Make sure all danger areas are clear of personnel;b. Verify that the main disconnect switch or circuit breaker cannot be moved to the on

position;c. Use a volt meter or other equipment to check for electrical current activity;d. Press all start buttons and other activating controls on the equipment itself;e. Shut off all machine controls when the testing is finished.

15. Performing the work.

a. Look ahead, and avoid doing anything that could re-activate the equipment;b. Do not by-pass the lockout when putting in new piping or wiring.

16. Removing Lockout/Tagout:

a. Make sure the equipment is safe to operate;• Remove all tools from the work area• Be sure the system is fully assembled

b. Safeguard all employees;• Conduct a head count to make sure everyone is clear of the equipment• Notify everyone who works in the area that lockout/tagout is being removed

c. Remove the lockout/tagout devices. Except in emergencies, the person who put it on must remove each device;

d. In some workplaces, the last person to remove his/her lock/tag may have extra duties;• They may have to remove the hasp and lockout device• Tags should be removed, signed, and turned in• In some companies, the supervisor always removes the last lock or tag

e. Follow a checklist of required steps to re-energize the system.

17. Special Situations: When outside contractors or workers are performing service or maintenance in the workplace, follow the outside Contractor's lockout/tagout system and be alert for new types of devices.

18. If servicing lasts m ore than one shift:

a. Lockout/tagout protection must not be interrupted;b. At many facilities, employees leaving work do not remove their locks until the ones

arriving are ready to lock out.

19. When the worker who applied a lock or tag is not there to remove it:

a. The lock or tag can be removed only in an emergency, and only under the direction of the employer;

b. Many companies use the "Two Person Rule." The lock or tag is not cut unless the supervisor is present;

c. Never remove the lock or tag without making sure it is absolutely safe to do so;d. File any necessary reports.

20. These procedures are meant as a guide in working safely around hazardous energy sources. It is up to the individual employee to guard his/her own life and health by putting these and company specific rules into action.

LOCKOUT/TAGOUTPERIODIC INSPECTION FORM

Date: _____________________

Machine/Equipment/Vehicle Name ________________________________________________________

Authorized Employee ___________________________________________________________________

Affected Employee _____________________________________________________________________

AUDIT PERFORMED BY:_______________________________________________________________

1. Are documented training records available? Yes _____ No _____ (if no, explain action taken)

________________________________________________________________________________________________________

________________________________________________________________________________________________________

________________________________________________________________________________________________________

2. Is there a written lockout/tagout procedure “customized” for each equipment/vehicle type? Yes _____ No _____ (if no, explain action taken)

________________________________________________________________________________________________________

________________________________________________________________________________________________________

________________________________________________________________________________________________________

3. Does the procedure identify all potentially hazardous energy sources? Yes _____ No _____(if no, explain action taken)

________________________________________________________________________________________________________

________________________________________________________________________________________________________

________________________________________________________________________________________________________

4. Are lockout/tagout devices used only for energy control purposes? Yes _____ No _____(if no, explain action taken)

________________________________________________________________________________________________________

________________________________________________________________________________________________________

________________________________________________________________________________________________________

5. Are written procedures readily available? Yes _____ No _____ (if no, explain action taken)

________________________________________________________________________________________________________

________________________________________________________________________________________________________

________________________________________________________________________________________________________

6. Are tags attached with non-reusable devices (nylon ties-not twistable ties)? Yes _____ No _____(if no, explain action taken)

________________________________________________________________________________________________________

________________________________________________________________________________________________________

________________________________________________________________________________________________________

7. Does the lockout/tagout device identify the employee who applied the device? Yes _____ No _____ (if no, explain action taken)

________________________________________________________________________________________________________

________________________________________________________________________________________________________

________________________________________________________________________________________________________

8. Do affected employees understand the purpose of energy control procedures? Yes_____ No_____ (if yes, explain action taken)

________________________________________________________________________________________________________

________________________________________________________________________________________________________

________________________________________________________________________________________________________

9. After walking through a lockout/tagout with an authorized employee, is the procedure clear to the employee? Yes _____ No _____ (if no, explain)

________________________________________________________________________________________________________

________________________________________________________________________________________________________

________________________________________________________________________________________________________

10. Has each authorized employee signed the written procedures for lockout/tagouts they perform? Yes _____ No _____(if no, explain action taken)

________________________________________________________________________________________________________

________________________________________________________________________________________________________

________________________________________________________________________________________________________

EMERGENCY ACTION AND FIRE PREVENTION PROGRAM & PROCEDURES OSHA COMPLIANCE: REF: 29 CFR 1910.38,157

Scope

This program applies to all employees of the Company.

Emergency Action and Fire Prevention Plans minimize personal injury, property damage and business interruption during unplanned emergencies. The goal is to develop a state of readiness and use specific procedures to reduce the effects of the emergency.

This plan establishes minimal criteria for emergency situations: Fire, gas release, spills, power failures, bomb threats and natural disasters (e.g., storms, hurricanes, tornadoes, etc.).

In accordance with the Company Environmental Health and Safety Policy and federal regulations, this program is designed to prepare an emergency and fire prevention plan. The objectives of the plan are to:

• Provide for effective response to emergency situations;• Minimize the effect of emergencies on personnel and community;• Keep property and equipment losses to a minimum; and• Insure the release of accurate information both corporately and publicly

Emergency Action Plan

While insuring compliance, flexibility is also necessary in determining a facility's specific emergency needs. Considerations must be made for the type of emergency, number of employees involved and the protective features.

Facility Layout

Employees as well as emergency personnel should prepare a diagram/drawing of the property for use. It should indicate the placement of buildings, fuel and flammable/combustible material storage, parking, traffic patterns, assembly areas, etc. A separate layout of each building should illustrate:

• Ingress and egress, hallways, routes of travel and emergency exits;• Fire suppression equipment;• Location of flammable/combustible product storage; • First aid kits.

Emergency Services

Emergency Services are normally limited to administering minor first aid and containing incipient fires until professional assistance can be rendered.

• Designate supervisory personnel who will maintain first aid/CPR certification, and • Control of incipient fires should be by trained employees within their own work area. Fires with

greater potential should result in immediate evacuation.

Reporting/Notification

• Employees shall be instructed to notify their immediate supervisor or the most senior employee available about any emergency situation or its potential.

• Supervisors, Management, or their designee will notify fire and/or emergency medical services upon determining the severity of the situation.

• The Company Safety Officer should be notified promptly about accidents or other emergencies. This notification should be made immediately when injuries or fatalities are involved.

Evacuation

Depending on the emergency situation, employees may be required to evacuate their specific work area or the facility. This should be under the direction of supervisory personnel. The following is recommended depending on the nature of the emergency:

• Evacuate the affected building or work area in case of fire, gas release, or bomb threats;• Assemble at predesignated safe areas;• Evacuate to designated shelter areas in the event of natural disasters; and• Evacuate to areas outside the property lines during explosive or flammable situations.

Unless specifically trained and assigned by Management, all employees must immediately evacuate any area deemed to be in a state of emergency. Return to duty must be under the instruction of management personnel.

Alarm Systems

Since the majority of employees are deployed in company vehicles equipped with two- way radios, or in work groups of less than ten, verbal notification is a primary method of alarm. Other acceptable devices include paging systems, air horns and cellular communication. The selected method of alarm should provide:

• Reaction time for safe egress;• The ability to be perceived above ambient noise or light; and• A distinctive and recognizable signal to evacuate.

All employees must be instructed on how to report emergencies and activate/initiate the alarm system.

Testing of Emergency Plan

Emergency Action Plans and their associated alarm systems should be tested periodically to insure they are workable and up-to-date. Emergency drills should be performed at least annually, and should suit the local operation and be made as realistic as possible. Revise plans as indicated by test results and changing conditions.

CommunicationsThe control of emergencies can be aided by establishing an emergency communications system, equipped to receive and transmit information by phone, radio or other devices. The facility size will suggest and govern the type of network adopted. The main office, unless nonfunctional, should be presumed to be the central communications center unless otherwise determined by Management.

Fire Prevention Plan

A Fire Prevention Plan, as an integral part of the Emergency Action Plan, is established to deter potential ignition sources, maintain control over flammable/combustible and waste materials and assign duties, including the inspections and maintenance of equipment.

The normal fire protection system utilizes portable multipurpose extinguishers (ABC) for general use and carbon dioxide type extinguishers for computer and electrical use. The focus is extinguishing small incipient fires before they can increase in intensity and severity. Escalating fire emergencies should result in the initiation of the evacuation plan.

Essential elements of a Fire Prevention Plan include:

• Performing periodic inspections (documented) of areas known to contain fire hazards;• Inspecting serviceability of portable extinguishers (documented);• An annual maintenance check of fire extinguishers by a qualified vendor;• Informing employees of fire hazards in their work area and/or inherent in their job duties; • Developing a list of major workplace fire hazards, handling and storage procedures, ignition

sources, types of equipment and maintenance responsibilities.

Training

Each facility must designate and train a sufficient number of employees to assist in specific functions associated with the Emergency Action Plan. All employees must be familiar with the parts of the Emergency Plan, which would affect them individually in an emergency situation. The Emergency Plan should be reviewed with all employees:

• When the plan initially becomes effective;• Upon employment or transfer into new job assignment;• Whenever an employee's assigned role in the plan is changed or modified;• When the plan itself is changed.

A copy of the written Emergency Plan should be kept in a conspicuous location, where it can be made available to employees for review.

Only First Aid/CPR trained employees should be involved in the treatment of injured personnel and assure a smooth transition between mutual aid (ambulance, EMS) and on site personnel.

All employees should be trained to extinguish incipient fires, and are responsible for taking immediate action in such situations to prevent minor incidents from escalating.

Portable Fire Extinguisher Training Topics

1. Inspection of the extinguisher:

a. Look for dents or physical damage;b. Insure monthly inspection ID documented on tag;c. Insure annual inspection is current;d. Pin must be in place;e. Arrow in GREEN area - showing charge.

2. Use proper extinguisher for specific type of fire:

a. Class A - Combustible Materials b. Class B - Flammable Liquidsc. Class C - Electrical Firesd. Class D - Metals

Note: The most common type of fire extinguisher used is a combination A, B, C rated extinguisher.

3. Discharge the fire extinguisher while aiming at the base of the fire in a “sweeping motion.”

Outline of an Emergency Action Plan

A. Scope of Emergencies1. Internal Types - In-plant fires, gas releases, spills, power failures and explosions.2. External Types - Natural causes (floods, tornadoes, snow, ice, storms, lightning), bomb threats,

etc.3. Operational Considerations

a. Personnel - total number and distribution by shifts.b. Property and building - hazards and layout.c. Operations - types of activity.d. Fire Hazards and Explosions - flammable, combustible, corrosive or toxic materials;

radiation hazards.e. Fire suppression equipment - portable and fixed; personnel trained in use.

B. Emergency Systems1. Local Alarms

a. Alarm signal device - siren, etc.b. Voice communication - intercom, radios, telephones

2. Communications to and from areas of the facilityc. Telephoned. Radio

3. Emergency lighting, alternate sources of power4. Evacuation routes

C. Responsibility for Initiation of Plan

1. Appointment of a person in charge of emergency response2. Sounding of alarm3. Notification of communications center4. Notification of supervisory personnel; emergency telephone list

D. Management Evaluation of Emergency Situation1. Notify supervisor responsible for area.2. Evaluate effect on other facility operations.3. Evaluate effect to adjacent community - notification of local authorities.

E. Evacuation Procedures1. Evacuation routes2. Designation of personnel assembly areas3. Accountability for all personnel (headcount)

F. Return and Start-up1. Check of building or emergency area2. Communications of "all clear" signal3. Inspection and report of damage4. Determination of safe start-up (return to work)

G. Testing of Emergency Systems

1. Periodic (at least annual) tests of alarms, communications, evacuation procedures, fire drills, etc.Facility Questionnaire

A. General Information:1. What is the main business function of the facility?

2. What management levels exist at the facility and the individuals who hold those positions?

3. Are there any employees regularly at this site who are trained in first aid/CPR? List Names.

4. Is this geographic area prone to:

Floods?Hurricanes?Tornadoes?Earthquakes?

5. How many physical levels does the facility have?

B. Work Environment:

1. List heavy labor jobs at this facility.

2. Are any hazardous materials used at this facility? This includes chemicals, etc.

3. Does this facility emit any types of gases or exhaust into the air?

4. Does this facility house large quantities of flammable materials? If so, what types?

5. What types of emergency incidents have occurred since this facility began operations?

C. Fire Protection:

1. What type of fire alarm system does the facility have? How is it activated? Is the fire department automatically notified?

2. How are people in the facility made aware of a fire or other emergency?

3. What type(s) of smoke detectors does the facility have?

4. Does the building have windows that may be open on a regular basis? Can they be shut quickly?

5. What types of fire extinguishers are available and are they identified for their appropriate use?

6. Are there people designated for extinguishing fires?

7. Have these people received the necessary training?

8. Does the facility have a fire suppression system? If so, how is it activated? When was it last inspected/certified?

9. Are there procedures for evacuating employees/guests?

10. Are there any fireproof rooms in your facility?

11. What phone numbers need to be called in the event of a fire?

12. Are procedures in place to evacuate persons with disabilities?

D. Bomb Threat:

1. Who is designated to assist police, arson or bomb squad with a search?

2. Who will document the caller information?

E. Loss of Utilities:

1. What types of utilities are utilized by this facility?

2. Which companies supply these utilities?

3. Does a loss of any particular utility pose a hazard to the environment?

4. Are there back-up systems in place for temporary utilities, and if so, how do they work?

F. Community Response Services:

1. What telephone number will be called in the event of a health emergency?

2. Where are the closest medical facilities? Who will act as the Company’s contact with those facilities?

3. W here is the closest Trauma Center?

4. What is the telephone number of the local police department? Is a 911 system installed in the community?

5. Does the town or city have a HAZMAT team?

6. Who are the media sources in the area?

7. Who is designated from the company to respond to media questions?

MULTI-PIECE / SINGLE-PIECE RIM WHEELS OSHA COMPLIANCE: REF 29 CFR 1910.178

Scope

This section applies to any company that services or uses multi-piece and single-piece rim wheels used on large vehicles such as trucks, tractors and trailers. Application of this program will include training for any employee including tire repair personnel, drivers, or operators whose responsibilities include changing tires, servicing, daily inspections of multi-piece or single-piece rims.

Types of Wheels/tires

A rim wheel is the component assembly of wheel (either multi-piece or single-piece), tire and tube, plus other components.

A single-piece wheel is the component of the assembly used to hold the tire, form part of the air chamber (with tubeless tires), and provide the means of attachment of the assembly to the vehicle axle. A multi-piece wheel is a vehicle wheel consisting of two or more parts, one of which is a side or locking ring that holds the tire and other components on the rim wheel by interlocking the components when the tire is inflated.

The standard does not apply to the servicing of rim wheels utilizing automobile tires or vehicle tires designated "LT".

Hazards

The principal difference between accidents involving single-piece rim wheels and those involving multi-piece rim wheels is the effect of the sudden release of the pressurized air contained in a single-piece rim wheel.

In a multi-piece rim wheel accident, the wheel components separate and are released from the rim wheel with violent force. The severity of the hazard is related not only to the air pressure but also to the air volume.

Single-rim wheel accidents occur when the pressurized air contained in the tire is suddenly released, whether by the bead breaking or the bead slipping over the rim flange.

The principal hazards involve pressurized air. Once released, it can pick up and hurl an employee across the shop if the employee is in close proximity to the rim wheel and within the trajectory. It can also propel the rim wheel in any potential path or route (basically along the axis of the rim wheel) that a rim wheel component may travel during an explosive separation, or the area into which the air blast from a single-piece rim wheel may be released.

Employee Training

The company must provide a program to train all employees who service rim wheels in the hazards involved and the safety procedures to be followed.

The company must assure that no employee services any rim wheel unless the worker has been instructed in correct procedures of mounting, demounting, servicing activities and the safe operating precautions for the type of wheel being serviced.

At a minimum, the training program must include the contents of the OSHA standard and the information in the manufacturer's rim manuals or the OSHA charts. Charts are available from OSHA regional, area, or national offices.

The instruction must be conducted in an intelligible way. Employees who are unable to read the charts or rim manuals must be trained in the subject matter. The company must assure that each worker demonstrates and then maintains the ability to service rim wheels safely by correctly performing the following tasks:

• Demounting tires, including deflation.• Inspecting and identifying rim wheel components.• Mounting tires, including inflating them with a restraining device or other safeguard.• Handling rim wheels.• Inflating tires when single-piece rim wheels are mounted on a vehicle.• Understanding the necessity of standing outside the trajectory during inflation of the tires and of

inspecting the rim wheels following inflation.

Installing and Removing Rim Wheels.

The company must regularly evaluate each employee's performance and provide additional training, as necessary; to assure that each employee maintains his or her proficiency.

The Servicing Equipment

The company must furnish a restraining device for inflating a tire on a multi-piece wheel, and must provide a restraining device or barrier for inflating a tire on a single-piece wheel unless the singlepiece rim wheel is bolted onto a vehicle during inflation.

The restraining device can be a cage, rack or an assemblage of bars and other parts that will constrain all rim wheel components during an explosive separation of the multi-piece rim wheel or during the sudden release of the contained air of a single-piece rim wheel.

