Workplace safety has come a long way since earlier times.

Some jobs require a

bit more workplace safety than others. In todays world, an employer wont be able to
get away with certain conditions because of various organizations founded to combat
those issues. Most known organization is OSHA (Occupational Safety and Health
Administration). They have put standards and rules in effect that must be followed to the
point or the job site will receive punishments such as
fines, or worse. They take workplace safety very
seriously as it is a big deal, which it is. No one should be
going to work and expect to injure themselves or
become sick. This also works the other way around, as
customers shouldnt be exposed to certain risks or
dangers either. Our project has one goal in mind and
that is to improve upon workplace safety by educating
you on proper safety guidelines and things you can do to
improve the safety at your job.
At our company, we have found a lack in the essentials to workplace safety. Most
employees are uneducated when it comes to the basics of workplace safety and
bringing a needed change to how the company handles violations, and risks will
improve the overall health of not only the employees but also the company. Having a
safe workplace will keep the work going smoothly and the money flowing. Our group
proposes a project that would educate our employees and install new and updated
safety requirements that should have been here in the first place. The following will
include our project plan. The project plan will demonstrate how we will go about

implementing the education required for the employees and what as well as how, the
exact improvements to the company will be. Then we will include a detailed project
schedule, showing how the new improvements and anything associated with improving
the safety in the plant will be implemented. Lastly, we will include the resources
necessary to complete these actions.
Taking a walk around our manufacturing plant, we noticed several issues with
safety involving the employees, the equipment and the products. We will begin to
address all the issues regarding safety in each area of the plant. The most concerns
seem to steam from the equipment being used by the employees. Certain incidents that
have been brought to our attention have called for this change in action. We must act
swiftly to provide changes to this workplace so incidents with injuries are a thing of the
past. Some of the issues we noticed included but not limited to:

Equipment missing safety features

Equipment doesnt show proper safety techniques
Lack of walkways for employees around heavy machinery
Improper cleaning
Exposed dangers (wiring)
Improper placement of materials
Wrong supplies
Cross-contamination of chemicals

These were just a few of the various dangers we found throughout our company. Each
of these hazards will be addressed and fixed.

Injuries By Area
Welding Station; 10%

Load/Unload Station; 10%

Cutting Station; 20%

Grinding Station; 60%

Our project plan will begin with a thorough inspection of the material and supplies
used throughout the plant. While we dont want to shut down the entire plant, we will
work area by area so not all operations are cancelled. We will work on each area, one
at a time. Each area will be specifically calculated as to not disrupt the flow of work. Our
team will inspect the entire plant and make a chart of the areas being inspected and
worked on. Each area will go through a phase of action. These actions include:
1.
2.
3.
4.
5.
6.
7.
8.
9.

Stopping all equipment

Close examination of the tools
Checklist of hazards
Resume operation of equipment
Spectate employees working in current working conditions
Review what we learned
Analyze data
Consult with higher-ups about findings
See changes/improvements in real time

With these steps we can ensure the proper changes are being done. We will begin by
stopping the equipment and halting the process of the first area of designation. Once

the designated area has been handed over to our team of professionals, we will begin
to examine the tools, equipment and any materials being used at that site. We will begin
inspecting for any hazards that coincide with broken tools or any action that could result
in injury. One incident reported to us was a piece of machinery severely cutting an
employees finger. These kinds of hazards will be double checked and ensured to not
produce that result again. All equipment inspected will be given a grade and based upon
the feedback, will be altered to ensure the safety of the operator. This might include
guards or wiring to protect the user from being able to hurt themselves. Materials used
during normal production will be inspected so that any dangers resulting from using
them will be eliminated. We will also provide a grade for the materials and supplies
being used and make note of what is being used and what isnt.
After inspection is completed, we will allow the employees to return to their
stations and operations will continue as normal. Our team is then instructed to spectate
the process and make note of various hazards, dangers
and risk we might come across. We want to see the area
working in real time, as this will give us a better view of
what were dealing with. We can see wrongdoings firsthand and see what needs to be fixed. Crucial
speculations may be made on the spot, but we prefer to
consult the actions as a team and roll out the fixes at a later time.
Once we are done inspecting the area and have the notes we need to begin the
fix, we will assess what we saw along with our recordings and begin a group meeting.
These meetings will take place after each area so only that area being worked on will

