Managing Health & Safety in Depot Maintenance Red...
Transcript of Managing Health & Safety in Depot Maintenance Red...
Tank-Automotive & Armaments Command Red River Army Depot
November 13, 2012
Managing Health & Safety in Depot
Maintenance
Red River Army Depot
Tank-Automotive & Armaments Command Red River Army Depot
Installation
Characteristics
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Location: North East Texas (Four States
Area)
Size: 15,840.015 Acres
Buildings: 1,052
SF of Buildings: 7,801,985
Railroads: 52 miles
Roads: 330 miles
Structures: 340
SF of Structures: 161,040
Leased Buildings: 7
Leaseback Buildings: 18
Water, Sewer, Industrial Waste &
Electrical Utilities-Privately Owned
Gas, Steam (Boiler Plant) & Air
Utilities- RRAD Owned
Over 300 Product Programs
Combat Platforms (Bradley, MLRS)
Tactical Systems (Heavy Trucks, HMMWV, MRAP, FMTV)
Main Production
Area
MSSC
DLA CL IX Storage
Location: North East Texas (Four
States Area)
Size: 15,840.015 Acres
Buildings: 1,052 (7,801,985 sqft)
Railroads: 52 miles
Roads: 330 miles
Structures: 340 (161,040 sqft)
Water, Sewer, Industrial Waste &
Electrical Gas, Steam (Boiler Plant)
& Air Utilities
Over 300 Product Programs
Combat Platforms (Bradley, MLRS)
Tactical Systems (Heavy Trucks,
HMMWV, MRAP, FMTV)
FY 2006: On DoD TOP 40
FY 2007: Came off TOP 40 FY 2007: Began pursuit of VPP
FY
TE Hrs
(M)
Lost Time
Case Rate Reduction
Total Case
Rate
FY06 5.9 1.5 0% 4.7
FY07 5.6 1.3 13% 4
FY08 6.3 1.1 27% 2
FY09 6.5 0.9 40% 2
FY10 6.4 0.5 67% 1.6
FY11 6.6 0.4 73% 1.4
Reductions are based on the FY06 rates
Tank-Automotive & Armaments Command Red River Army Depot
Where We Are
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• In FY 2012, total exposure hours (net regular and overtime hours worked on depot) for all
RRAD DA civilians equaled 5.7M. Injury rates ~80% lower than Industry Benchmarks for
similar heavy industrial workplaces.
• FY12 Lost Time Case Rate = 0.8 (47% reduction from FY06)
• FY12 Total Case Incident Rate = 1.7 (64% reduction from FY06)
• AMC NTE GOAL: Lost time injury rate is 1.0 and total case incident rate is 1.9.
• OHSAS 18001:2007 – Registration achieved in Dec 2009 (re-evaluated semi-annually)
• OSHA – VPP:
• Graduated OSHA VPP Challenge – Nov 2010
• Approved OSHA VPP Merit Worksite – Jul 2012
• Army Safety Awards:
• FY2009 AMC Exceptional Organization Safety (Brigade)
• FY2010 Sec Army/COS Army and AMC Individual Safety Excellence
• FY2011 Sec Army/COS Army and AMC Exceptional Organization Safety (Garrison)
• FY 2012 Theodore Roosevelt Workers Compensation & Disability Mgmt Award
Tank-Automotive & Armaments Command Red River Army Depot
Critical to Our Success
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• Red River Operating System (RROS) – All RRAD production areas start
“everyday” with a Tier I meeting (1st line supervisor & members of that cost center).
• Industrial Hygiene – Sampling/monitoring/testing: Performs air sampling,
health hazard assessments, chemical reviews, indoor air quality assessments, and
personal protective equipment (PPE) reviews on an on-going basis.
• Job Safety Analysis (JSAs) – Developed JSAs for all moderate and high level
tasks. Newly assigned team members review prior to beginning work – all members
review at least annually.
• “360o for Safety” – Weekly Command Health, Safety and Environmental
(HSE) Assistance Visits. Team of subject matter experts conduct HSE walk –
objective to expand & improve the identification of hazards and/or unsafe
conditions/processes and assist 1st line supervisor in corrective action.