A barrier can be a fence, wall, or other structure or object placed between a single-piece rim wheel and an employee during tire inflation to contained air. Each barrier or restraining device must be able to withstand the maximum force of an explosive rim wheel separation or release of the pressurized air occurring at 150 percent of the maximum tire specification pressure for the rim wheel being serviced.

Restraining devices showing any of the following defects must be immediately removed from service:

• Cracks at welds.• Cracked or broken components.• Bent or sprung components caused by mishandling, abuse, tire explosion, or rim wheel

separation.• Component pitted due to corrosion or other structural damage that would decrease its

effectiveness.

Restraining devices or barriers removed from service must not be returned to service until they are repaired and reinspected. Restraining devices or barriers requiring structural repair such as component replacement or rewelding must not be returned to service until they are certified by either the manufacturer or a Registered Professional Engineer as meeting the strength requirements as stated above (the force of 150 percent of the maximum tire specification pressure).

Current chart or rim manuals containing instructions for the types of wheels being serviced must be available in the service area, including a mobile service unit.

Only tools that are recommended in the rim manual may be used for the type of wheel being serviced.

The employer must also supply airline equipment with a clip-on chuck with sufficient length of hose between the chuck and in-line valve or regulator to allow the employee to stand outside the trajectory, as well as an in-line valve with a pressure gauge or a presettable regulator.

The size (bead diameter and tire/wheel width) and type of both the tire and wheel must be checked for compatibility prior to assembly of the rim wheel. Mismatching of half sizes such as 16-inch and 16.5 inch tires and wheel must be avoided.

Multi-piece wheel components must not be interchanged except as indicated in the applicable charts or rim manuals.

Multi-piece wheel components and single-piece wheels must be inspected prior to assembly. Any wheel or wheel component that is bent out of shape, pitted from corrosion, broken, or cracked must be marked or tagged "unserviceable" and removed from the service area. Damaged or leaky valves must be replaced.

Rim flanges, rim gutters, rings, and the bead-seating areas of wheels must be free of any dirt, surface rust, scale, or loose or flaked rubber buildup prior to tire mounting and inflation.

Safe Operating Procedures

Multi-piece Rim Wheels

The company must instruct employees to use the following steps for safe operating procedures:

1. The tire must be completely deflated by removing the valve core before a rim wheel is removed from the axle in the following situations:

• When the tire has been driven under inflated at 80 percent or less of it's recommended pressure.

• When there is obvious or suspected damage to the tire or wheel components.

2. The tire must be completely deflated by removing the valve core before demounting.

3. A rubber lubricant must be applied to the bead and rim mating surfaces when assembling the wheel and inflating the tire unless the tire or wheel manufacturer recommends against it's use.

4. If a tire on a vehicle is underinflated but has more than 80 percent of the recommended pressure, the tire may be inflated while the rim wheel is on the vehicle, provided remote control inflation equipment is used, and no employee remains in the trajectory during inflation.

5. The tire shall be inflated outside a restraining device only to a pressure sufficient to force the tire bead onto the rim ledge and create an airtight seal with the tire and bead.

6. Whenever a rim wheel is in a restraining device, the employee must not rest or lean any part of his/her body, or equipment, on or against the restraining device.

7. After tire inflation, the tire and wheel must be inspected while still within the restraining device to make sure that they are properly seated and locked. If further adjustment is necessary, the tire must be deflated by removing the valve core before the adjustment is made.

8. An attempt must not be made to correct the seating of side and lock rings by hammering, striking, or forcing the components while the tire is pressurized.

9. Cracked, broken, bent, or otherwise damaged wheel components must not be reworked, welded, brazed, or otherwise heated.

Heat must not be applied to a multi-piece wheel.

Whenever multi-piece rim wheels are being handled, employees must stay out of the trajectory unless the employer can show that performance of the servicing makes the employee's presence in the trajectory necessary.

Single-piece Rim Wheels

Employees must be instructed in and must use the following steps for safe operating procedure with single-piece wheels:

1. The tire must be completely deflated by removal of the valve core before demounting.

2. Mounting and demounting of the tire must be performed only from the narrow ledge side of the wheel. Care must be taken to avoid damaging the tire beads, and the tire must be mounted only on a compatible wheel of mating bead diameter and width.

3. A nonflammable rubber lubricant must be applied to bead and wheel mating surfaces before assembling the rim wheel, unless the tire or wheel manufacturer recommends against the use of any rubber lubricant.

4. If a tire-changing machine is used, the tire may be inflated only to the minimum pressure necessary to force the tire bead onto the rim ledge and create an airtight seal before removal from the tire-changing machine.

5. If a bead expander is used, it must be removed before the valve core is installed and as soon as the rim wheel becomes airtight (when the tire bead slips onto the bead seat).

6. The tire may be inflated only when contained within a restraining device, positioned behind a barrier, or bolted on the vehicle with the lug nuts fully tightened.

7. The tire must not be inflated when any flat, solid surface is in the trajectory and within 1 foot of the sidewall.

8. The tire must not be inflated to more than the inflation pressure stamped in the sidewall unless the manufacturer recommends a higher pressure.

9. Employees must stay out of the trajectory when a tire is being inflated.

10. Heat must not be applied to a single-piece wheel.

11. Cracked, broken, bent, or otherwise damaged wheels must not be reworked, welded, brazed, or otherwise heated.

WORK ENVIRONMENT

Scope

Maintenance facilities and office locations.

Housekeeping

• All stairways, ladders, passageways and gangways must be kept free from material, supplies and obstructions at all times.

• Tools, materials and debris should not be strewn about in a manner that may cause tripping or other hazards.

• Tools and supplies should be located near work areas where they will be used.

• Discarded lunch bags, paper cups, cans and any other trash should be removed from work areas daily.

• Oily rags and open cans of flammable liquids must not be left at employee workstations.

• All spills of any nature must be marked, blocked off and cleaned up immediately.

Proper Lighting

• All work areas and passageways must be properly illuminated before employees can begin work.

• The intensity/brightness of lights should be uniform throughout worker facilities.

• The lighting should be sufficient to provide a safe working environment and comfortable vision.

• Emergency exits must be clearly marked with lighted exit signs.

Defined Walkways

• Passageways/walkways for employees should be clearly defined.

• All work areas must have an adequate and defined means of ingress/egress.

• All emergency exit aisle ways should be wide enough to ensure safe passage.

• If not obvious, defined walkways should be specially marked with reflective tape or other types of readily visible markings.

• Defined walkways should have a slip-resistant surface and be kept as dry as possible at all times.

• Non-slip rubber matting should be utilized in areas that are susceptible to being wet such as facility entrance/exit areas.

Proper Storage

• Do not locate storage areas for combustible or flammable liquids near heated pipes or areas exposed to sunlight or other sources of heat.

• Provide appropriate and approved containers for the storage of flammable liquids.

• Flammable liquids should be stored separately from other materials in locked and identified cabinets.

• Storage areas for flammable liquids should be located away from employee areas.

• Cabinets containing flammable liquids should be clearly marked FLAMMABLE - KEEP FIRE AWAY.

• Tools and supplies should be located near work areas where they will be used.

• Storage areas for supplies should be easily reached by employees.

• Designate storage areas for large pieces of material or equipment.

• Designate enough storage space near working areas for storing supplies, tools and infrequently used equipment.

• Provide space for racks, bins, and shelves.

• Provide sturdy, wooden or metal shelves and storage cabinets.

• Appropriate stepladders should be provided as necessary to aid employees in reaching stored materials, which are not easily accessible.

Proper Safeguards

• Identify hazardous conditions in the workplace and design, install and maintain proper safeguards to protect employees.

• Be sure that any hazardous conditions are communicated to employees and that the areas where hazards exist are clearly marked and easily seen by employees.

WORKPLACE AUDIT / INSPECTION REPORT

Location: ______________________________________________________________________

Audited By: ____________________________________________ Date ___________________

Audit Item / PracticeCheck () if Item / Practice not in compliance

Housekeeping General

Are aisles marked? .22 Are correct lockout/tagout procedures in use? .14

Width of aisles maintained? .22 Is compressed air for cleaning under 30 psi? .242(b)

Are aisles in good condition? .22 Are storage cabinets used to hold flammable liquids labeled “Flammable – Keep Fire Away”? .106(d)(3)(ii)Are work areas clean? .22

Is housekeeping maintained? .22 Are flammable liquids such as gasoline kept in safety cans? .144(a)(1)If carbon monoxide is present due to forklifts, heaters, or idling vehicles, are signs posted warning of its presence? .1200(f)

Exits

Are exits properly marked? .36/.37 Is protective clothing and equipment provided and used when cleaning up spilled toxic or otherwise hazardous materials or liquids?Any emergency power supply? .36/.37

Does lighting in hallways and 3exit signs conform to government standards? (20 foot- and 5 foot-candles respectively) .36/.37

Are all cord-connected, electrically operated tools used by employees at their workplace in good condition? .243

Are exits blocked? .36/.37 Are work surfaces kept dry or appropriate means taken to assure surfaces are slip-resistant?

Fire Protection Are all spilled materials or liquids cleaned up immediately?

If you have a fire alarm system, is it tested bimonthly? .165

Is emergency eyewash (and shower facilities, if applicable) within the work area where employees are exposed to injurious corrosive material? .151(c)

Are all fire extinguishers accessible, and their location clearly designated? .157Are all fire extinguishers inspected and recharged regularly, and noted on the inspection tag? .157

Are standard guardrails provided wherever aisle or walkway surfaces are elevated more than 30 inches above any adjacent floor or the ground?

Air Emissions First Aid

If carbon monoxide is present due to forklifts, heaters, or idling vehicles, are signs posted warning of its presence? .1200(f)

Are first aid kits easily accessible to each work area, with necessary supplies available, periodically inspected, and replenished as needed? .151(b)

Are MVAC technicians certified to properly handle refrigerant and is the certification on display? 40 CFR 82.40 and .42

Emergency Precautions Postings

Are emergency phone numbers posted where they can be readily found in case of an emergency?

Is the OSHA 2203 poster properly displayed? 1903Is the EEOC’s Americans with Disabilities poster displayed?Are fire evacuation procedures posted?

Are tornado shelter and fire evacuations posted?

Is the Family and Medical Leave Act notice properly displayed?

Are signs concerning exiting from buildings, room capacities, floor loading, biohazards, exposure to x-ray, microwave, or other harmful radiation or substances posted where appropriate?

Are all State required posters displayed?

Personal Protective Equipment

Are protective goggles or face shields provided and worn where there is any danger of flying particles or corrosive materials? .133

Is there a hospital clinic or infirmary for medical care in proximity of your workplace? .15(a) Are approved safety glasses required to be

worn at all times in areas where there is a risk of eye injuries such as punctures, abrasions contusions, or burns? .133

If medical and first aid facilities are not in proximity of your workplace, is at least one employee on each shift currently qualified to render first aid? .151(a) Are protective gloves, aprons, shields, or

other means provided against cuts, corrosive liquids, and chemicals? .132Are medical personnel readily available for

advice and consultation on matters of employees’ health? .151 Are employees who need corrective lenses

(glasses or contacts) in working environments having harmful exposures required to wear only approved safety glasses, protective goggles, or use other medically approved precautionary procedures? .133(a)(3)

Portable (Power Operated) Tools and Equipment

Are grinders, saws, and similar equipment provided with appropriate safety guards? .243 Are hard hats provided and worn where

danger of falling objects exists? .135Are power tools used with the correct shield, guard, or attachment recommended by the manufacturer? .243

Is appropriate foot protection required where there is the risk of foot injuries? .136

Are rotating or moving parts of equipment guarded to prevent physical contact? .243Are appropriate safety glasses, face shields, etc. used while using had tools equipment which might produce flying materials or be subjected to breakage? 1910 subpart I

Repairs/corrections must be completed by (date) ___________________________________

Routed to _____________________________________________________________ Date _________________________

Repairs/corrections from above have been done.

Supervisor ____________________________________________________________ Date _________________________

Operation

Contact

DCGR

Date

Check "X" under S for Satisfactory Condition Observed; I for Improvement Recommended of Condition observed at this time; NA if Not Observed at this time. For each I, comment on what was observed.

S I NA Housekeeping S I NA Electrical

Aisles/pathways clear Outlets grounded - good condition

Floors clean/free of debris No temporary wiring

"No Smoking" signs posted Ground Faults where needed

U/L listed oily rag cans Extension cords grounded and in good condition, i.e. no cracked insulationCabinets/shelves secured to wall

Oil absorbing material for spills Adequate for area covered

Spare parts stored in orderly manner

Trouble lights grounded and in good condition/protective cages in place

Tires stored safely Emergency lighting provided and tested on a monthly basis

Comments Comments

S I NA Flammables S I NA Cleaning Tanks

U/L listed Flammable Storage Cabinet for the storage of flammable paints, solvents, starting fluids, etc.

Is a non-flammable solvent used for cleaning parts

Approved bonding/grounding provided to transfer of liquids to smaller containers Comments

Comments

S I NA Carbon Monoxide Systems S I NA Compressed Air Systems

CO systems available - good condition

Are belt drives guarded on automatic start systems

Are the systems being used Is the tank and piping system drained of moisture daily

Operation

Contact

DCGR

Date


Elephant trunks of sufficient length to vent outside and in good condition

Are hoses/coupling devices in good condition, i.e. no cracks, adequate for pressure used

Protective covers in place for in-ground systems

Is compressed air used for cleaning purposes

Comments Comments

S I NA Portable Power Tools S I NA Tire Inflation Cage

Are power tools in good conditionIs a cage provided and used for the inflation of multi-piece rimsIs there any evidence of cracked

cases or other defects

Are tools grounded, has the third prong been cut off

Comments

If guards are provided are they intact and working as designed

Comments

S I NA Oxygen & Acetylene Cylinders S I NA Eyewash Station

Welding cart in good condition and equipped with charged multipurpose fire extinguisher

Available and in good condition

Unobstructed access and labeled

Spare stock stored separately, i.e. minimum of 20 feet between oxygen and acetylene

Portable stations recharged with clean water supply on a regular basis

Are cylinders protected from temperature extremes, i.e. direct sunlight

Comments

Are all cylinders chained in upright position to prevent falling S I NA Stationary Power Equipment

Are areas identified for both full and empty cylinders

Are stationary tools mounted to the floor to prevent tipping

Cylinders identified as to type of gas

If guards are provided, are they intact and working as designed

Operation

Contact

DCGR

Date


Inspect for dents, corrosion, etc.Is bench grinder equipped with safety shield, which are in good condition

Max. use pressure of Acetylene is 15 psi

Are the tool rests on the bench grinder adjusted to 1/8" from wheel

Oxygen gauges marked "Use No Oil"

Cylinders over 30 lb. equipped with valve protection caps

Is paper washer intact on wheel, i.e. paper should be between the metal washer and the abrasive wheelAcetylene stored with valve end

caps

Empty cylinders have valves closed Is storage rack provided that will allow spare wheels to stand on end

Comments Comments

S I NA Fire Prevention Equipment S I NA Battery Recharging Area

Are the correct size and type provided, i.e. 40 lb dry chemical/300' area

Is a well ventilated area provided for charging/storage of batteries - away fro spark producing agents

Are locations conspicuous and labeled

Are racks made of plywood or other non-sparking material

Is the maximum travel distance between extinguishers 75'

Are vent caps in place during charging - to prevent electrolyte spray

Are extinguishers inspected on a monthly bases - date of last

Is recharging area accessible to eye-wash station

Are extinguishers serviced, i.e.. recharged annually - date of last Are “No Smoking” signs posted

Comments Comments

S I NA Means of Egress S I NA Personal Protective Equipment

Operation

Contact

DCGR

Date


Are there a sufficient number of exits, i.e. minimum of two

Is eye protection provided and used for grinding and welding operations

Are they clearly visible - labeled Is hearing protection provided and used during high noise operations

Provided with emergency lightingIf spray painting is performed are personnel provided with approved respiratory protection

Clear of obstructions Is equipment clean and in a useable condition

Are “non-exit” doors labeled as such

Is a First-Aid kit provided and maintained at full stock

Comments Comments

S I NA Hoisting Equipment S I NA Hand Tools

Is hoisting equipment inspected annually - date of last

Are hand tools in good condition

Are mushroom heads present on hammers, cold chisels & punches

Is the rated capacity marked on equipment

Are there a sufficient number of jack stands available - inspected annually - date of last

Hammer handles should not be taped - hides cracks and other defects

Are all slings, towing/lifting cables, and chains load tested annually - date of last

Is a locked cabinet provided for securing hand tools

Comments Comments

PERSONAL PROTECTIVE EQUIPMENT PROGRAM & PROCEDURESOSHA COMPLIANCE - REF: 29 CFR 1910.132,133,135,136,138

Scope

This program addresses the Personal Protective Equipment (PPE) requirements for Company employees as they apply to head, face, eyes, extremities, protective clothing, shields and barriers. Respiratory protection is addressed in the Respiratory Protection Program and Procedures.

In accordance with the Company Environmental Health and Safety Policy, the Company desires to protect employees from hazards of processes, the environment, chemical or radiological hazards, mechanical hazards or irritants which may be capable of causing injury or impairment in the function of any part of the body through absorption, inhalation or physical contact.

Employee Owned Equipment

The Company will assure the adequacy, proper maintenance and sanitation of PPE, which may be provided by employees for their personal use.