talked about. This will provide direct attention to the area at hand and reduce the risk of
missing out any details or fixes that need to be done. Our team will spend a certain
amount of time, usually as much as we need, to iron out what exactly needs to be done.
This will include conversing about the current state of operation, improper safety
procedures and how exactly to go about fixing the problems. The meetings will be
mandatory for each member and a final draft will be constructed at the end of the
meeting with fixes, improvements and an overall score for the area. This is also where
data will be analyzed and constructed. Records will be kept for everything we do as a
safekeeping.
Upon the conclusion of the meetings, we will have all the information needed to
begin the correction process for that specific area. We will sit down with the managers
or person in charge and present to them a manifest of our findings. Our goal is for the
manager to review our suggested improvements and implement them in a timely
fashion. We want the manager to be educated on what we want changed and how to go
about doing it. With his help, we will implement the changes. Along with what exactly
needs to be handled, will be a budget for the fixes and resources needed. All the work
will be done, it would only be a matter of getting the ok to begin the process.
Our work wont be completed until we see the improvements in real time. Once
the changes have been approved, we will work with the company to ensure the changes
happen. The corrections will be started as soon as possible, as time is key. Depending
on the severity of the hazards, and grading of the various equipment, materials, and
conditions, some aspects will be dealt with before others. We want to see the plant
become safer. After a certain period of time we will return to the site and observe any
changes being made. We have a schedule set in place to conduct our project and have

it completed within a reasonable time period. One of the ways we could improve up
future hazards is to require written job safety analysis like the one shown in figure 1.

Figure 1
We understand that a working plant is hard to stop and go, as it results in a loss,
but these changes would be necessary if the plant wants to continue operating. With the
changes will come a reduced rate of workplace incidents and overall safety for the
workplace. Our project only expects each section being worked on to be down for a
small period of time. In the following section, we will include a planned schedule to
conduct our project in the plant.
Project Schedule
There are 10 total areas in the plant, they are as follows:
1. Grinding Station 1
2. Grinding Station 2
3. Grinding Station 3
4. Cutting Station 1

5. Cutting Station 2
6. Cutting Station 3
7. Load/Unload Station
8. Filling Station
9. Packaging Station
10. Welding Station
Each station will get its own downtime and inspection. We plan on each station taking a
day to complete what we need to do, excluding fixing time. Each station will be down
the same amount of time. Each station will require 8 hours to work on. This is split in 4
different parts:
1.
2.
3.
4.

Halting Operation
Observation Period
Consulting
Consult with Operation Manager

Each section will have its own time required for completion. You can find these numbers
below. Since there are 10 stations, a full 10 days will be required to complete the overall
project minus the fixing stage. The fixing stage will require a certain amount of time
agreed upon by the Operation Manager and our team. This could be anywhere from a
week to a month depending upon the Operation Manager and higher-ups. Because
some urgency might be required, various fixes may be implemented on the same day.

Station Schedule: 1 Full day

Halting operation: 1 hour

Power down
Standard closing procedure
Vacate area
Inspect equipment
Inspect supplies/materials

Observation Period: 1 hour

Allow employees to resume positions

Power on equipment
Observe normal operation
Inspect operation
Gather information about how station operates

Consulting: 4 hours

Assemble with team

Review grades
Assess wrong doings
Assess correctness
Propose list of dos/donts
Consult list of various fixes
Draft final report for that station

Consult With Operation Manager: 2 hours

Review summaries
Present information to Operation Manager
Consult about hazards
Draft plan to correct
Finalize draft
Consult budget
Consult schedule
Finalize documents

Once each respective station is completed, we will move onto the fixing stage. Again,
the time required will depend upon the fixes required. We will give an estimation of 1
month for each and every fix to be implemented.
Project Resources

In order for our project to be successful we will need certain resources that will
help us within the project. The necessary resources for this project will include, but not
limited to:
Research

Computer with internet

Phone
Transportation to Plant
Notebooks
Pens
Conference Area
o Refreshments
o Chairs
o Table
o Internet Access
o White board
Access to company safety files/records

Observations

Required safety clothing/accessories

Paper
Pens
Phone
Contact with Operation Manager

Results

Computer with internet

Printer
Paper
Pens
Conference Area
Refreshments
Contact to various departments
Access to company safety files/records

Contact with Operation Manager

This list of required resources should serve as the necessary items needed to conduct
our project. With everything listed at our disposal we will be able to proceed with the
project without any obstacles or interruptions.

