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Crush/Amputation Hazards
OSHA standards require employers take all necessary
steps to protect employees from coming in contact with
moving equipment, or parts. This can be done through
several different methods depending on operations and
may include, but not necessarily be limited to, guarding by
distance/location, fixed guards, or devices. Regardless of
the method, effective machine guarding will prevent haz-
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Fall Hazards
Most die casting operations do not involve working aloft, and
yet fall hazards continue to be cited by OSHA during inspections. Exposures range from issues with walking and working
surfaces creating slip/trip hazards, to employees working
on equipment being exposed to falls greater than four feet.
Walking and working surfaces must be kept in good working
condition and in good repair at all times. As difficult as this
may be we also need to work to eliminate wet areas through
appropriate drainage, grates, or other effective means. Spills
must be cleaned up quickly and steps should be taken to
repair any leaking (i.e. hydraulic oil) equipment.
OSHAs standards for general industry require employees
be protected from falls greater than four feet, or any case
www. diecasting.org/dce
Health Issues
Material Handling
The handling, moving and storage of equipment, known
as material handling creates a number of exposures in the
workplace. Industrial lift trucks account for roughly 85
fatal accidents per year. In terms of serious injury, 34,900
are injured, with another 61,800 classified as non-serious
in the workplace each year. These numbers indicate over
11% of all forklifts in the United States will be involved in
some kind of accident each year. 2 Due to the wide variety
of lifts and operations it is difficult to address each specific
hazard. In order to address this, OSHA requires all forklift operators to be properly trained. This training must
include some type of classroom or lecture based training
(CBT is acceptable), practical training to hone an operators skills, and an evaluation. The evaluation must be done
on a lift similar to the one to be operated and in a similar
environment to which the operator will be exposed. The
evaluation must be completed every three years.
Ergonomics
According to the BLS, approximately 36% of nonfatal injuries
in the die casting industry are strains and sprains.3 The risk
factors for strains and sprains found in die casting facilities
include physical factors (heavy loads, pushing/pulling, highfrequency repetitive lifting, awkward postures, excessive work
duration); and environmental factors (heat, high humidity,
noise, poor lighting). Good ergonomics can eliminate or
reduce exposure to nearly all of the physical risk factors in the
workplace. A comprehensive ergonomics program includes
training to increase ergonomic awareness, identifying risk
factors in the workplace that are causing injury and discomfort, giving workers input into how they do their jobs, and
developing ways to control ergonomic hazards by modifying
equipment and the organization of work. OSHAs current
ergonomics inspection plan prioritizes inspection of high
injury workplaces in industries which have been identified as
having a significant number of injuries related to ergonomic
hazards. OSHAs plan to reduce ergonomic hazards calls for
enforcement under the general duty clause where ergonomic
hazards exist and employers are not making good-faith efforts
www. diecasting.org/dce
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Combustible Dust
Training
Controlling Hazards
Companies must Recognize, Evaluate, and Control hazards in the workplace. Due to the wide variety processes
and operation it is imperative manufacturers conduct a full
hazard assessment to identify (recognize) the hazards. This
assessment should include facilities, equipment, and manufacturing processes to identify all known and potential
hazards. Once identified, steps should be taken to control
the hazards using the hierarchy of controls.
Eliminate
Substitute
Engineering Controls
Administrative Control
Work Practices
PPE
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www. diecasting.org/dce
Employee Involvement; Worksite Analysis; Hazard Prevention & Control; and Safety & Health Training. Each of these
guidelines has several embedded guidelines to help the user
along with the process. This model lays the foundation for what
OSHA sees as a successful safety and health program and the
backbone for the Voluntary Protection Program (VPP).4
Other safety management system models exist; including
OHSAS 18001 and ANSI/AIHA Z10, which each rely on
process development and documentation to define safety
as a business process and to ensure continual improvement.
Each has its own merits and can provide a model by which
a company can develop their own effective system of safety
and health management. The most effective approach would
be to take tenets from each on their own merits.
Safety Management Systems provide a systematic
approach to evaluating and controlling risk in the workplace.
In an era of limited resources the implementation of a strong
safety management system keeps safety at the forefront by
making it a part of our business processes. From ANSI Z10
to OHSAS 18001, companies with an SMS experience the
benefits as pertains to OSHA citations and exposure, and
the overall bottom line of the company.
Resources
G
eorgia Tech Research Institute
www.oshainfo.gatech.edu
Georgia Techs OSHA Training Institute
www.pe.gatech.edu/gt-oti
OSHA
www.osha.gov
State Consultation Programs
www.osha.gov/dcsp/smallbusiness/consult.html
Industry Organizations such as NADCA
References
1 Bureau of Labor Statistics; News Release,
USDL-12-2121, Thursday, October 25, 2012
2
Emery I Reddy, July 7, 2011, OSHA Focuses
on Forklift Hazards.
www.emeryreddy.com/2011/07/osha-focuses
-on-forklift-hazards
3 BLS, Percent Distribution of nonfatal injuries and
illnesses, 2011. Table R113.
www.bls.gov/iif/oshwc/osh/case/ostb3315.pdf
4 United States Department of Labor/Occupational
Safety and Health Administration.
www.osha.gov/SLTC/etools/safetyhealth/index.html
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