Hazard Assessment

The Company will conduct a hazard assessment of the workplace to determine what if any hazards are present, or likely to be present, which indicates the use of PPE is necessary. This assessment will cover all operational activities such as drivers, helpers, equipment operators, mechanics and others. If such hazards are present or likely to be present the Company will:

• Select, and have each affected employee use, the types of PPE that will protect the employee from the hazards identified in the hazard assessment.

• Communicate selection decisions to each affected employee; and

• Select PPE that properly fits each affected employee.

Hazard Assessment Categories

Basic hazard categories evaluated during the hazard assessment include:

• Impact • Heat

• Penetration • Harmful Dusts

• Compression • Light (optical) radiation

• Chemical • Noise

Hazard Assessment Certification (Forms PPE-A and PPE-B)

The Company will verify the required workplace hazard assessment has been performed through written certification as follows:

• Name of the person certifying the evaluation has been performed;• Date(s) of the hazard assessment; and• The document is identified.

Defective or Damaged Equipment

Defective or dam aged equipment will not be used and will be replaced as necessary. All PPE will comply with appropriate American National Standards Institute (ANSI) standards.

Training

The Company will provide training to each employee who is required to use PPE. Employees will be trained to know at least the following:

• When PPE is necessary;• What PPE is necessary;• How to properly put on, remove, adjust and wear PPE;• The limitations of PPE;• The proper care, maintenance, useful life, and disposal of PPE.

Each employee will demonstrate an understanding of the training described above and the ability to use PPE properly before being allowed to perform work requiring the use of PPE.

Retraining

The Company will retrain any employee who, in the opinion of Management, does not adequately demonstrate the understanding and skill necessary to properly use and care for PPE assigned to him/her. Circumstances where retraining is indicated include, but are not limited to situations where:

• Changes in the workplace render previous training obsolete; or• Changes in the types of PPE to be used render previous training obsolete;• Inadequacies in an affected employee's knowledge or use of assigned PPE indicate the

employee has not retained the necessary understanding or skill.

Training/Retraining Certification

The Company will verify that each affected employee has received and understood the required training through written certification, which contains:

• The employee's name;• The date(s) of training or retraining;• The PPE addressed in the training;• The name and signature of the trainer.

Common Types of PPE [See Appendix A]

Eye and Face Protection Requirements

Employees will use appropriate eye and face protection when exposed to hazards from flying particles, molten metal, liquid chemicals, acids or caustic liquids, chemical gases or vapors or potentially injurious light radiation.

Employees will use eye protection that provides side protection when there is a hazard from flying objects. Detachable side protectors (clip-on) are acceptable.

Employees who wear prescription lenses while working in operations that involve eye hazards will wear eye protection that incorporates the prescription in its design. As an alternative, they may use eye protection which can be worn over the prescription lenses provided such protection does not disturb the proper position of the prescription or protective lenses.

Eye and face PPE will be distinctly marked to facilitate identification of the manufacturer.

Each employee will use PPE with filter lenses that have a shade number appropriate for the work being performed for protection from injurious light radiation.

See Appendix B for appropriate shade numbers for various operations. See Appendix C for eye and face protection selection chart.

Protective eye and face devices purchased after July 5, 1994 will comply with the ANSI Z87.1 - 1989 standard. Equipment purchased before July 5, 1994 will comply with the ANSI Z87.1 - 1968 standard or is equally effective.

Head Protection

Employees will wear protective helmets when working in areas where there is a potential for injury to the head from falling objects.

Affected employees will wear protective helmets designed to reduce electrical shock hazard, when near exposed electrical conductors that could contact the head. Only Class A Helmets proof tested to 2,200 volts will be used for low voltage exposures. Only Class B Helmets proof tested to 20,000 volts will be used for high voltage exposures. Helmets made of aluminum will not be used.

Protective helmets purchased after July 5, 1994 will comply with the ANSI Z89.1 - 1986 standard. Equipment purchased before July 5, 1994 will comply with the ANSI Z89.1 -1969 standard or is equally effective.

Foot Protection

Employees will wear protective footwear (safety shoes/boots) when working in areas where there is a danger of foot injuries due to falling or rolling objects, objects piercing the sole or where such employee's feet are exposed to electrical hazards.

Protective footwear purchased after July 5, 1994 will comply with the ANSI Z41 - 1991 standard. Protective footwear purchased before July 5, 1994 will comply with the ANSI Z41.1 - 1967 standard or is equally effective.

Safety shoes and boots which meet the ANSI Z41-199 standard provide both impact and compression protection. Certain tasks may also require footwear with puncture or metatarsal protection. This determination will be made as appropriate based on identified hazards.

Hand Protection

Employees will wear hand protection when working in an area or with materials that would cause harm to the hands, fingers. Only approved types of gloves will be permitted to be worn by employees. Some different types are:

LeatherLeather gloves will have Kevlar Thread and single leather construction. These gloves provide resistance to cuts, abrasions, burns and some punctures.

Chemical ResistantThese gloves provide protection against most chemical exposures. Verify manufacturers recommendations regarding the types of chemicals that apply prior to issuing them to employees.

TYVEKCommonly used in painting applications because they can be disposed of after use.

Welder’s GlovesThese gloves consist of a leather material resistant to higher than normal temperatures. A gauntlet usually covers the entire arm to the elbow providing protection against slag drops.

Hearing Protection

See the "Hearing Conservation Program and Procedures" for a detailed guide to hearing protection.

Respiratory Protection

See the “Respiratory Program and Procedures” section for a detailed guide to respiratory protection.

Recordkeeping

All records associated with the program will be maintained in a separate Personal Protective Equipment Records File. At a minimum this will include:

• PPE Hazard Assessment • Form PPE-A

• PPE Requirements • Form PPE-B

• Records for Training for PPE

PPE - APPENDIX ACOMMON TYPES OF PERSONAL PROTECTIVE EQUIPMENT

Eye and Face Protection

Eye protection is required when there are hazards, which include flying objects, glare, liquids, intense light, or ultraviolet radiation. Face shields protect the face and neck from flying particles, liquid sprays, and splashes or hot metal. Three basic styles of face shields include headgear without crown protectors, with crown protectors and with crown and chin protectors. Eye and face protection must be manufactured in accordance with ANSI Z87.1. Eye protection must be distinctly marked with the manufacturer's identification and indicate conforming to ANSI Z87.1.

Head Protection

Protective headwear is designed to protect the employee's head against impact and penetration of falling objects and, in some cases, from high voltage electric shock. The specifications on helmets are established in ANSI Z89.1. Identification inside the helmet shell must list the manufacturer's name, ANSI designation, and either Class A, B or C:

Class A For protection against impact hazards and low voltage electricity.

Class B For protection against impact hazards and high voltage electricity.

Class C For protection against impact hazards with NO voltage protection.

Foot Protection

Safety shoes and boots provide protection from falling or rolling objects, sharp object, hot surfaces and slippery surfaces. Steel, reinforced plastics and hard rubber are used for safety shoes. To protect the upper foot from impacts, over-foot (metatarsal) guards can be added. Safety shoes should have puncture resistant soles. Metal insoles provide added puncture protection. ANSI Z41 standardizes specifications for footwear. Leggings offer protection to the lower leg and feet from welding sparks.

Hand Protection

Gloves protect the hands and arms from abrasions, burns, cuts, punctures and chemical splashes. There is a wide assortment of gloves. Lengths vary from those made to extend just above the wrists to gauntlet-types that cover the entire arm. Gloves are made of leather, cotton, natural rubber, synthetic rubber and other materials. Various coatings and finishes are applied to increase puncture and cut resistance.

Hearing Protection

Hearing protection devices (HPD) must be used when average noise levels equal or exceed 90 decibels measured on the A-scale (DBA). Employees who have experienced a standard threshold shift, or any employee who is exposed to an 8-hour TWA of 85dBA or greater and has not yet had a baseline audiogram must wear HPDs. Each protector is provided with a Noise Reduction Rating (NRR) number, an estimate of its effectiveness. This number can be subtracted from the noise level in the workplace to arrive at the noise level received in the employee's ear. Two types of HPDs are generally preferred: ear plugs and earmuffs. Earplugs are available in throwaway and reusable types.

Refer to the Hearing Conservation Program & Procedures for more information.

Respiratory Protection

Respirators provide protection against air contamination with harm ful dusts, fogs, fumes, mists, gases, smoke, sprays or vapors. Respirators vary in design, application and protective capabilities. Proper selection depends upon the toxic material(s) encountered, environmental conditions, employee capabilities and equipment fit. The National Institute for Occupational Safety and Health (NIOSH) provides testing and certification of respirators.

Refer to the Respiratory Protection Program and Procedures for information on selection, use, maintenance, evaluation and training.

Body Protection

Aprons are used to protect the body from flying hot metal fragments created during welding or cutting, corrosive or caustic liquid chemical splashes or intense heat. Apron material selection should be based on anticipated exposure. Safety vests provide higher levels of visibility (conspicuity) for employees working near moving traffic or in reduced light conditions. Vests should utilize iridescent colors and incorporate reflective stripes.

Filter Lenses for Protection Against Radiant Energy

Operations Electrode Size (inches diameter)

Arc Current(Amperes)

Minimum *Protective Shade

Shielded metal arc welding Less than 3/323/32 - 5/325/32 - 8/32More than 8/32

Less than 60 60 - 100160 - 250250 - 550

781011

Gas metal arc welding and flux coded arc welding

Less than 60 60 - 160160 - 250250 - 550

7101010

Gas Tungsten arc welding Less than 500 500 - 1,000

8810

Air carbon Arc cutting

(Light)(Heavy)

Less than 500500 - 1,000

1011

Plasma arc welding Less than 2020 - 100100 - 400400 - 800

681011

Plasma arc cutting (Light) **(Medium) **(Heavy) **

Less than 300300 - 400400 - 800

8910

Torch brazing - 3

Torch soldering - 2

Carbon arc welding - 14

Plate Thickness

inches mm

Gas welding: Light Medium Heavy

Less than 1/81/8 to ½More than ½

Less than 3.23.2 - 12.7More than 12.7

456

Oxygen cutting: Light Medium Heavy

Less than 11 to 6More than 6

Less than 2525 to 150More than 150

345

* As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter shade, which gives sufficient view of the weld zone without going below the minimum. In useful gas welding or cutting, where the torch produces a high yellow light, it is desirable to use a filter lens that absorbs the yellow or sodium line in the visible light of the (spectrum) operation.

** These values apply where the actual arc is clearly seen. Experience has shown that lighter filters may beused when the arc is hidden by the work piece.

Eye and Face Protection Selection Chart

Source Assessment of Hazard Protection

IMPACT - Chipping, grinding machining, masonry work, woodworking, sawing, drilling, chiseling, powered fastening, riveting, and sanding.

Flying fragments, objects, large chips,particles, sand, dirt, etc ............………

Spectacles with side protection, goggles, face shields. See notes (1), (3), (5), (6),(10). For severe exposure, use face shield.

HEAT. Furnace operations, pouring, casting, hot dipping, and welding.

Hot sparks ................................….........

Splash from molten metals ...................

High temperature exposure ……………

Face shields, goggles, and spectacles with side protection. For severe exposure, use face shield. See notes (1), (2), (3).

Face shields, worn over goggles. See notes (1), (2), (3).

Screen face shields, reflective face shields. See notes (1), (2), (3).

CHEMICALS - Acid and chemicals handling, degreasing plating.

Splash ..................................…………...

Irritating mists .........……...............….....

Goggles, eyecup and cover types. For severe exposure, use, use face shield.See notes (3), (11).Special-purpose goggles.

DUST - Woodworking, buffing, general dusty conditions.

Nuisance dust .........................…...........

Goggles, eyecup and cover types. See note (8).

LIGHT and/or RADIATION Welding:Electric arc

Optical radiation .................................... Welding helmets or welding shields.Typical shades: 10-14. See notes (9), (12)

Welding: Gas Optical radiation ......................….......... Welding goggles or welding face shield.Typical shades: gas welding 4-8, cutting3-6, brazing 3-4. See note (9).

Cutting, Torch Brazing, Torch SolderingOptical radiation .................................... Spectacles or welding face shield. Typical

shades: 1.5-3. See notes (3), (9).

Glare Poor vision .............................….......….Spectacles with shaded or special purpose lenses, as suitable. See notes (9), (10).

NOTES TO EYE AND FACE PROTECTION SELECTION CHART:(1) Care should be taken to recognize the possibility of multiple and simultaneous exposure to a variety of hazards.

Adequate protection against the highest level of each of the hazards should be provided. Protective devices do not provide unlimited protection.

(2) Operations involving heat may also involve light radiation. As required by the standard, protection from both hazards must be provided.

(3) Face shields should only be worn over primary eye protection (spectacles or goggles).(4) As required by the standard, filter lenses must meet the requirements for shade designations in §1910.133(a)

(5). Tinted and shaded lenses are not filter lenses unless they are marked or identified as such.(5) As required by the standard, persons whose vision requires the use of prescription (Rx) lenses must war ether

protective devices fitted with prescription (Rx) lenses or protective devices designed to be worn over regular prescription (Rx) eyewear.

(6) Wearers of con tact lenses must also wear appropriate eye and face protection devices in a hazardous environment. It should be recognized that dusty and/or chemical environments may represent an additional hazard to contact lens wearers.

(7) Caution should be exercised in the use of metal frame protective devices in electrical hazard areas.(8) Atmospheric conditions and the restricted ventilation of the protector can cause lenses to fog. Frequent

cleansing may be necessary(9) Welding helmets or face shields should be used only over primary eye protection (spectacles or goggles).(10) Non-side shielded spectacles are available for frontal protection only, but are not acceptable eye protection for

the sources and operations listed for "impact."(11) Ventilation should be adequate, but well protected from splash entry. Eye and face protection should be

designed and used so that it provides both adequate ventilation and protects the wearer from splash entry.(12) Protection from light radiation is directly related to filter lens density. See note (4). Select the darkest shade that

allows task performance.

PPE HAZARD ASSESSMENT

Certification: Company _________________________________ Evaluator ___________________________________________Location __________________________________ Date _______________________________________________

TASK / ACTIVITY

EYE FACE FOOT

IMPACT HEAT CHEMICALS DUST LIGHT/RADIATION IMPACT HEAT CHEMICALS DUST IMPACT COMPRESSION

(ROLLOVER) PUNCTURES ELECTRIC SHOCK

Driver

Welder Y Y Y Y Y Y Y Y Y Y

Painter Y Y Y

Fueler Y

Tire Repair Y Y Y

Mechanic GRINDING BAT. PW. FUELS GRINDING BAT. PW. FUELS

Powered Ind. Equip. Oper.

Y

Trk./Equip. Washing

Y

KEY Y = Yes BAT = BatteriesPW = Parts Washing FO = Falling ObjectsFuels = Oil, Grease, Diesel, Gasoline SO = Stationary Objects

Form PPE-APage 1 of 2

PPE HAZARD ASSESSMENT

Certification: Company _________________________________ Evaluator ___________________________________________Location __________________________________ Date _______________________________________________

TASK / ACTIVITY

HANDS / ARMS BODY HEAD

CUTS ABRASIONS PUNCTURES CHEMICALS BURNS HEAT /COLD CHEMICALS VISIBILITY HEAT DUST PUNCTURES /

PENETRATIONELECTRIC

SHOCK

Driver

Welder Y Y Y Y

Painter Y Y Y Y

Fueler Y Y

Tire Repair Y Y Y

Mechanic Y Y BAT. PW. FUELS ROAD CALLS

Powered Ind. Equip. Oper. Y Y Y ROAD CALLS Y-FO

Trk./Equip. Washing Y Y

KEY Y = Yes BAT = BatteriesPW = Parts Washing FO = Falling ObjectsFuels = Oil, Grease, Diesel, Gasoline SO = Stationary Objects

Form PPE-APage 1 of 2

PPE REQUIREMENTS

Certification: Company _________________________________ Evaluator _______________________________________

TASK / ACTIVITY SAFETY GLASSES

FACE SHIELD GLOVES SAFETY

SHOESHEARING

PROTECTION RESPIRATOR ARM PROTECTION APRON HEAD

PROTECTION

Driver

Welder Y Y Y Y 2 Y - 1, 3 Y Y

Painter Y - 3 Y Y 2 Y -3

Fueler Y Y 2

Tire Repair Y Y Y 2

Mechanic Y Y - 3 Y Y 2

Powered Ind. Equip. Oper.

Y Y Y 2 Y

Trk./Equip. Washing

Y Y 2 Y Y

KEY 1 = When Necessary or Appropriate2 = As Determined Based on Noise Surveys3 = Refer to Respiratory Protection Program

Form PPE-B

Use of Equipment

Scope

Applies to all types of equipment used by any employees during the performance of a job task.

Identification of Equipment

Management should identify all pieces of equipment which are used during the scope of employment for each individual job. Proper techniques for using all pieces of equipment should be established.

Training of Employees

Training on proper techniques for using hazardous equipment should be given to all employees for equipment they will be using during the performance of their job duties.

Hand Tools/Power Tools

All employees should be shown proper techniques for using and maintaining hazardous hand tools (hammers, saws, etc.), power tools (drills, sanders, etc.), and ladders.