WBS

is key tool used by organizations

during projects to deliver task
and services into manageable
sub tree's. WBS is a tool that

helps its user visually see whole tree and its branch of task and work assigned or
needed for a certain project. WBS stands for Work Breakdown Structure.

Benefits of WBS:

Project Cost estimates

Deliverables are not forgotten
Brainstorming tool
Visual tool to inspire new ideas

Project scope statements

Project requirements on why resource is needed
Delivers "Decomposition" of total project scope
Tool to live update new request and project needs.
Time based task scheduling.
With WBS any project can be easily managed due to its decomposition into

smaller parts which makes it easier for project managers and organizations to properly
assign help and resources. For Manufacturing Plant, you have teams that consist of
Grinding Team, Cutting Team, Load/Unload Team and Processing Team. Here is an
overall WBS of all areas in the plant and how they correspond with each other.

Manufacturin
g Plant
Grinding
Team

Cutting Team

Load/Unload
Team

Processing
Team

Station 1

Station 1

Filling
Section

Station 2

Station 1

Packaging
Station

Station 3

Station 1

Welding
Station

Projected Budget:
We used Microsoft Project to draw out our Projected Project Plan of insuring Workplace
safety. Here are overview of all the processes we have scheduled to carry out in our
Project Schedule.
10. Stopping all equipment
11. Close examination of the tools
12. Checklist of hazards
13. Resume operation of equipment
14. Spectate employees working in current working conditions
15. Review what we learned
16. Analyze data
17. Consult with higher-ups about findings
18. See changes/improvements in real time

Cost: Each of our 9 section are at least day long procedure. Typical work day is
8 hours a day with 9 sections this would take about two week to complete. Each step
requires another step in place before our proper Workplace Safety procedures can be
implemented.
For example Stopping All Equipment is the first step which requires all machine
in the designated area to stop. This step requires minimum of 8 hours work shift that to
halt causing all employees to be paid normally but with no work being performed while

proper workplace safety precedes are being tested and implemented. To calculate the
cost, we have to include the number of employees+hourly rate to count minimum cost of
this step. We can use $10/hr rate to calculate the cost based on the number of
employees for 8 hours.
For second step we are doing close examinations in which station is examined.
For example each Grinding Station + Cutting Station are inspected and closely
examined for proper height, gear and tools to oversee current safety procedures
currently being deployed at the stations. Cost here is again same as above which is
cost of number of employees stationed at each station + hourly rate of those
employees.
Third step includes checklist of all hazards in which could take less than 8 hours
to complete but we are giving our self at least 8 hours to complete this step to take
necessary steps on proper OSHA guidelines. In this step we are ensuring each stations
are properly marked with their designated safety risk and tools needed to operate in
these stations.
Fourth step that overlaps with Resume Operations of Equipment is Training and
Education. This is the main set of step that includes proper training is being issued by
the manufacturing plant and our consulting is providing sufficient knowledge of OSHA
guidelines to all manager, supervisors and employees working on each stations. They
must be aware of all dangers, safety risk, knowledge of tools and machines. With
proper training completed it is must to resume operations at manufacturing plant as
downtime is huge cost deliverable for any company as no one can afford to stay shut for
a long period of time. Any company or plant can take huge losses in case of any miss