• Injury Compensation Program Administrator (ICPA)
• Must be actively engaged – thoroughly investigate “each & every” case
• Develop appropriate “action plans” for each case
• Aggressive Light Duty Return-to-Work Initiatives
Best Practice
Best Practice
Tank-Automotive & Armaments Command Red River Army Depot
Critical to Our Success
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• Team Member Involvement – A MUST! Tools used to empower and mobilize members and ensure Behavior Based Safety is truly owned & effective across the entire enterprise. Some initiatives include:
• Safety Excellence Rally Team – 13 team members assigned safety related special projects
• Safety Videos – Depot team members become STARS by writing and producing custom safety related videos – topics: Home Safety, PPE, Drunk Driving/Holiday Safety, Forklift Safety, VPP
• Collateral Duty Safety Officers ~ 90
• Safety Incentive Award Program (Spinning Wheel) – “Real-time” recognition of accident avoidance, near miss reporting, hazard identification/abatement & other proactive measures.
• Accident Review Boards – Directors chair monthly meeting where team members & supervisors discuss injuries and preventive measures
• LEAN Events – Identify/Correct at least 3 safety hazards per event
• Captain Hydrate
• The Butler Boys
Tank-Automotive & Armaments Command Red River Army Depot
Critical to Our Success
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• Training…that doesn’t look and feel like training – Fun/innovative approaches to
train & involve team members to identify/eliminate/mitigate workplace hazards –
• VPP Questions/Answers “year-round”
• “Stop to Investigate” – Communication of mishaps (with photo)
• “Grass Roots Safety” & “Weed Alerts” (unsafe/hazard alerts)
• “Turkey Shoot” (hazard identification & abatement competition)
• “Skating on Thin Ice” (unnecessary risks)
• “The Good – The Bad – The Ugly” (what-right-looks-like)
• LEAN Events – Identify/Correct at least 3 safety hazards per event
• “Safety Success Stories” (Photo of unapproved/approved tools)
• Daily “STAR” tips (365 days - Start Thinking Accident Reduction (STAR)
• Training … conventional classroom - 10 hr General Industry OSHA – for
leaders/supervisors/collateral duty officers 600+)
Tank-Automotive & Armaments Command Red River Army Depot
Road Ahead
“Safety Excellence!”
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• A culture where everyone realizes they are responsible for their own safety
• A “proactive” approach – more near miss investigations VS accident investigations
• Increased attention to detail – sweat the small stuff
• More involvement from everyone
• An accident free workplace
• Accountability – It is easy to dodge responsibilities, but we cannot dodge the consequences!
• Recognized as “Safety Excellence” across all industries – not just DOD Organizations or Military Armored Vehicle, Tank, and Tank Component Manufacturing
Tank-Automotive & Armaments Command Red River Army Depot
What Happened
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• History
• It is believed that Cadmium levels at the Depot began increasing around Jan 1998
• Probable cause was change in type of workload • First identified as a problem in abrasive blast operations
• Not an obvious hazard in most process
• Cadmium Health Effects
• Acute (Metal Fume Fever and Acute Pulmonary Edema)
• Chronic (Kidney Damage, Lung and Prostate Cancer)
Tank-Automotive & Armaments Command Red River Army Depot
How We Did It
“Hierarchy of Controls”
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• Elimination (Ceased welding on mounting bolts on 5T cabs)
• Substitution (Substituted with non-Cd plated Hardware)
Tank-Automotive & Armaments Command Red River Army Depot
How We Did It
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• Engineering Controls (Ventilation in Paint Prep 412B)
• Administrative Controls (Using water in HMMWV
bracket removal)
• PPE (Paint Prep 323 & Abrasive Blast)
Tank-Automotive & Armaments Command Red River Army Depot
Common Challenges
for Compliance
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• Communicating Health Effects
• Enforcing PPE Use
• Mandatory Showering
• Frequent IH Sampling
• Strict Adherence to Fume Extractor Use
• Getting People to the Health Clinic
• Housekeeping “…as clean as practicable…”
• Future Characteristics of “Mild Steel”
Tank-Automotive & Armaments Command Red River Army Depot
Detailed Information
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• Bonnie Lewis
Chief, Safety Office (903) 334-2371
Red River Army Depot
100 James Carlow Drive
Texarkana, Texas 75507-5000
• Brent Jones
Chief, Industrial Hygiene Office (903) 334-2965
Red River Army Depot
100 James Carlow Drive
Texarkana, Texas 75507-5000
• Ann Harmon
Injury Compensation Program Administrator (903) 334-2398 Red River Army Depot
100 James Carlow Drive
Texarkana, Texas 75507-5000