Machinery

Proper-use and maintenance training should be given for every piece of machinery which is used by an employee in the performance of their job duties, regardless of whether the employee is familiar with the machine or not. Where possible, safe operating instructions should be posted near each type of hazardous machinery. A training certificate should be signed by each employee as he/she receives training on each particular piece of hazardous machinery.

Ladders

All employees should be instructed on the proper-use and maintenance of ladders. If, at any time, an employee is observed using equipment in an unsafe manner, the employee should not be permitted to continue using the equipment until the employee has received instruction on the proper use of the equipment.

Maintenance

Maintenance of all tools, machinery and ladders should be performed according to a predetermined schedule.

The handles of tools should be checked for cracks and splits. Machinery should be cleaned and lubricated according to manufacturer specifications. Ladders should be inspected for weakened, broken or missing steps and side rails.

Safeguarding

All machinery whose operation exposes an employee to injury will be guarded at the point of operation that are hazardous. All machinery must be properly guarded before operation. Machinery with damaged or missing guards shall not be operated.

Tool Safety Tips

General

All hand and power tools or similar equipment, whether furnished by the Company or the employee, shall be maintained in a safe condition. When power operated tools are designed to accommodate guards, they shall be equipped with such guards when in use. Belts, gears, shafts, pulleys, sprockets, chains, etc. or any moving parts of equipment shall be guarded if such parts are exposed to contact by employees or otherwise pose a hazard. Employees operating such equipment and exposed to the hazard of falling, flying, abrasive, and splashing objects, or exposed to harmful dusts, fumes, mists, vapors, or gases will be provided with the particular personal protective equipment necessary for protection and shall use it appropriately.

Manually Operated Hand Tools

Wrenches

• Should be pulled and not pushed• Jaw corrugations and threads on adjusting screws should be sharp and clean to prevent slips.• Do not force a wrench with a hammer.

Chisels

• Heads shall be clean and free of mushrooming.• Re-grind mushroomed heads.• Use a sponge rubber pad over the knuckles.• Use chisels of proper size and drive with a hammer of sufficient weight for the job.

Steel Hammers

• Shall not be used on hardened steel surfaces.• Do not use claw hammers and crowbars to snap metal bands.

Cutters

• Use correct size cutter for bands, wire rods, and bolts.• Wear safety glasses or goggles when cutting.• Cut materials straight across, and keep one gloved hand over ends of wire or bands that can fly

loose.

Files

• Shall not be used as pries or punches.• Should have handles over the tag.

The handles of tools i.e., hammer, picks, etc., should be checked for cracks and splits. It is recommended that a schedule be set for inspection or testing of hand tools. Sledgehammers, picks, shovels, axes, and other tools, which are swung, require that their users be properly positioned to avoid striking workers behind or around them. Employees who use these tools should be in good physical condition.

Power-Operated Hand Tools

• Electric power-operated tools shall either be of the approved double-insulated type or ground plug connected.

• Using electric cords for hoisting/lowering tools shall not be permitted.• Pneumatically driven nailers, staplers or similar equipment that has automatic fastener feed will

have a safety device on the muzzle to prevent accidental discharge.

Abrasive Wheels and Tools

• Floor/bench-mounted grinders shall be provided with work rests rigidly supported and readily adjustable. The work rests will be kept at a distance not to exceed 1/8 inch from the wheel surface.

• Guards are required to be mounted in order to maintain proper alignment with the wheel, and the guard and its fastenings shall be of sufficient strength to retain fragments of the wheel in case of accidental breakage.

Woodworking Tools (i.e. Radial Arm Saws, Circular Table Saws, etc.)

• The point of operation on such machines whose operation exposes an employee to injury will be guarded and an employee shall not operate the machine without the appropriate guard.

• Power/operating controls should be located within easy reach of the operator while at the normal work location, eliminating the need to reach over the cutting head to make adjustments.

Electric and Gas Welding and Cutting

• Only persons of proven competency shall perform welding operations.

• A qualified person shall inspect welding apparatus frequently. Defective equipment shall be removed from service repaired or replaced.

• Cylinders shall be handled with care. Valve protection caps shall be in place when cylinders are not in use. Cylinders shall at all times be secured in an upright position against toppling or accidental dislodgment.

• Cylinder valves shall be opened only with hand wheels or tools, specifically designed for that purpose. Cylinder valves shall be closed when not in use.

• Where arc welding and cutting operations are being performed in the vicinity of other workmen or the public, fire resistant screens shall be provided to shield them from the welding rays and flashes.

Ladder Safety

• Ladders must be regularly and frequently inspected. All defective ladders (weakened, broken or missing steps, broken side rails, etc.) must be tagged, removed from service and reported to the supervisor immediately.

• Ladders and scaffolds must be strong enough for intended use. Check with the supervisor if the strength is questionable.

• Do not use portable metal ladders near energized electrical circuits.

• Ladders must not be placed in front of doors, which open toward the ladder unless the door is open, locked or guarded.

• In placing a ladder, the distance between the bottom of the ladder and the supporting point should be approximately one-forth of the ladder length.

• Portable ladders, when in use, must be firmly placed, held, tied, or otherwise secured to prevent slipping or falling.

• Use only company owned ladders. Do not use chairs, boxes, etc., as ladders. Do not use ladders as scaffold platforms. Do not use portable straight ladders without a nonskid base. Only company employees are authorized to use county ladders.

• Do not place a ladder against an unsafe support. Never put spliced ladders together to make a longer ladder. When using stepladders, be certain the legs are fully spread.

• Do not use stepladders as straight ladders.

• When using a stepladder longer than 10 feet, another person must hold the ladder (except a platform ladder).

• Have both hands free when ascending and descending ladders.

• Only one employee is to use a ladder at a time. If two employees are needed, use another ladder.

• Do not climb to the top of a ladder. Do not go higher than the second step from the top. Do not climb straight ladders higher than the third step from the top.

• When dismounting a ladder from an elevated position, be certain the side rails extend at least 3 feet above the dismount position or that grab bars exist.

POWERED INDUSTRIAL TRUCKS (FORKLIFTS) OSHA COMPLIANCE REF: 29 CFR 1910.178

Scope

These procedures apply to all employees who operate powered industrial trucks, such as forklifts.

General Information

Federal OSHA Regulation 29 C.F.R. § 1910.178 (I) requires that only trained and authorized operators be permitted to operate a powered industrial truck, such as a forklift.

Only those employees who have been properly trained and authorized in the safe operation of powered industrial trucks (e.g., forklifts) will be permitted to independently operate such equipment.

It is the responsibility of all facility and/or garage managers/supervisors to ensure that all affected employees are properly trained and certified.

Frequency of Training

We are required to train all new employees as well as employees whose changing responsibilities place them in an area where forklifts are utilized. This training must be completed before the employee operates a forklift independently for the first time. Once the training has been completed, operators must be evaluated while they operate the vehicle in the workplace.

For currently trained employees, the standards require a periodic evaluation to ensure that their skills remain at a high level. This periodic training must be conducted at least once every three years. In addition, operators must receive refresher training whenever there is a demonstrated need for it, which would be indicated by an instance of unsafe operation, an accident or a near miss incident, whenever operators are assigned to different types of equipment, or whenever environmental conditions in the workplace change that would affect safe operation.

Training Content

The training program must contain the following elements: classroom and practical training in proper vehicle operation; the hazards of operating a forklift in the workplace; the requirements of the OSHA standard for powered industrial trucks; and an evaluation of the operator’s performance in the workplace.

The OSHA standard requires that operators shall receive initial training in the following topics, except those in which the employer can demonstrate that the subject is not applicable to safe operation of the truck in the employer’s workplace.

Truck-related topics:

• Operating instructions, warnings, and precautions for the types of truck the operator will be authorized to operate;

• Differences between the truck and the automobile;

• Truck controls and instrumentation: where they are located, what they do, and how they work;

• Engine or motor operation;

• Steering and maneuvering;

• Visibility (including restrictions due to loading);

• Fork and attachment adaptations operation, and use limitations;

• Vehicle capacity;

• Vehicle stability;

• Any vehicle inspection and maintenance that the operator will be required to perform;

• Refueling and/or charging and recharging of batteries;

• Operating limitations;

• Any other operating instructions, warnings, or precautions listed in the operator’s manual for the types of vehicle that the employee is being trained to operate.

Workplace-related topics

• Surface conditions where the vehicle will be operated;

• Composition of loads to be carried and load stability;

• Load manipulation~ stacking, and unstacking;

• Pedestrian traffic in areas where the vehicle will be operated;• Narrow aisles and other restricted places where the vehicle will be operated;

• Hazardous (classified) locations where the vehicle will be operated;

• Ramps and other sloped surfaces that could affect the vehicle’s stability;

• Closed environments and other areas where insufficient ventilation or poor vehicle maintenance could cause a buildup of carbon monoxide or diesel exhaust;

• Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation.

Required Documentation

OSHA requires written documentation of the training conducted with each operator. This documentation must specify the name of the operator, the date of the training, the date that the operator’s knowledge of operational safety was evaluated, and who provided the training and evaluation.

Each maintenance facility should assemble a 3 ring binder entitled “Training Manual”. Individual pages should be inserted each time any type of training session is conducted, including the topic covered, when the training was completed, the person conducting the training, the signed class roster, the

acknowledgments by the employees that they have been trained, and the written review showing that the employees understood the material presented.

Operator Responsibilities

Individuals who operate forklifts must realize that the equipment may weigh as much as 6 to 8 times more than the vehicles they typically drive to work. Therefore, extreme care must be exercised while operating a forklift. Other points of significance are as follows:

a forklift can steer faster and may have its steering axle in the rear;

the center of gravity changes on a forklift as a load is lifted or lowered;

there is a far greater chance of striking a pedestrian because of poor visibility when carrying a load;

a forklift carrying a load cannot be stopped as easily as other vehicles we typically operate.

Approximately 2-4% of all forklift accidents involve roll over. The remainder of the accidents (96- 98%) involves striking people or objects or losing a load. The severity of these accidents can have a tremendous bearing on the safety and well being of all employees, as well as that of the company. Employees must constantly be reminded to take all precautions to avoid the opportunity of an accident.

Fuel and Fueling Hazards

Four types of fuel are used in powered industrial lifts: electric; propane; diesel; and gasoline. Each contains specific hazards, as follows:

Electric Powered Units

• Normally, electric forklifts are plugged into battery chargers for several hours during periods when not in use. There are a number of hazards to watch for.

• While charging a wet cell type battery, the acid bubbles produce a flammable gas called hydrogen. For this reason, smoking is never permitted in or near a charging area.

• When checking the fluid electrolyte level in a battery, never use a match or lighter for to see into the battery. This will almost always cause an explosion!

• The forklift battery should not be used to power anything except the forklift itself. Components such as headlights, radios or tape players must never be hooked up to the unit’s battery supply.

• Forklift batteries should not be used to jump-start cars or other engines.

• The liquid inside the battery contains acids, which may burn the skin and clothing. If this liquid comes in contact with a person’s skin, the area should be rinsed and washed thoroughly with water. If the acid enters the eyes, they must be rinsed immediately at the nearest eye wash station for a minimum of 15 minutes, even if the pain subsides. Medical treatment should follow in all cases.

• If the forklift is not placed on a charger during off-periods or weekends, the operator should disconnect the battery plug from the truck plug to prevent drainage. During normal shift use, the forklift may remain plugged into the battery when left unattended.

Propane Powered Units

• Propane gas is invisible and extremely flammable. Propane is, however, detectable to the smell. If propane odor is detected, determine the origin of the leak. Supervision must be notified in all cases so that arrangements can be made to have the leak repaired.

• There must be is no smoking while operating a propane powered forklift.

• Propane securement straps (normally two) must be in good working order and properly used. There may be no more than two propane tanks on any vehicle at one time.

• The pin on the forklift must fit into the cutout holes provided on the LP cylinder, by law.

• If the propane tank gets punctured at any time, get away from the vehicle immediately and keep ignition sources (e.g., smoking, welding, running engines, etc.) away from the vehicle. Supervision must be notified immediately.

Diesel Powered Units

• Diesel forklifts are normally much larger than propane powered vehicles and typically have a fuel capacity ranging from 20 to 100 gallons. This increased capacity creates the opportunity for problems of a much greater magnitude.

• Diesel fuel has a flash point (the point at which it will ignite and burn) in the range of 100 degrees Fahrenheit. If involved in a spill situation in cold weather and the outside temperature is 15 degrees, there is not likely to be a fire hazard. However, if the spill occurs when the outside temperature is 98 degrees, the pavement could reach a temperature of 125 degrees. Diesel fuel in this situation becomes an explosive hazard. The same fuel is normally more hazardous in warm weather than in cold.

• Another property of diesel fuel is that, when the temperature is very cold, it may turn to a gel- like substance and not flow through the fuel lines of the forklift. When this happens, the engine may not get sufficient fuel and will stop running. If the unit is equipped with power assisted brakes and steering, these systems will not be operative unless the engine is running.

Gasoline Powered Units

• Always turn off the engine when fueling a gasoline-powered forklift. Filling a gasoline-powered forklift with cans rather than directly from a pump increases the danger of a spill. If a spill occurs, be certain the spilled fuel is properly cleaned up. If the fuel gets on the clothing, the employee must change immediately. Gasoline fumes can stay in the clothing for hours and creates a danger of igniting.

Vehicle Maintenance

Because of the extreme weight of the forklift unit together with its load, the brake system is of paramount importance and must be in excellent condition at all times, without exception.

Brakes

The following steps should be performed when checking the brake system prior to use:

1. Depress the brake pedal as far as possible, with the engine running. Some free play should occur before resistance is felt.

2. Release the pedal. It should return to the normal position.

3. Depress the pedal again and hold for 15 seconds. The pedal should not be spongy or sink. Release the pedal.

4. Apply the parking brake. Attempt to slowly move the forklift. It should not move.

Supervision should be notified if any defect is discovered. The vehicle must not be operated until all defects have been corrected.

Steering

With the engine running, turn the steering wheel in both directions, all the way to the stops. You should have very little free play and the pump should not squeal until the wheel reaches its stop. If any defects are discovered, supervision should be notified and the unit not operated until repaired.

Pre-Shift Inspection

Prior to operating a forklift, the operator must perform a pre-shift inspection and submit the appropriate form (contained herein) to their supervisor for filing. These inspection forms must be maintained in the maintenance files for a period of 6 months.

The following items are to be checked during the pre-shift inspection:

tires headlights, tail lights, warning lights and flashers service brakes, parking brakes, brake lights and back-up lamps steering system damage, leaks, broken or loose parts forks, fork pins and stops horn seatbelts mirrors overhead protection or cage hour meter, gauges and instruments oil, water, battery electrolyte and fuel I LP gas levels battery plug and charge indicator LP gas tanks hydraulic oil hydraulic controls for lift system

Forklift Safety Rules

The following safety procedures are to be included in the employee-training program:

Federal Regulations require that all forklift operators be properly trained.

Check equipment to determine if the unit can safely be placed in service. This should be done at the beginning of each shift. Items to be checked are the engine oil level, radiator water level, fuel level or LP gas gauge, obvious damage and leaks, tire conditions, lights, warning lights, hour meter, other gauges and instruments, horn, steering, service brakes, parking brake and hydraulic controls.

Only the operator shall ride on a forklift. At no time will passengers be allowed to ride on either the extended forks or with a load of freight.

Safety belt must be worn when operating forklift.

The forklift must be operated at a speed that will permit the forklift to stop in a safe manner, under all conditions.

Fast driving, stunt driving, or horseplay will not be permitted while operating the forklift.

Reduce speed when the floor is wet or slippery.

Whether loaded or unloaded, reduce speed when making turns so that the turn will be smooth and even.

Extreme care should be taken, and speed reduced, when operating forklifts on grades.

Descend ramps backward with load tilted against backrest and ascend ramps forward with the load tilted against backrest.

When the grade is greater than 10% the load must be carried up grade.

Parking a forklift on an incline or ramp should be avoided whenever possible. If parking on an incline or ramp is required, the wheels must be chocked to prevent rollaway.

When picking up a load: square the forklift with the load to be lifted; stop 18- 24” away from the load; raise the forks to eye level and level them to a horizontal position; raise the forks to the proper entry height; enter the load and maintain clearance around the forks to avoid load disturbance; raise the load so it is completely suspended; tilt the load back; check the rear area behind the fork lift; beep the horn and proceed backward slowly; stop the forklift after backing 18 - 24”; lower the load to the proper travel height.

Make sure the load being carried is stable and safely arranged. Loads that cannot be centered must be handled with extreme caution.

The forks shall be placed under the load as far as possible and carefully tilted backward in order to stabilize the load. Use extreme caution when tilting the load forward or backward, particularly in a high tier location.

When loading moving skids, make certain that the blades of the forklift do not extend past the front of the skid.

To ensure safe stacking, always be aware of the weight of the object you are loading. Improper stacking can cause injuries and freight damage.

If the freight being moved by the forklift extends higher than the operator’s head, the forklift must be equipped with an overhead guard or protective cage to protect the driver from any freight,

which may shift or fall. If one skid of freight must be removed from the top of another skid of freight, a forklift with an overhead guard must be used. The only time that a forklift without an overhead guard can be used is when the freight does not extend above the operator’s head.

Only those loads within the weighted capacity of the forklift shall be handled. Do not attempt to lift overweight loads.

When traveling with a load on the forks, the operator shall travel with the load as low to the floor as practical and tilted back slightly for improved stability.