handling of employees safety and to ensure this mostly all plants and companies are
open to spending loads of resources of time and money to proper insure them self in
case any lawsuit falls on them during any accident.
Review step would include overview of all knowledge and procedures we saw
while consulting. Collecting sufficient information is the key here to ensure proper
consulting takes place to ensure data is analyzed properly. While this is not the most
expensive step it still requires Management team and consulting team to sit down and
review the data. Cost here would be the time spend with management of different
stations. Usually one manager is employed at each station.
Analyze data is critical to any consulting firm to ensure their work and services
are valued. Consulting with upper Management required proper knowledge of current
steps of running heavy machine while measuring hazards seen across all stations.
Second to last step is Consulting the Management would impact the most as any
change you suggest must pass with the management before its implemented in any firm
or manufacturing plant. Any mislead or confusing information can break or make the
contract, usually upper managements are not interested in outside firm educating them
on proper workplace procedures. Cost would be the heaviest here as Upper
Management salary is most high across all firms and organizations.
Last step is to see how the improvements that were reviewed, analyzed and
consulted with the managements made any difference. If any changes were not
accepted follow must be done to ensure proper workplace safety is being followed and
why a certain recommendations was accept or rejected.

System Performance Expectations:

System performance expectations would require that each device or machine in
any workplace works properly and is well maintained. Not only machine or devices
need to be fully maintained but the users its employees need to be fully educated on
proper use of any machinery and importance of safety. To better expect overall system
performance we must focus on proper use of tools to prevent failures and any
workplace safety issues.
Machine Grinding: "The National Safety Council estimates that nearly 20% of all
permanent disabilities result from injuries associated with machinery" (Martin, page
235). Machine Grinding: To prevent safety issue and get better performance from
employees or the machine avoid any direct contact with moving parts, avoid splash of
material, prevent mechanical failures and electrical failures. One of the main issues
that face workplace safety is human failure which is often the cause of failures and
accidents.
Main part of Machine Grinding are motions, every employee must be educated
on rotary motion or reciprocating motion. Any rotary action can be dangerous as during
the motion loose clothing or body parts get in stuck in motion casing an accident.
Guarding is the next step into mandating workplace safety. Guard any power linked
with heavy machinery and around the machine. Signs and guarding of the area which
danger machine is used must be guarded or surrounded by some sort of fence or area

respecting workplace safety. OSHA regulations 29 CFR 1910.212 specifies guarding of

area around machinery. (Martin, page 237)
Cutting Stations: Cutting station can use many different types of machinery and
tools. For Manufacturing plant most likely special types of blades are used for heaving
cutting and sharpening the edges of different material.
For better performance from Cutting stations education on proper use of cutting
is mandatory. Operators of blades must understand how to change the height of the
blade, change location of blade and speed of the blades. Hazards from cutting can
effect system performance from hazards material flying after being cut at the speed of
the sharp blades. Work place safety can be mandated by using proper lubricated gears
and avoiding any contact with exposed blade. While recommended eye protection is
used that can withhold flying debris being cut and flying away from the object being cut.
Stone cutting for example will expose small rocks that can directly impact employees
eye protection instead of hitting the worn glasses and not damaging the skin exposed.
Prevent Kickbacks from heavy cutting blades by proper adjusting the height and
speed of the blades. OSHA Regulation 29 CFRE 1910.213 ((Martin, page 245)
mandates proper cutting equipments for workplace safety.
"The purpose of the safety and health program is to prevent accidents and
illnesses; protect workers, property, and community; control or reduce losses; provide
means for management/employee involvement in the safety and health program; and to
comply with legal requirements". ( Martin, page 1)

Suleman Shahid, 24 years old currently pursuing a degree in ICT with

concentration in Networking as Bachelors of Science from ECU. Starting Senior in Fall
2015 semester. Originally from Pakistan but living in United States for the past 13
years. Fluent in Urdu, Punjabi, English. Married for three years. Hobbies include
Networking, computers and Cricket-Sport not famous in United States. Currently
employed by Cisco System and working at Network Engineer in RTP campus located in
Morrisville, NC.
Tyler LeMoine is a 22 year old student attending East Carolina University. A
senior graduating in the winter of 2016, Tyler is pursuing his dream of working with
computers and becoming a systems administrator. Tyler grew up in New York but
recently moved to North Carolina upon his parents retirement. He resides in Greenville,
NC enjoying his time with friends and family while actively attending school and working
a part time job.