When dropping off a load: square the forklift with the intended resting position; stop 18 - 24” away from the resting position; raise the load to the proper entry height; drive forward slowly and position the load over its resting location; lower the load to a height of 4”; tilt the load forward to a level, horizontal position; lower the load to its resting platform; check behind the forklift, blow the horn and back away from the load slowly and carefully.

When the forks are empty, the operator shall travel with the forks at a negative pitch and as low to the floor as practical. The operator is responsible for adjusting the height of the forks to a safe level when the operating terrain warrants.

The forklift should be moved in a backward direction whenever possible. This allows the driver a good view of the path of travel

Whether backing or moving forward, the driver should keep a clear view of the path of travel. Watch out for pedestrians.

Do not place your head, hands, arms, or legs between the uprights of the mast or outside the running lines of the forklift.

Avoid running over loose objects on the floor.

The forklift should not be driven up to someone standing in front of a bench or fixed object. If your brakes fail, you may crush this individual.

Do not let anyone, including you, stand under or pass under a load or the elevated portion of the forklift.

If your forklift is left unattended (which means you, the operator, are more than 25 feet away or the forklift is out of your direct view), the forks must be fully lowered until resting on the floor, controls in neutral, power shut off, brakes set, ignition key removed, LP gas valve fully closed and wheels chocked if parked on an incline.

When lowering unloaded forks, the forks should be first tilted forward and the lowered to the ground until the tips of the forks come in contact with the ground.

When following another vehicle, you should stay back at least three vehicle lengths.

When loading trucks, trailers, or boxcars, you need to make sure the brakes are set and wheels chocked on the vehicle being loaded.

Do not use your forklift for opening or closing freight doors or overhead doors.

Pedestrians always have the right of way.

Cross railroad tracks diagonally.

Do not park within 8 feet of the center of railroad tracks.

When entering an elevator or lift, enter load first.

A safe distance shall be maintained from the edge of ramps, platforms or pits to prevent the unit from falling.

Extreme caution must be exercised regarding overhead installations such as lights, pipes and sprinkler systems.

Forklifts should not pass each other when traveling in the same direction, at intersections, locations with blind spots or other dangerous locations.

Operators must slow down and sound the horn at cross isles or other locations where vision may be obscured.

The engine must be turned off when refueling the forklift. Never smoke during refueling.

Spillage of oil and fuel should be cleaned up before restarting the engine.

When the operating temperature of any part or system of the forklift is found to be in excess of its normal operating range, the unit must be removed from service until the cause has been determined and corrected.

Forklifts must be kept in a clean condition, free of lint, dirt, excess oil and grease. Only non-combustible agents should be used for cleaning purposes.

Should any malfunction occur at the time of operation, the forklift will be parked, emergency brake set and the key removed from the ignition switch. Notify your supervisor immediately.

Only authorized personnel shall make all repairs.

Acknowledgment of Training

I acknowledge I have been given a copy of the forklift operations procedures listed below:

Introduction

Operator Responsibility

Fuel Sources

Electric Propane Diesel Gasoline

Vehicle Maintenance

Pre-Shift Inspection

Standard Safety Rules

In addition, I have received hands-on training on the proper operating techniques. I have read and understand the information presented and have had the opportunity to ask questions. I agree to follow these rules and procedures in the performance of my work.

Trainee’s Name (print) ______________________________________________ Date _______________

Trainee’s Signature ____________________________________________________________________

Instructor’s Name (print) ________________________________________________________________

Instructor’s Signature ___________________________________________________________________

Forklift Training Record

The employees listed below have received training in accordance with OSHA 29 CFR 1910 178 (I). This training took place on _____________________________.

Name (Please Print) Signature

1.

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3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

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Forklift Training Test

Trainee’s Name (Print) ____________________________________________ Date _________________

Trainee’s Signature ____________________________________________________________________

True / False

_____1. Operators shall watch for pedestrians and workers while in motion.

_____2. The forklift will not be left unattended with the motor running.

_____3. Rest forks on ground when machine is not in use.

_____4. Operator may start to elevate his load while traveling to and from the stack.

_____5. No forklift can be safer than the person who is operating it. Only authorized persons shall be permitted to operate forklifts.

_____6. Operators should check the condition of their equipment as soon as they go on duty and prior to each use.

_____7. Before restarting an engine, all spilled gasoline shall be cleaned up.

_____8. Inspect all loads to be moved; do not overload; do not move a questionable or unsafe load.

_____9. Slow down at cross aisles and intersections; sound horn before proceeding. When doors, corners or elevators obstruct vision, sound horn.

_____10. No passengers shall be allowed on forklifts.

_____11. A fire extinguisher must be on hand when filling gasoline. All operators should know how to operate a fire extinguisher.

_____12. When your machine is not in use, the forks should be lowered to about one inch from the floor or ground.

_____13. It is not necessary to set the hand brake if parked on level ground.

_____14. Check the load before moving or lifting to make sure no material will fall.

_____15. No one may “ride’ the load being handled by a fork lift. This includes “riding” a load being raised or lowered

_____16. Forks should always be the same distance from the center of the supporting cross bar.

_____17. On the loading dock, it is your job to make sure the trailer wheels are chocked before you drive onto the trailer.

_____18. You can use a pallet on your forks to lift a worker for high work.

_____19. When leaving your forklift, leave the forks raised at driving height in case someone else needs to use it quickly.

_____20. Never permit anyone to stand under suspended loads.

_____21. Each operator must know the load capacity of his machine.

_____22. Feet should be kept inside of running line of forklift.

_____23. Raising or lowering forks while traveling is permissible.

_____24. All loads must be inspected to determine whether or not they can be safely moved.

_____25. Don’t worry about overhead clearances when driving fork lifts.

Fork Lift Training Test (Answer Sheet)

1. TRUE 14. TRUE

2. TRUE 15. TRUE

3. TRUE 16. TRUE

4. FALSE 17. TRUE

5. TRUE 18. FALSE

6. TRUE 19. FALSE

7. TRUE 20. TRUE

8. TRUE 21. TRUE

9. TRUE 22. TRUE

10. TRUE 23. FALSE

11. TRUE 24. TRUE

12. FALSE 25. FALSE

13. FALSE

Fork Lift Pre-Shift Inspection Checklist

Employee Name___________________________________________________ Date________________

Forklift Number__________________________ Hour Meter Reading_____________________________

OK NEEDS ATTENTION

____ ____ Tires

____ ____ Headlights, taillights, warning lights & flashers

____ ____ Steering System

____ ____ Damage, leaks, broken or loose parts

____ ____ Forks, fork pins & stops

____ ____ Horn

____ ____ Seatbelts

____ ____ Mirrors

____ ____ Overhead protection or cage

____ ____ Hour meter, gauges & instruments

____ ____ Oil, water, battery electrolyte, fuel/LP gas levels

____ ____ Battery plug & charge indicator

____ ____ LP gas tanks

____ ____ Hydraulic oil

____ ____ Hydraulic controls for lift system

Operator Signature_____________________________________________________________________

BUS SPECIFIC PROCEDURES

BUS FUELING PROCEDURES

Scope

These procedures apply to all company employees and vendors or contract workers who fuel buses and other equipment.

General Information

Fueling of buses with the engine running is strictly prohibited, as is smoking or exposing any open flame in the vicinity of the vehicle.

Buses must be grounded while fueling by continuously pressing the nozzle against the intake pipe. The person fueling the bus will remain at the intake pipe until the job is completed.

Fueling of buses in enclosed buildings with passengers on board is strictly prohibited. When passengers are on board, buses will be fueled only when reasonably necessary, and then only in an open environment.

Fueling hoses will not be dropped on the ground where they can leak or obstruct pedestrian traffic. They will be secured on holders designed for that purpose.

All employees and other applicable individuals will know where the emergency shut-off switch for the fuel pump is located in the event of a failure of the automatic stop. This switch must be readily accessible and clearly marked for easy identification.

There will be an approved and certified fire extinguisher (ABC) immediately available at all fueling points. The extinguisher must be fully charged and have a current inspection tag affixed thereto. Employees and other applicable individuals will be trained in its use.

Spills will be cleaned up by approved means and residue disposed of in appropriate containers. Supervisors will immediately contact appropriate management personnel for further guidance as required. Material Safety Data Sheets and emergency assistance contact information will be available for use when necessary for the cleanup of spills.

SEWAGE WASTE (LAVATORY HOLDING TANK) PROCEDURES

Scope

These procedures apply to all company employees and vendors or contract workers who drain lavatory-holding tanks on buses.

General Information

The dumping of sewage waste from bus lavatory holding tanks will be performed only at locations expressly approved for this purpose.

When a lavatory holding tank is to be dumped, the bus will be parked with the tank directly and squarely over the catch basin to prevent splashing on any adjacent area. The catch basin cover will be completely removed to allow for the free flow of waste products.

Employees will wear appropriate protective equipment (e.g., eyewear, long pants and footwear, gloves, etc.) necessary to prevent contact with waste and chemicals contained in the holding tanks.

Employees will be certain that no passengers or other individuals are in the immediate vicinity of the dumping process to avoid contact with the dumped waste.

Covers will be replaced over the catch basin after lavatories are emptied. Splashed waste must be washed completely off adjacent areas with the clean-up materials deposited in the catch basin.

Once the tank has been properly drained, employees replenishing the tank chemical will be provided a copy of the Material Safety Data Sheet obtained from the chemical manufacturer. All employees involved in this process will be properly trained in understanding the M.S.D.S. and the necessary precautions to prevent inadvertent contact with the chemical. Supervisors will assure proper handling of lavatory holding tanks by reviewing waste disposal procedures with affected employees on a routine basis, as needed.

"MYSTERY BUS DAMAGE" PROCEDURES

Scope

These procedures apply to all company employees and vendors or contract workers who operate, maintain, service and dispatch buses.

General Information

When a driver swaps buses with another driver, they must carefully check each other's damage sheet, precisely noting all damage. They must also sign off on each other's sheets and insure that all sheets are submitted to the dispatch office on a daily basis. If new damage is observed, drivers will follow reporting procedures as outlined herein.

The possibility exists that damage be incurred while it is legally parked and unattended, such as the case when a driver is away from the coach.

Drivers are to complete the appropriate damage report sheet for each coach they operate, prior to all departures, accurately noting every mark and the slightest damage. Drivers will be held responsible for any damage not previously reported, even if they did not cause the damage.

Drivers are to turn in the completed damage report to the supervisor on duty prior to departure. The supervisor will carefully compare this report against the last report submitted for that particular bus.

If no new damage is noted, the supervisor will sign the current report, return the carbon copy to the driver and file the original in its appropriate file.

If new (previously unreported) damage is found, the supervisor will:

• Personally inspect the bus with the driver reporting the damage;

• Take photos of the new damage;

• Note the new damage on the Master Sheet for that coach;

• Complete a report and submit with appropriate documentation to the safety supervisor for further investigation.

Drivers are to retain their copies of departure damage reports for a period of two months from the date of operation to eliminate disputes and resolve conflicts that may arise.

Upon arrival at the conclusion of an assignment, drivers will park their coach in the designated inspection area and notify the supervisor on duty (or another individual responsible for post-trip inspections) who will conduct a visual inspection of the coach along with the driver. Existing damage will be compared to the driver's original (pre-trip) copy of the damage report, or, in the case of a swapped bus, with the report submitted by the originating driver.

If no new damage is discovered, the supervisor will sign the damage report and file it in the appropriate file. At this point, the driver will be released from further responsibility and the coach turned over to the maintenance department for servicing. If new damage is observed, the inspector will:

• Immediately notify the driver of the new damage;

• Obtain an accident report or written statement from the driver, explaining how the damage was incurred;

• Take photos of the new damage;

• File a report along with all supporting documentation to the safety supervisor;

• Note the new damage on the master sheet for that particular coach;

• Release the coach to the maintenance department for repair and service.

If maintenance or service personnel subsequently damage a coach, it will be discovered during the ensuing pre-trip inspection. The responsibility for damage sustained while in the custody of the maintenance department must be assigned to the appropriate person following a thorough investigation.

Master damage sheets for each coach must be kept in a binder, accurately illustrating the various types, models, and manufacturers of the current fleet. These sheets must be updated on a continual basis.

A bus-specific file system must be maintained for completed damage reports for comparison purposes when disputes arise concerning unidentified damage.

A designated area must be provided for the pre and post-trip inspection of coaches. This area must be conveniently accessible to the supervisor's office and adequately lit to allow thorough, uninhibited examinations of coaches.

PASSENGER ASSISTANCE PROCEDURES

Scope

These procedures apply to all employees who come in contact with our customers.

General Information

Employees will be courteous and will provide assistance and service to our customers. Such assistance will include, but not be limited to, the following:

• Assistance in boarding and alighting, including passengers with special needs;

• Assistance with baggage and large carry-on items;

• Information about their route, such as times and locations to re-board, services available, etc.;

• Courteous answers to questions and responses to requests;

• Comfortable physical environment (e.g., temperature, cleanliness, operable reading lights, clean windows, serviced restroom, etc.)

Employees will be aware of and show empathy for the five different types of travelers (i.e., relaxed/casual, outgoing/mixers, adventurous/explorers, anxious/fearful, picky/nervous), all of which may be on the coach at the same time.

Employees will practice good listening skills to evaluate a customer's message clearly, without misinterpretation. The keys to effective listening are as follows:

• Be quiet and focus totally on the customer;

• Maintain eye contact without staring at the customer;

• Use appropriate facial expressions, uncross your arms and stand up straight;

• Listen without responding until the customer is finished talking - never interrupt or interject;

• Send appropriate acknowledgments to let the customer know you are paying attention;

• Paraphrase what the customer has said. ("Let me see if I understood what you said.")

When boarding (or de-boarding) passengers, employees will:

• Make certain that all interior lights are on and the coach is well lit;

• Acknowledge each person individually in some small way;

• Remain outside the coach at the entrance door and offer assistance as needed;

• Be certain all carry-on items are secure in the overhead parcel racks;

• Count your passengers to be certain all are present and not left behind;

• Make appropriate pre-departure and pre-arrival safety and comfort announcements, reminding them to remain seated while the coach is in motion and to exercise extreme caution if they must move about the coach for any reason.

When operating charters and tours, employees will introduce themselves to the group leader(s), ask for specific requests or instructions and review the travel itinerary. In addition, employees will:

• Keep track of the number of baggage items loaded in the baggage compartments and notify the group leader whenever there appears to be a bag missing;

• Keep the group leader informed about any enroute delays or difficulties encountered that may affect the trip;

• When lost, do not try to hide this fact from your passengers - stop and ask for directions as soon as possible.

• Check coach for "lost' items left on board prior to departing de-boarding location.

• Employees are expected to go the extra mile in meeting the customer's expectations while maintaining a positive and patient attitude.

BAGGAGE HANDLING PROCEDURES

Scope

These procedures apply to all employees and other applicable individuals who load and unload passenger baggage and/or freight. This process is intended to insure the safety and security of all affected parties, and that all items remain in the same condition as received and accepted.

Carry-On Baggage

Customers are generally responsible for handling their carry-on baggage. However, if a customer needs assistance, employees must always offer to handle it.

Carry-on baggage must not cause a safety hazard or nuisance to others or block passenger space or aisles in any way. Carry-on baggage must fit securely in the overhead racks. Drivers must make certain that items stored in the overhead racks are secure prior to all departures, including rest stops.

Baggage Compartments

Items not meeting the requirements of carry-on baggage must be transported in the baggage compartments underneath the bus.

Unlike carry-on baggage, the company is directly responsible for the handling and delivery of all items transported in the baggage compartments. Care must be taken so that such items are not delayed, damaged or lost.

Customers must have identification tags containing their name, address and telephone number attached in a secure manner to the outside of all items transported in the baggage compartments.

Items that are poorly packed and/or sealed should not be accepted for transportation in the baggage compartments.

Hazardous and certain other items may not be transported. Such items include, but are not limited to, acids, batteries containing liquids, cylinders containing compressed gases (except portable oxygen cylinders used for medical reasons and personal use), combustible liquids, explosives, flammable materials, flammable, corrosive or caustic liquids, fuel tanks containing fuel, fireworks, gases, firearms, ammunition, radioactive materials, strike anywhere matches, poisons, or materials with disagreeable odors.

Proper Baggage Handling

• Use caution when opening baggage compartment doors. Items may have shifted inside and could fall out unexpectedly, causing injury or damage.

• Always secure baggage compartment doors in the open position by using safety pins, clips or other methods available.

• Be certain that items are stored so as not to obstruct the door or the hinges when closing the baggage compartment doors.

• Load the heaviest items in the baggage compartment first, followed by the lighter items, to avoid damage.

• Employees must observe proper lifting procedures at all times to prevent personal injury and damage to baggage.

• Slide objects rather than lifting them, whenever possible. Attempt to move an object only once.

• Lift comfortably. Place one foot ahead of the other and alongside the object to be lifted.

• Be sure to have a firm grip on the object by using the palms of your hands in addition to your fingers.

• Pull the object close to you; keep your elbows into your sides and your body weight centered over your feet.

• Bend your knees and lift straight by pushing upwards with your legs, with your back in a comfortable position.

• Do not twist or turn during the lifting process, Instead, move your feet when you turn.

• Brace your upper body with one arm when reaching into a baggage compartment for a bag to help take the strain off your back.

• Plan ahead by not placing heavy objects too high or too low.

• Take your time when lifting and avoid short cuts. Get assistance with heavy or awkward objects.

HOURS-OF-SERVICE PROCEDURES

Scope

These procedures apply to all drivers of commercial vehicles whose operation is governed by Section 395 of the Federal Motor Carrier Safety Regulations.

General Information

The Hours-of-Service rules are specific requirements for all operators of commercial motor vehicles. All phases of our operation must adhere to these regulations, except under rare situations where adverse or emergency conditions are encountered, as specified herein.

Adverse Driving Conditions

A driver who encounters adverse driving conditions and because of these conditions cannot safely complete the run within the 10 hour maximum driving period may be permitted to drive an additional two hours in order to complete that run. Such adverse conditions must not have been apparent, on the basis of information known, at the time the run began.

Emergency Conditions

In the case of an emergency, a driver may complete his/her run without being in violation of the hours of service, if such a run could have reasonably been completed absent the emergency.

Maximum Driving and On-duty Time• No location shall permit or require any driver used by it to drive, nor shall any such driver drive:• More than 10 hours following 8 consecutive hours off duty;• For any period after having been on duty 15 hours following 8 consecutive hours off duty;• For any period after having been on duty 60 hours in 7 consecutive days if the location does not

operate every day of the week, OR;• For any period after having been on duty 70 hours in any period of 8 consecutive days if the

location operates every day of the week.

100 Air-Mile Radius Driver Exemption

A driver is exempt from completing a "record of duty status" (drivers log) if:

• The driver operates within a 100 mile radius of the normal work reporting location;

• Returns to the work reporting location and is released within 12 consecutive hours on duty;

• At least 8 consecutive hours off duty separate each 12 hours on duty;

• The driver does not exceed 10 hours maximum driving time following 8 consecutive hours off duty;

• The location maintains and retains accurate and true time records for a 6 month period, showing reporting time, total hours and release time.

ACCIDENT/INCIDENT REPORTING AND INVESTIGATION REPORTING

REQUIREMENTS FOR REPORTING AND RESPONDING TO ACCIDENTS

Scope

Applies to all accidents/incidents regardless of severity or financial impact on the company.

Effective immediately the following procedures are in effect for all operations:

Reporting of Accidents

Accident – an event which results in any injury, no matter how minor, to employees or other parties, occurring within company owned facilities or involving the operation of company owned vehicles, through the actions of company employees and representatives, or damage to any property, whether company owned or not, resulting from actions of company employees or the actions of others, except when only a company vehicle is damaged, and repair of the damage is less than $1,000.00.

This will include when passengers fall or are injured upon the bus as a result of braking, acceleration, etc. It will also include when passengers are injured as the board or deboard the bus.

Upper management will address any under reporting or non-reporting appropriately.

For each accident, an accident report will be filled out; preventability will be determined; and the appropriate completed forms will be sent to Carmen Daecher within 48 hours of the event. If preventability cannot be determined by that time, an appropriate explanation will be included with the form with a specific date by which preventability will be determined. Use the attached forms for accident reporting by email from this point forward.

If the accident is deemed to be preventable, specific dates for retraining, suspension, or termination of the driver will be included on the accident form.

Accident Response

All accidents must be reported by drivers as quickly as possible, and always within 24 hours of the occurrence. This is required even if the driver is not returning to the facility within the 24-hour period.

The investigation of each accident will commence immediately upon reporting of the accident. Preventability will be determined within 48 hours after the report is received. The only legitimate delays in determining preventability will be if a driver is on a multiple day trip and cannot be interviewed within a 48-hour period. However, even if a driver is on a multiple day trip a phone interview concerning the accident should be used rather than waiting for the driver to return.

Witness statements, passenger statements, police reports, etc. should be obtained and used in determination of preventability. Photos taken by the driver should be required and used as part of this investigation.

If only the driver’s statement is available for determination for preventability, then a personal inspection of the damage to the coach as well as an attempt to call the other party involved in the accident to gain their account of the accident is required.

If, within 48 hours, you have not been able to contact the other party and have not received any other information from witnesses, passengers, etc., then the driver ‘s statement will be the basis for determination of preventability.

If an accident is deemed to be non-preventable, supporting documentation is required. Photos of damage to the bus; written notes of interview with the other party involved in the accident; or witness/passenger statements will be necessary to confirm that an accident was non-preventable.

All documentation used in determining preventability or non-preventability will be filed and kept for at least 3 years.

If an appeal process exists, and the driver wishes to exercise it, he/she will have 1 business day from the date of your decision to exercise an appeal.

If an appeal is exercised, those considering the appeal will render a decision within 1 business day from the appeal request.

If an accident is determined to be preventable, all appropriate action dictated by the driver management policy in effect will be taken immediately. The only exception to this will be if an appeal has been requested or if a driver is on a multiple day trip before returning to the facility. No delay of appropriate management actions will be accepted.

DEFINITION

An accident or incident is an unplanned happening or event, which did or had the possibility of resulting in injury, illness, death or damage to property or the environment (includes near misses).

REPORTING

Reporting requirements vary upon the type of incident.

No Injury or Damage

The Employee Incident Report Form should be completed immediately following an incident that occurs that does not result in injury or damage and forwarded to Company Management.

Employee Injury

The Report of Injury Form must be completed immediately and forwarded to Company Management. The nature and severity of the injury may require immediate telephone reports to the Safety Department, workers compensation adjuster and OSHA.

Within eight (8) hours following the death of any employee from a work-related incident or the in-patient hospitalization of three or more employees as the result of a work-related incident, the Company (employer) must orally report the fatality/hospitalization by telephone to the nearest Federal or State OSHA office.

Property/Environment

For incidents occurring where no employees are injured, but where damage to property or the environment occurs, the Employee Incident Report Form should be completed immediately following the incident and forwarded to Company Management.

Vehicle Accidents

All events involving Company vehicles must be reported on the Automobile Accident form immediately following the event. All details regarding vehicles and parties involved, parties injured, witnesses, location, sequence of events, responding police/emergency service agencies, etc. must be included and forwarded to Company Management.

Passenger Injury

The Passenger Incident Report form must be completed immediately following all events involving passengers tripping, falling, etc., while on or entering/exiting Company vehicles and forwarded to Company Management.

Guest/Visitor Injury

The form must be completed immediately following all events involving guests/visitors while on Company property. Falls, cuts, bumps, sprains, strains, etc., must be reported to Company Management.

RECORDING

Accurate, complete and up-to-date recording of accidental losses is important for determining trends, tracking loss costs, measuring performance and proper accident investigation/review procedures.

Employee Injuries

A separate file should be created for each work-related injury or illness. The file should contain all documents related to the incident, including the Report of Injury Form, medical treatment and release information, adjuster's reports, etc.

The Company must maintain a “log” containing entries for all work-related injuries and illnesses requiring medical treatment. The log should provide a brief description of the injury/illness, employee name, cost data, days lost, etc.

The OSHA Log 300 must be maintained for all "recordable" injuries/illnesses. Entries are to be made within 6 days of knowledge of their occurrence. First-aid type injuries should not be entered on the OSHA Log. First-aid injuries are described as a one-time treatment and subsequent observation for minor cuts, scratches, bruises, burns, splinters, etc. The OSHA Log must remain current with regard to up dating for days lost and days of restricted activity. A Report of Injury Form must be available for each entry on the OSHA LOG.

The OSHA Log 300 must be maintained on a calendar year basis. It should be placed in a separate file designated solely for each year's OSHA Log. THESE LOGS MUST BE RETAINED FOR FIVE (5) YEARS.

Vehicle Accidents

A separate file should be created for each vehicle accident. The file should contain all documents related to the incident, including Police Report, witness statements, Commercial Vehicle Inspection Report, adjuster's reports, etc.

If the accident involves any fatality, injuries treated away form the scene, or disabling damage to any vehicle involved (see definitions, FMCSR, Part 390) the accident must be recorded on an Accident Register for compliance with DOT Regulations. The following items must be included on the register:

Date City/Town of occurrence Driver’s name Number of injuries Number of fatalities Any hazardous materials spilled (excluding fuel from vehicle fuel tank)

AUTOMOBILE/EQUIPMENT LOSS REPORT FORMTO BE COMPLETED BY EMPLOYEE OR IMMEDIATE SUPERVISOR

Location of Accident Street/Road_____________________________________________

City & State____________________________________________

Date of Accident________________ Time of Accident__________

Driver/Operator

Name____________________________________

County Vehicle/Equipment Yr. Make, Model of Vehicle/Equipment______________________

Vehicle/Equipment Serial Number__________________________

Driver License #_________________________________________

Driver Relation to Co. _____Employee _____Volunteer _____Other

Damage to

Vehicle_______________________________________

Involved Party #1 Name(s)________________________________________________

Vehicle Make_________________ Model & Year_______________

Address_________________________________________________

City/State/Zip____________________________________________

Phone: Home ( )______________ Work ( )______________

Involved Party #1 Insurance Company_______________________________________

Insurance Information Policy

#_______________________________________________

__

Involved Party #2 Name(s)________________________________________________

Vehicle Make_________________ Model & Year_______________

Address_________________________________________________

City/State/Zip____________________________________________

Phone: Home ( )______________ Work ( )______________

Involved Party #2 Insurance Company_______________________________________

Insurance Information Policy #_________________________________________________

(Attach additional pages if there are more than 2 involved parties.)

Description of Accident ___________________________________________________(Attach additional pages,if more space is needed) ___________________________________________________

___________________________________________________

___________________________________________________

BY ARROWINDICATE NORTH

Witnesses: Name___________________________________________________

Address_________________________________________________

City/State/Zip____________________________________________

Phone: Home ( )______________ Work

( )______________

Witnesses: Name___________________________________________________

Address_________________________________________________

City/State/Zip____________________________________________

Phone: Home ( )______________ Work

( )______________

Authorities Police ____Yes ____ No _________________________

Contacted/Responding Fire ____Yes ____ No _________________________

Ambulance ____Yes ____ No _________________________

Describe Citations Issued_____________________________________________________________________

Completed By: Name____________________________________________________

Signature_________________________________________________

To Be Completed by Department Head: Date Reported__________________

1. What was immediate cause(s):____ Unsafe Condition ____ Unsafe Act ____ No Fault

2. What was contributing Cause(s):________________________________________________________________________________________________________________________

3. What can be done to prevent re-occurrence of this type of loss:________________________________________________________________________________________________

4. When will corrective steps be taken:____________________________________________

Remarks:______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

REPORT OF INJURY FORM

(Supervisors must report all accidents involving an injury to an employee)

Name of Injured employee:_______________________________________________________

Age:__________________ Male Female

Department:____________________________________________________________________

Length of Service with Company:____________________

Date of Accident:_______________ Time:_________ P.M. / A.M.

Location of Accident:____________________________________________________________

Description of Incident:__________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Nature of Injury & Part of Body Involved:_________________________________________________________________________________________________________________________

Was any Protective Equipment Being Used? If Yes, What Type?_______________________________________________________________________________________________________

Was any Machinery, Tools, etc. involved (If yes, describe)___________________________________________________________________________________________________________

What Job was the Employee Performing When He/She was Injured?____________________________________________________________________________________________________

Were any Safety Rules Violated? (Please Explain)___________________________________________________________________________________________________________________

Was any First Aid Provided at the Scene of the Accident? ______Yes ______No

By Whom? ______Doctor ______Emergency Personnel ______Other

Page 1 of 2

REPORT OF INJURY FORM (CON’T)Names and Addresses of Witnesses to Incident:

1. ____________________________________________________________________________

2. ____________________________________________________________________________

3. ____________________________________________________________________________

4. ____________________________________________________________________________

I have completed this report and it is correct to the best of my knowledge

Signature of person completing this report

I have read this report and it is correct to the best of my knowledge

Employee’s Signature

To Be Completed by Department Head

What was the immediate cause(s) of the accident?

______Unsafe Conditions ______Unsafe Act ______No FaultWhat was contributing cause(s) of the accident:_______________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

When will corrective steps be taken?________________________________________________

This accident involves: ______Disabling (Lost time) ______First Aid Treatment

______Medical Care ______No-Injury Accident

Disposition of Injured:

______Sent ______Went ______Hospital / Clinic ______Home

Doctor____________________________________________________________________

Anticipated Number of Days Off___________________________________________________

Actual Number of Days Lost______________________________________________________

Page 2 of 2

EMPLOYEE INCIDENT (No-Injury Accident) REPORT FORM(This must be completed IMMEDIATELY after an accident when there is no injury.)

Exact location of incident:_____________________________________________ Department:___________________________

Occurrence Date:__________________________ Time:_____________ Date Reported:_____________

Employee Involved:______________________________ SS____________________ Employee ID____________________

Job Title:________________________________ Employment Date:___________ Time on Present Job:___________

1. Property Damaged:__________________________________________________________________________________

Cost $_________________ Length of downtime__________________

2. Unsafe condition at time of incident be specific)___________________________________________________________

__________________________________________________________________________________________________

3. Unsafe practice contributing to the incident (be specific)____________________________________________________

__________________________________________________________________________________________________

4. Witness(es) to incident:_______________________________________________________________________________

5. Sequence of events: (detailed)_________________________________________________________________________

__________________________________________________________________________________________________

__________________________________________________________________________________________________

Employee Signature:_________________________________________________

To Be Completed by Department Head: Date Reported_______________

1. What was immediate cause(s):

_____ Unsafe Condition _____ Unsafe Act _____ No Fault

2. What was contributing cause(s):________________________________________________________________________

__________________________________________________________________________________________________

3. What can be done to prevent re-occurrence of this type of loss:_______________________________________________

__________________________________________________________________________________________________

4. When will corrective steps be taken:____________________________________________________________________

Remarks:________________________________________________________________________________________________

________________________________________________________________________________________________________

________________________________________________________________________________________________________

________________________________________________________________________________________________________

________________________________________________________________________________________________________

Supervisor:________________________________________________________ Date:_____________________

Immediately forward copies of this report to Department Management© 1998 The Daecher Consulting Group, Inc.

PASSENGER INCIDENT FORMInstructions to Driver: Please complete this form each and every time there is a problem or injury with occupant in you vehicle. Always

take photographs of the fall/injury area if possible.IMMEDIATELY REPORT THIS INCIDENT TO YOUR SUPERVISOR.

DRIVER INFORMATION (Please complete as fully as possible)

Your Name: _____________________________________________________________________________________________Last First M.I.

Company Name:__________________________________________________________________________________________Company Address:________________________________________________________________________________________

________________________________________________________________________________________Tel: ( )______________ Date:____________ Time:____________ A.M. / P.M.

Insurance Police No:____________________________Vehicle Identification No.(VIN)________________________________Accident/Incident Location:_________________________________________________________________________________

Name of Passenger:_______________________________________________________________________________________Last First M.I.

Address: ______________________________________________________________________________________________________________________________________________________________________________________________

Home Phone No: ( )______________ Work Phone No.: ( )______________

Was your passenger removed from the scene? Yes NoIf Yes, By Whom?______________________________________________________________________________________________If Yes, to Where?______________________________________________________________________________________________

TYPE OF PROBLEM (Please check as many boxes as necessary.)Passenger Fall Passenger Injury Incident Downstairs Struck by object overhead Complaint Upstairs Struck by carried object Argument Near bus Struck by falling person Lost article Step stool Tripped on board Fighting In aisle Struck head on overhead rack Vandalism In restroom Injury at/around baggage doors Asleep Other:__________ Injury, other cause:__________ Other:__________

DESCRIPTION OF INCIDENT (Please print clearly.) Names of Witnesses and Contact Information:

Name:__________________________________________________________________________________________________Last First M.I.

Address:________________________________________________________________________________________________Telephone No.: ( )______________

Name:__________________________________________________________________________________________________Last First M.I.

Address:_________________________________________________________________________________________________Telephone No.: ( )______________

DRIVER: PLEASE COMPLETE PASSENGER LIST/SEATING CHART AND COURTESY CARDS FOUND IN YOUR VEHICLES ACCIDENT REPORT KIT.

© 1998 The Daeche r Consulting Group, Inc.

PASSENGER INCIDENT FORM (Con’t)

To Be Completed by Department Head: Date Reported____________

1. What was immediate cause(s):_____ Unsafe Condition _____ Unsafe Act _____ No Fault

2. What was contributing cause(s):______________________________________________________________________________________________________________________________________________________

3. What can be done to prevent re-occurrence of this type of loss:____________________________________________________________________________________________________________________________

4. When will corrective steps be taken:__________________________________________________________

Remarks:_______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

EMPLOYEE SAFETY INFORMATION FORM

Description of unsafe condition or practice

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Causes or other contributing factors

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Employee’s suggestion for improving safety

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Has this matter been reported to your supervisor? YES_______ NO_______

Employee Name (OPTIONAL)____________________________________________________

Employees are advised that the use of this form or other reports of unsafe conditions or practices are protected by law. It would be illegal for the employer to take any action against an employee in reprisal for exercising their rights to participate in communications involving safety.

INVESTIGATION

Management and department heads should help investigate accidents resulting in lost workdays or major property damage and incidents, which could have resulted in serious injury or substantial damage. When management actively participates in accident investigation, it can evaluate the hazard control system and determine whether outside assistance is desired or required to upgrade existing structures and procedures. Management also must review accident/incident reports in order to make informed decisions. When investigation reveals the need or desirability of specific corrective actions, management must determine whether the recommended action has been implemented.

Employee input and involvement is also necessary. This knowledge of conditions and work practices allows them to provide insight and possible corrective actions that should be considered. Their involvement also enlists their support of changes in work habits and work conditions among each other.

What to Investigate

The investigation must answer many questions. Because of the infinite number of accident producing situations, contributing factors, and causes, it is impossible to list all the questions that apply to all investigations. The following questions are generally applicable, however, and will be considered in most accident/incident investigations:

• What was the injured person doing at the time of the accident? Performing an assigned task? Maintenance? Assisting another worker?

• Was the injured employee working on an unauthorized task? Was the employee qualified to perform the task and familiar with the process, equipment, and machinery?

• What were other workers doing at the time of the accident?• Was the proper equipment being used for the task at hand (screwdriver instead of can opener to

open a paint can, file instead of grinder to remove burr on a bolt after it was cut)?• Was the injured person following approved procedures?• Is the process, operation, or task new to the area?• Was the injured person being supervised? What was the proximity and adequacy of supervision?• Did the injured employee receive hazard recognition training prior to the accident?• What was the location of the accident? What was the physical condition of the area when the

accident occurred?• What immediate or temporary actions could have prevented the accident or minimized its effect?• Had corrective action been recommended in the past but not adopted?

During the course of the investigation, the above questions should be answered to the satisfaction of the investigators. Other questions that come to mind as the investigation continues should be recorded.

Conducting InterviewsInterviewing accident or injury victims and witnesses can be a difficult assignment if not properly handled. The individual being interviewed often is fearful and reluctant to provide the interviewer with accurate facts about the accident. The accident victim may be hesitant to talk for any number of reasons. A witness may not want to provide information that might implicate friends, fellow workers, or the supervisor. To obtain the necessary facts during an interview, the interviewer must first eliminate or reduce an employee’s fear and anxiety by establishing good rapport with the individual. The interviewer must create a feeling of trust and establish open communication before beginning the actual interview. Once good rapport has been developed, the interviewer can follow this five-step method.

1. Discuss the purpose of the investigation and the interview (fact-finding, not faultfinding).

2. Have the individual relate his or her version of the accident with minimal interruptions. If the individual being interviewed is the one who was injured, ask what was being done, where and how it was being done, and what happened. If practical, have the injured person or eyewitness explain the sequence of events that occurred at the time of the accident. Being at the scene of the accident makes it easier to relate facts that might otherwise be difficult to explain.

3. Ask questions to clarify or fill in any gaps.

4. The interviewer should then repeat the facts of the accident to the injured person or eyewitness. Through this review process, there will be ample opportunity to correct any misunderstanding that may have occurred and clarify, if necessary, any of the details of the accident.

5. Discuss methods of preventing recurrence. Ask the individual for suggestions aimed at eliminating or reducing the impact of the hazards that caused the accident. By asking the individual for ideas and discussing them, the interviewer will show sincerity and place emphasis on the fact-finding purpose of the investigation, as it was explained at the beginning of the interview.

In some cases, contractual agreements may call for an employee representative to be present during any management interview, if the employee so requests.

Preparing the Accident Investigation ReportAn accident in any organization is of significant interest to employees, who will ask questions that reflect their concerns. Is there any potential danger to those in the immediate vicinity? What caused the accident? How many people were injured? How badly?

Those who investigate accidents should answer these questions truthfully and avoid covering up any facts. On the other hand, they must be certain they are authorized to release information, and they must be sure of their data.

Because the accident report is the product of the investigation, it should be prepared carefully and adequately to justify the conclusions reached. It must be issued soon after the accident. When a report is delayed too long, employees may feel left out of the process. If a final report must be postponed pending detailed technical analysis or evaluation, then management should issue an interim report providing basic details of the investigation.

Summaries of vital information on major injury, damage, and loss incidents should be distributed to department manager. Such summaries should include information on accident causes and recommended action for preventing similar incidents. Management should maintain incident and statistical report files as dictated by company policy.

Supervisors need to keep employees informed of significant accidents and preventive measures proposed or executed. Posting accident reports is one way to make information available.

Implementing Corrective Action

Until corrective action is initiated, any recommendations - no matter how earnest, thorough, and relevant - remain “paper promises.”

The same is true of accident investigation when it is used as a monitoring technique. Viewed from the perspective of hazard control, accident investigation serves as a monitoring function only when it provides the impetus for corrective action.

Whenever management and safety professionals review monthly accident reports, they exercise an essential auditing function. Management (including the chief executive officer) can demonstrate interest in safety by requiring prompt reporting of all serious or potentially serious incidents. They use accident reports to make decisions to prevent similar accidents from occurring, and they look for answers to certain key questions. Are all significant accidents being reported? Are all parts of the organization equally committed to the hazard control effort? Are there trends or patterns in accidents or injuries? What system breakdowns predominate? What supervisors require additional training? Are employees advised of the results of accident investigation and of preventive measures being instituted? What management deficiencies are indicated? Accident investigation as a monitoring function occurs after the hazard control system has already broken down. Although no amount of investigation can reverse the accident, accident investigation serves an important monitoring function. Past mistakes can be used to improve future operations. As George Santayana has written, “Those who cannot remember the past are condemned to repeat it.”

Identifying Causal Factors and Selecting Corrective Actions

In any incident, many factors are at work that triggers a sequence of events resulting in an injury. The idea behind the corrective action selection procedure is to identify all the factors for which a corrective action is possible. Management then selects the ones likely to be most effective, most cost/beneficial, most acceptable, and so on, and implements those.

Attached is a guide for Identifying Causal Factors and Corrective Action. The Guide contains four parts: equipment, environment, people, and management. Although these elements usually combine to produce products and profits, at times they result in incidents. The questions in those four sections help the investigator to analyze the contribution each factor made to the incident.

The structure of the Guide makes it easy to identify the causal factors. Questions are answered by placing an X in a circle or a box. An X in a circle means the item is a causal factor, while an X in a box indicates the item is not a causal factor.

The comment column provides space to record the specific information about the incident being investigated. The Recommended Corrective Actions column has room to enter specific corrective actions for each causal factor. After listing all of the possible corrective actions identified on the Guide, each action must be evaluated for effectiveness, cost, feasibility, reliability, acceptance, effect on productivity, time required to implement, and any other factor deemed important, before deciding which ones to implement.

This systematic approach to selecting corrective actions ensures three basic steps. First, all major actions are considered; second, the analyst does not stop with familiar and favorite corrective actions; and third, each corrective action chosen for implementation is carefully thought out.

Answer questions by placing an X in the “Y” circle or in the “N” box for no.

F G 1.0 WAS A HAZARDOUS CONDITION(S) A CONTRIBUTING FACTOR? Y N If yes, answer the following. If no, proceed to Part 2.

Causal Factors Comment PossibleCorrective Action

RecommendedCorrective Actions

F GY N

1.1 Did any defect(s) in equipment /tool(s)/ material contribute to hazardous condition(s)?

Review procedure for inspecting, reporting, maintaining, repairing, replacing, or recalling defective equipment/ tool(s)/material used.

F GY N

F GY N

F GY N

1.2 Was the hazardous condition(s) recognized?

If yes, answer A & B.If no, proceed to 1.3

A. Was the hazardous condition(s) reported?

B. Was employee(s) informed of the hazardous condition(s) and the job procedures for dealing with it as an interim measure?

Perform job safety analysis. Improve employee’s ability to recognize existing or potential hazardous conditions. Provide test equipment, as required, to detect hazard. Review any change or modification of equipment/tool(s) /materials.

Train employees in reporting procedures. Stress individual acceptance of responsibility.

Review job procedures for hazard avoidance. Review supervisory responsibility. Improve supervisor/employee communications. Take action to remove or minimize hazard.

F GY N

1.3 Was there an equipment inspection procedure(s) to detect the hazardous condition?

Develop and adopt procedures (for example, an inspection system) to detect hazardous conditions. Conduct test.

F GY N

1.4 Did the existing equipment inspection procedure(s) detect the hazardous condition(s)?

Review procedures. Change frequency or comprehensiveness. Provide test equipment as required. Improve employee ability to detect defects and hazardous conditions. Change job procedures as required.

F GY N

1.5 Was the correct equipment/tool(s)/ material used?

Specify correct equipment/ tool(s)/material in job procedures.

F GY N

1.6 Was the correct equipment/ tool(s)/ material readily available?

Provide correct equipment/ tool(s)/material. Review purchasing specifications and procedures. Anticipate future requirements.

PART 1 EQUIPMENT



F GY N

1.7 Did employee(s) know where to obtain equipment/tool(s)/ material required for the job?

Review procedures for storage, access, delivery, or distribution. Review procedures for obtaining equipment/tool(s)/ material.

F GY N

1.8 Was substitute equipment/ tool(s)/material used in place of correct one?

Provide correct equipment/ tool(s)/material. Warn against use of substitutes in job procedures and in job instructions.

F GY N

1.9 Did the design of the equipment/tool(s) create operator stress or encourage operator error?

Review human factors engineering principles. Alter equipment/tool(s) to make more compatible with human capability and limitations. Review purchasing procedures and specifications. Check out new equipment and job procedures involving new equipment before putting into service. Encourage employees to report potential hazardous conditions created by equipment design.

F GY N

1.10 Did the general design or quality of the equipment/ tool(s) contribute to a hazardous condition?

Review criteria in codes, standards, specifications, and regulations. Establish new criteria as required.

F 1.11 List other casual factors in “Comment” column.

F G 2.0 WAS THE LOCATION OF EQUIPMENT/MATERIALS/EMPLOYEE(S) A Y N CONTRIBUTING FACTOR?

If yes, answer the following. If no, proceed to Part 2.



F GY N

2.1 Did the location/position of equipment/material/ employee(s) contribute to hazardous conditions?

Perform job safety analysis. Review job procedures. Change the location, position, or layout of the equipment. Change position of employee(s). Provide guardrails, barricades, barriers, warning lights, signs or signals.

PART 2 ENVIRONMENT



F GY N

F GY N

F GY N

2.2 Was the hazardous condition recognized?

If yes, answer A and B.If no, proceed to 2.3.

A. Was the hazardous condition reported?

B. Was employee(s) informed of the job procedures for dealing with the hazardous condition as an interim action?

Perform job safety analysis. Improve employee ability to recognize existing or potential hazardous conditions. Provide test equipment, as required, to detect hazard. Review any change or modification of equipment/tools/materials.

Train employees in reporting procedures. Stress individual acceptance of responsibility.

Review job procedures for hazardous avoidance. Review supervisory responsibility. Improve employee/supervisor communications. Take action to remove or minimize hazard.

F GY N

2.3 Was employee(s) supposed to be in the vicinity of the equipment/ material?

Review job procedures and instructions. Provide guardrails, barricades, barriers, warning lights, signs, or signals.

F GY N

2.4 Was the hazardous condition created by the location/position equipment/material visible to employee(s)?

Change lighting or layout to increase visibility of equipment. Provide guardrails, barricades, barriers, warning lights, signs or signals, floor stripes, etc.

F GY N

2.5 Was there sufficient workspace?

Review workspace requirements and modify as required.

F GY N

2.6 Were environmental conditions a contributing factor (for example, illumination, noise levels, air contaminant, temperature extremes, ventilation, vibration, radiation)?

Monitor, or periodically check, environmental conditions as required. Check results against acceptable levels. Initiate action for those found unacceptable.

F 2.7 List other casual factors in “Comment” column.

F G 3.0 WAS THE JOB PROCEDURE(S) USED A CONTRIBUTING FACTOR? Y N If yes, answer the following. If no, proceed to Part 3.6.



F GY N

F GY N

F GY N

F GY N

3.1 Was there a written or known procedure (rules) for this job?

If yes, answer A, B, and C.If no, proceed to 3.2.

A. Did job procedures anticipate the factors that contributed to the accident?

B. Did employee(s) know the job procedure?

C. Did employee(s) deviate from the known job procedure?

Perform job safety analysis and develop safe job procedures.

Perform job safety analysis and change job procedures.

Improve job instruction. Train employees in correct job procedure.

Determine why. Encourage all employees to report problems with an established procedure to supervisor. Review job procedure and modify if necessary. Counsel or discipline employee. Provide closer supervision.

F GY N

3.2 Was employee(s) mentally and physically capable of performing the job?

Review employee requirements for the job. Improve employee selection. Remove or transfer employees who are temporarily, either mentally or physically, incapable of performing the job.

F GY N

3.3 Were any tasks in the job procedure too difficult to perform (for example, excessive concentration or physical demands)?

Change job design and procedures.

F GY N

3.4 Is the job structured to encourage or require deviation from job procedures (for example, incentive, piecework, work place)?

Change job design and procedures.

F 3.5 List other causal factors in “Comment” column.

PART 3 PEOPLE

F G 3.6 WAS LACK OF PERSONAL PROTECTIVE EQUIPMENT OR EMERGENCY EQUIPMENT Y N A CONTRIBUTING FACTOR IN THE INJURY? If yes, answer the following. If no, proceed to Part 4.Note: The following causal factors relate to the injury.



F GY N

F GY N

F GY N

F GY N

3.7 Was appropriate personal protective equipment (PPE) Specified for the task or job?

If yes, answer A, B, and C.

If no, proceed to 3.8

A. Was appropriate PPE available?

B. Did employee(s) know that wearing specified PPE was required?

C. Did employee(s) know how to use and maintain the PPE?

Review methods to specify PPE requirements.

Provide appropriate PPE. Review purchasing and distribution procedures.

Review job procedures.Improve job instruction.

Improve job instruction.

F GY N

3.8 Was the PPE used properly when the injury occurred?

Determine why and take appropriate action. Implement procedures to monitor and enforce use of PPE.

F GY N

3.9 Was the PPE adequate? Review PPE requirements. Check standards, specifications and certification of the PPE.

F GY N

F GY N

F GY N

F GY N

3.10 Was emergency equipment specified for this job (for example emergency showers eyewash fountains)?

If yes, answer A, B, & C.

If no, proceed to Part 4.

A. Was emergency equipment readily available?

B. Was emergency equipment properly used?

C. Did emergency equipment function properly?

Provide emergency equipment as required.

Install emergency equipment at appropriate locations.

Incorporate use of emergency equipment in job procedures.

Establish inspection, monitoring system for emergency equipment. Provide for immediate repair of defects.



F 3.11 List other causal factors in “Comment” column.

F G 4.0 WAS A MANAGEMENT SYSTEM DEFECT A CONTRIBUTING FACTOR? Y N If yes, answer the following. If no, STOP. Your causal factor identification exercise is complete.



F GY N

4.1 Was there a failure by supervision to detect, anticipate, or report a hazardous condition?

Improve supervisor capability in hazard recognition and reporting procedures.

F GY N

4.2 Was there a failure by supervision to detect or correct deviations from job procedures?

Review jab safety analysis and job procedures. Increase supervisor monitoring. Correct deviations.

F GY N

4.3 Was there a supervisor/ employee review of hazards and job procedures for tasks performed infrequently? (Not applicable to all accidents.)

Establish a procedure that requires a review of hazards and job procedures (preventive actions) for tasks performed infrequently.

F GY N

4.4 Was supervisor responsibility and accountability adequately defined and understood?

Define and communicate supervisor responsibility and accountability. Test for understandability and acceptance.

F GY N

4.5 Was Supervisor adequately trained to fulfill assigned responsibility in accident prevention?

Train supervisor in accident prevention fundamentals.

F GY N

4.6 Was there a failure to initiate corrective action for a known hazardous condition that contributed to this accident?

Review management safety policy and level of risk acceptance. Establish priorities based on potential severity and probability of reoccurrence. Review procedure and responsibility to initiate and carry out corrective actions. Monitor progress

F 4.7 List other causal factors in “Comment” column

PART 4 MANAGEMENT

MODIFIED RETURN-TO-WORK PROCEDURES

Scope

This program requires a cooperative effort from everyone. It is the responsibility of the General Manager to insure that all managers understand the process and comply with established procedures.

MANAGEMENT’S RESPONSIBILITIES

Understand and Support the Program

Top management must understand the fundamental elements of the modified work program if it is to have a significant impact on worker’s compensation costs. This includes recognition of the cost/benefit aspect of the program as well as its overall effect on the company and employees.

Once top management has gained an understanding of the program, it must make a firm commitment to provide the necessary support. This commitment from top management is vital to the program. It is a commitment to save money and human resources.

Choose Appropriate Modified Work Jobs

If the company operates under a bargaining unit agreement, the modified work must fall outside the guidelines of the contract. There are a number of jobs that injured workers can perform to enhance the productivity of the company (several sample modified positions appear in the Appendix section of this manual).

Management must determine what these jobs are and what physical abilities an injured employee would need to perform them.

Train Supervisors

To effectively implement the program, front-line supervisors will need to be trained in several areas, including the overall purpose of the program, its basic principals and their specific role and responsibilities. The supervisor figures significantly in both the management of injuries and the process of returning an injured worker to full-duty.

Choose a Company Physician

A company doctor who understands the purpose and benefits of modified work is essential to the program. Local facility managers must get acquainted with the medical community in their area and choose a doctor or clinic that will work in cooperation with them.

Meet with the Company Physician

Once a company physician has been chosen, the physician must then be educated in the concept and process of the modified work program. This includes an explanation of the physical and mental demands of each regular and modified job your employees perform. Invite the physician to visit your facility and experience both regular and modified job functions firsthand, through observation and participation. The key to a successful program lies in the doctor’s medical opinion. The better their understanding of modified work and your operation, the more likely they will be to agree to assign modified job positions.

Meet with Union Officials

If the company operates under a bargaining unit agreement, every effort must be made to involve union officials before, during and after the implementation of the modified work program. Introductory materials explaining the program should be sent to the union prior to distributing them to employees. This allows the union a chance to review the materials and be prepared to answer questions for their members. Another suggestion would be to invite union leaders to the company facility to discuss any concerns regarding the program. An open line of communication should continue to be maintained after the program is implemented.

Post the Policy Statement

A statement describing the company’s policy on modified work should be posted in a conspicuous location at each facility. Supervisors should address employee’s questions concerning the program.

Distribute Materials

One the policy has been established and presented to the workforce, top management should distribute all of the necessary forms and materials to the supervisors who will manage the program.

Monitor Progress

Once the program is in place, management must carefully observe and measure its progress, while making modifications as needed. Management should share the results of the program with the employees. It if is successful, recognize the workforce’s contribution in achieving success. If there are problems, seek their input to devise solutions and make improvements.

SUPERVISOR’S RESPONSIBILITIES

Conduct Post-Accident Activities

There is a sequential process that will help ensure that an injury is not only treated correctly, but that the proper follow-up procedures are also administered. The supervisor is integral to both the management and rehabilitation of the injury. The following activities correspond directly to his/her responsibilities:

• Go to Hospital or Clinic: If the injury is serious enough to require immediate treatment, the supervisor should take the injured worker directly to the hospital or medical clinic to be treated by the company physician. After treatment, a decision will be made on the employee’s ability to return to work. If the injury only requires first aid treatment, it should be administered immediately and the employee should return to work when able.

• Supervisor’s Report of Injury: The supervisor must document all details regarding the occurrence of the injury and all follow-up care.

• Employee’s Injury Report: The employee should document all circumstances regarding the accident, including time, place, hours of duty, etc.

• Post-Injury Interview: This is when the supervisor and injured employee discuss the accident together to determine the cause of the accident and to eliminate hazards that may still be present.

• Accident Investigation: After the post-injury interview has been conducted, the supervisor must personally review all circumstances surrounding the accident. This would include inspection of equipment or any other factors that may have contributed to the accident. Once the contributing factors are determined, measures must be taken to try and prevent future occurrences of similar accidents.

Provide Appropriate Return to Work Activities for Employees

In the modified work program, each supervisor will bear the responsibility for helping his injured worker progress from a modified job assignment back to full-duty. The supervisor’s belief and active participation in the modified work program are critical to its success.

Appropriate return to work assignments must be created, detailing the activities expected of the employee and considering the specific restrictions outlined by the company physician. The start and finish times, as well as the wages, must also be determined.

As the worker begins a modified job, the supervisor should ensure that the employee is “eased” into the position. This requires an understanding that the employee may not be able to work at full speed or m ay need to return to work on a part-time basis in order to build up strength and endurance. This responsibility also includes informing co-workers of the situation so they understand the injured employee’s limitations.

Provide Supervisory Support

Supervisors must treat an injured worker with care and concern at the time of the injury and throughout the rehabilitation process. This concern for the worker’s well being can be provided through the supervisor’s support and encouragement. If the supervisor displays a negative attitude through belittling or making life difficult for the employee in his modified job, the purpose of the program will be frustrated. Modified work is designed to build the employee’s self esteem by helping him/her feel like they are making a contribution to the organization. It should never be perceived as punishment.

The supervisor should not play the role of physician. He must maintain the attitude that all injuries are real and the worker cannot return to his/her full job function until the company physician has given him a complete release.

Provide Post-Injury Management

By actively managing the worker’s rehabilitation, the supervisor plays a vital role in helping him/her return to full-duty. This process involves several steps, from initial treatment of the injury to a restoration of complete health and full-duty status. Among these steps includes accompanying the worker to the company doctor for initial treatment, assigning a modified job in consultation with the doctor, monitoring the worker’s physical progress and making the assignment back to full-duty at the appropriate time.

During the time the employee is in a modified job, the supervisor will be responsible for monitoring his/her physical progress. This should be done through observations, conversations with the employee, and regular updates from the company doctor.

The supervisor will use a “Weekly Progress Chart” to track each injured employee’s physical progress. The chart will cover the employee’s abilities in such areas as lifting, standing and discomfort level. It should be updated weekly as to improvements made in the worker’s ability to perform these functions.

Prior to beginning the modified job, the supervisor must set a realistic goal with the employee for his/her return to full capacity. The employee should be focused on this target date and every effort should be made to attain the goal (within the constraints of the employee’s physical condition).

To effectively rehabilitate an injured employee, specific steps should be followed. The extent of the post injury management and the type of work assignment will be based primarily upon the physician’s evaluation of the employee’s physical abilities.

The supervisor will be responsible for adhering to the post injury process, which actually begins and ends when the employee is working at full capacity.

The post-injury management process involves the following:

• Employee working at full capacity and suffers a work-related injury.

• The injury is reported to the supervisor, either by the injured employee or by another worker if the employee is incapacitated.

• Supervisor takes the injured employee to the company physician or clinic for treatment.

• Company physician treats injured employee.

• Company physician completes the “Physician Evaluation of Physical Limitations” form based on treatment diagnosis.

• Company physician, supervisor and employee jointly discuss the employee’s physical abilities and decide on one of four options:

• Return employee to regular duty immediately.

• Allow employee the balance of the day off, with an agreement of returning to full duty the next day.

• Agree on a modified job assignment and return the employee immediately to the workplace in a modified capacity.

• Allow the employee to recuperate away from work. Agree on a timetable on when the employee could participate in a modified job.

After the employee’s work status has been agreed upon, the supervisor conducts a post injury interview with the worker and completes a “Supervisor’s First Report of Injury” form together with the employee.

Employee completes and “Employee’s First Report of Injury” form.

Supervisor investigates the injury.

If the decision is made to return the employee to a modified job assignment, the following steps need to be taken:

• Supervisor sends a completed modified work form letter to the employee, detailing the position, wage, shift, etc.

• Supervisor and employee meet on the first day of the modified job assignment and establish a goal for a return to full-duty.

• Supervisor works with other employees to provide a receptive, supportive atmosphere.

• Supervisor continues to extend encouragement and an understanding attitude to the employee, as progress is made toward a return to full-duty.

• Employee receives any necessary follow-up medical treatment.

• Supervisor holds weekly meetings with employee and updates the physical progress chart.

• Employee is medically cleared to resume to full-duty and returns to regular position.

TYPES OF RETURN-TO-WORK PROGRAMS

Modified Work

The injured employee is brought back to work and placed temporarily within an existing job that is not as physically taxing or demanding as their normal job. This temporary job placement must meet the physical restrictions that a physician has assigned to the injured employee.

Restricted Work

The injured employee is brought back to their normal job with restrictions assigned by the doctor. For example, this may involve placing a 30-pound lifting restriction on the injured worker. It is important to impress these restrictions on the injured worker. It is equally important to communicate the mandatory nature of these restrictions to others, including the injured worker’s supervisor, fellow employees with whom the injured worker will be in contact with, etc.

Transitional (Light) Duty or Total Accommodation

The injured employee is brought back to a position that has are specifically created which will accommodate the restrictions of any injured employee within a company. These positions may be previously established, or they may be created as injuries dictate.

Gradual Reclamation

The injured employee is gradually brought back to their full working capacity over a period of time. During a several week period, the injured worker may work several hours a day, several days a week. This process begins with limited work hours and gradually increases as time passes.

The result of these return-to-work programs is faster rehabilitation and return to normal work duties. In all instances, except for the Gradual Reclamation, the length of the temporary job should not exceed six (6) weeks.

GENERAL SAFETY RULES AND SUPERVISORY PROCEDURES

All rules are intended to illustrate our expectation for safety and hazard compliance. Employees must observe specific rules of conduct. Violation of these rules can result in immediate termination.

DRIVER SAFETY RULES

Must not have outside employment, instruction courses or other activities that are competitive, interfere with, or affect the performance of company duties, constitute a violation of the law, or deprive the employee of having at least eight (8) consecutive hours off in every twenty-four (24) consecutive hour period.

Must wear the company uniform as described by management. The tie is to be worn at all times in the presence of passengers, unless there is a climate control breakdown on the motorcoach. Drivers' ties must be secured with a tie clip or tucked into a shirt or jacket while inspecting the coach.

New employees (less than 30 days since hiring) who are waiting for the delivery of their uniforms will be expected to report to work in clean dress clothing (white shirt, dark slacks, tie) and black dress shoes. This includes all operators who may have run out of clean uniforms and are on a multi-day trip.

Must not permit any person to operate his/her bus except: Authorized Supervisor or Instructor; Garage mechanic or Maintenance Personnel Supervisor to make mechanical repairs or adjustments; or Student operator properly assigned by training.

No unauthorized passengers are allowed during trips.

Must submit record-of-duty status reports (logs) on a regular basis.

Must re-submit any missing logs promptly, as requested.

Must comply with all federal hours-of-service regulations.

Must submit photos (or camera) and witness slips following all accidents or unusual incidents.

Must make proper pre and post-trip safety inspections of vehicles.

Must make pre-trip, en route and pre-arrival passenger safety announcements.

Must assist passengers on and off the coach by positioning oneself at the entrance door on ground level.

Must report for all assignments in a timely manner.

Must report for all assignments neatly groomed and in the prescribed uniform.

Must not be involved in practical jokes, horseplay, etc.

Must not submit fraudulent or exaggerated workers compensation claims, or be involved in malingering following an on-the-job injury.

Must understand and comply with the Driver Management Policy.

FACILITY SAFETY RULES

Employees must know and observe safety rules applicable to their work. Each employee's compliance with all safety rules is a requisite for employment.

Any injury, no matter how slight, including exposure to hazardous fumes and contact with hazardous chemicals, must be promptly reported to management.

The following are strictly prohibited and will not be allowed: horseplay, practical jokes, fighting, throwing of objects, running except in extreme emergencies, alcohol, unauthorized use of drugs, firearms, tampering with equipment, use of equipment without authorization or proper training.

Equipment will not be operated unless all guards and safety devices are in place. Guards should never be removed or altered in any manner. They are there for your protection and anyone found tampering with an equipment guard or rendering it inoperable in any manner will be subject to immediate termination.

All personal protective equipment must be worn when and where required, including safety glasses, hardhats, shoes, gloves, etc. NOTE: All employees, including office personnel, must wear shoes that completely cover their feet. Steel toe shoes or boots are required in all production and product work areas. Employees violating the use of personal protective equipment policy will be subject to immediate termination.

Lockout and tag out procedures must be followed at all times.

Emergency equipment is not to be blocked for any reason.

Good housekeeping practices must be maintained at all times. Employees must leave their places of work orderly and clean in the interest of safety. There are many days when the floors of the facility are slippery due to weather change, be extremely careful when walking. Clean all spills immediately with proper equipment (mop and bucket, wet vacuum, absorbent pads, etc.)

All stairways, ladders, passageways and gangways must be kept free from material, supplies and obstructions at all times.

Tools, materials and debris should not be strewn about in a manner, which may cause tripping or other hazards.

Discarded lunch bags, paper cups, cans and any other trash must be removed from work areas daily.

All spills of any nature must be marked, blocked off and cleaned up immediately.

Never store combustible or flammable liquids in open containers. Use approved containers for flammable liquids and be sure they are closed after each use and when empty.

Oily rags and open cans of flammable liquids must not be left at employee workstations.

Flammable liquids should be stored only in their marked cabinets or other designated areas.

Do not lean large pieces of material or equipment against walls where they can fall.

Materials, tools and supplies should only be stored in their designated areas.

Do not store or leave anything on the floor in a passageway where it can become a tripping hazard.

If stacking materials, stack materials in stable piles that will not fall over.

Store items in storage cabinets by using bottom shelves and drawers first.

Store heavier objects on the bottom shelves of storage cabinets.

Do not stack objects on windowsills.

Use supplied and designated ladders to reach materials and tools, which are stored in high or awkward places. Never use chairs to reach high storage areas.

All unsafe acts and conditions must be corrected promptly and reported to management.

All containers of material must be clearly identified with the name of the material and NFPA chemical label. Do not use unidentified material.

Established safety procedures must be followed at all times.

Keep all chemical containers closed. Do not leave them open if unnecessary.

Read the Material Safety Data Sheet before working with an unfamiliar chemical.

Follow all manufacturers product use instructions. If working with a new product, review product use instructions first.

Leave areas of significant chemical spills immediately.

Do not transfer any chemical out of it's original container without first labeling the new container.

Incidents that may have weakened or damaged equipment must be reported to management at once.

Only authorized, qualified personnel may perform maintenance or repair work.

Any person present in, or passing an area, must observe the rules of that area.

Escape routes must be known by all personnel and rehearsed during emergency evacuation drills.

Jewelry, such as rings, bracelets, and necklaces, are not to be worn when working around electrical equipment or moving machinery.

Employees are not allowed to wear loose clothing, loose dresses or loose shirts when working around machinery. Long pants and appropriate shirts (tee shirts or other tight fitting garments) must be worn at all times within employee work areas. Work rules and exposure to equipment do not permit employees to work without long pants and shirts at any time or occasion.

The use of Walkman type radios or other devices that have the potential to reduce hearing will not be allowed within employee work areas.

Learn the proper and safe way to do a job; if any unsafe conditions exist, they are required to be brought to the supervisor's attention.

Always turn off the equipment when cleaning. This is for the safety of you and your equipment. (Follow proper lockout procedure for exposure to unprotected energy sources.)

All safety devices such as interlocks, barriers, gate locks, or other locking or restricting entry type, are for your protection and anyone removing or altering any safety device will be subject to immediate dismissal.

Approved type protective goggles of proper shade (color) must be worn when welding or working close to a welding operation.

Keep your hand tools in proper condition. If they are worn out, have your supervisor replace them. Broken or defective hand tools are required to be removed immediately from service and reported to management.

No employees may operate any piece of equipment unless authorized by the department supervisor.

Do not use compressed air to clean yourself or your clothing.

Any employee making repairs on a motor driven machine or other power-activated equipment must be sure that switches, valves and starting devices are turned off, locked and tagged out.

Any and all safeguards removed during repairs or maintenance must be properly replaced before the machine is put back into operation.

Know where fire extinguishers are located and how to use them. Tampering with fire extinguishers is cause for immediate dismissal.

Do not look into the heli-arc area when welding is being done; serious eye damage will result.

When lifting heavy loads use the strength of your legs and not your back.

Never use any power equipment unless there is a ground plug. Report any loose wiring to your supervisor immediately.

Drive at a slow, safe speed in the parking lot. Maximum speed - 10 MPH.

Keep objects away from electrical switch boxes; the area in front of them must remain clear in case an emergency-off is required. Never block fire extinguishers, fire hose, aisles, or exits with material or other objects.

Marked aisles must be kept clear at all times.

Ladders must be in good condition and equipped with safety feet. Assistance must be obtained prior to using when a slipping potential exists. Do not use any makeshift scaffolding, rigging or staging.

No one is allowed to operate a lift truck or pallet jack unless trained, qualified, and certified.

Do not lift personnel on forks or makeshift platform. Use only a secured, safety platform.

No one is allowed near a load or lift truck while the operator is lifting, lowering, or repositioning a load.

Employees must insure that all areas are properly illuminated prior to start of work.

Designated trained employees must be familiar with the location of fire equipment and the use of fire equipment.

SUPERVISOR SAFETY PROCEDURES

The company recognizes that our managers and supervisors spearhead safety. Enforcement of safety is one key to a successful safety effort. Supervisors are responsible for enforcing safety rules.

Supervisors have authority to enforce safety rules in their department. If they see an unsafe act or condition in another department, either correct or stop the unsafe situation and then tell or properly notify the appropriate supervisor of the situation immediately.

Supervisors will be disciplined for not enforcing safety rules. Disciplinary action can range from verbal warnings up to and including termination.

Safety discipline is as important as discipline for any other company rule, which is broken. If supervisors see an employee violating a safety rule, they must follow these steps:

Stop the employee from doing the unsafe act or working with unsafe equipment.

Turn off equipment, lock it out and call maintenance if they can correct the situation, if applicable.

Tell and show the employee what is unsafe.

Show and/or tell the employee how to do the job safely.

Take disciplinary action BUT do it correctly. Decide whether a simple verbal warning is sufficient or if a written warning is called for? Discuss with your manager.

If a supervisor is not sure of the disciplinary action, he must tell the employee to wait until he has discussed it with his manager. Then follow up!

Be prepared to refer the employee to Personnel or top management if necessary.

Documentation of all disciplinary action is mandatory, even if it is a simple note kept in a file. Names, date and a brief description of the incident are necessary.

When disciplining an employee, the supervisor must be firm, positive, control emotions and be consistent. Do not yell, threaten or abuse the employee in any way.

If the employee becomes insubordinate, ask the employee to accompany you to Personnel or top management. Do not allow a situation to escalate to a physical or threatening confrontation.

Supervisors must set the example and follow all safety rules.

An Employee Warning Record or a similar document must be used for all disciplinary action documentation.

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