By Jeff Hutchins, Manager, BWC Quality Assurance & Technical Safety Support
Sometimes workplace safety issues require employers to think outside the box for solutions. It’s inspiring to see the ideas they develop to overcome workplace hazards. To spotlight these employers, their innovative spirit, and their commitment to workplace safety, we sponsor our annual Safety Innovation Awards.
The program recognizes innovations that result in risk reduction, cost savings, and potential application to other workplaces, industries or operations. Examples of innovations include:
- Technological advancements.
- Creative use of existing equipment.
- Unique processes and practices.
- Development of new equipment.
This year we received more than 70 applications for consideration! After careful deliberations, we are pleased to introduce the following employers as the five finalists for the 2020 Safety Innovation Awards.
Diversified Fall Protection (Westlake) – Portable Truss Anchor
Diversified Fall Protection engineers, manufacturers, and distributes fall protection equipment. The company is located in the Cleveland area.
In an industrial setting, working at height above machinery poses a fall hazard. Unstable ladders and limited styles of fall protection when working in such an environment have proven to be ineffective. Contributing to this hazard is the practice of tying off to structures that are not capable of supporting the load if a fall does take place.
The innovation is a portable personal fall protection anchor that installs quickly overhead into the opening of the bottom chord of a roof application. The Portable Truss Anchor uses the overhead truss system in a building to create an Occupational Safety and Health Administration-compliant anchorage point for working at height. Unlike permanently attached fall protection anchor systems that require a self-retracting lanyard at each location, the Portable Truss Anchor is an alternative solution that installs in minutes – where and when it is needed.
More than 1,000 workers currently use the Portable Truss Anchor with no reported fall-related injuries associated with its use.
Fort Amanda Specialties (Lima) – Custom Cleaning-in-Place Safety Solution
Fort Amanda Specialties, LLC is a joint venture of Nouryon and BASF Corporation. They are a chemical producer of high-quality chelates.
Transport screws are used to move solid product in a multi-product processing unit. Cleaning out these screws during product changes created multiple hazardous exposures as workers had to remove the lids to wash the screws. This exposed workers to unguarded moving machinery, high-pressure water spray, and slip hazards from overspray on walking-working surfaces.
Custom made wash lids were designed with Plexiglass windows for inspection. The lids were installed along with permanently mounted spray nozzles inside, eliminating the need for manual high-pressure cleaning the rotating screw.
Contact with moving equipment and exposure to high-pressure water is eliminated. Wash water is contained inside the enclosure, reducing water use and eliminating slip hazards.
Mt. Vernon City Schools (Knox County) – Rapid Barricade
Mt. Vernon City Schools is a school district in Knox County serving 3,800 students at six elementary schools, one middle school, one high school, and a digital academy.
If a school or other public building experiences a threat, many of these facilities will activate a lock-down procedure. Door locking devices must be easy to deploy and remove and must withstand extreme force. Some locking devices do not comply with building/fire codes, require facility modifications to install or tools to deploy, and some require workers to verify deployment from a public area (i.e. the hallway), which exposes them to the threat.
The need was for a temporary door-locking device that meets all fire code and Americans with Disabilities Act (ADA) requirements and was always available, not stored somewhere.
School maintenance personnel worked with a local machine shop to create the Rapid Barricade. After the design was perfected, a patent was awarded. Workers can install the Rapid Barricade on any ADA-compliant door. It deploys in seconds and can withstand 1,200 pounds of force.
TFO Tech Co., LTD (Jeffersonville) – Furnace Pulley Unloader
TFO Tech Co., LTD produces wheel hubs, crankshafts, CVT pulleys, and other automotive parts in Jeffersonville, Ohio.
Workers had to manually rake 10- to 13-pound parts approximately 2.5 feet into a bin as the parts exit the heat treat furnace. The parts coming from the furnace are near 300 degrees Celsius, so excessive heat was a hazard. The raking motion exposed workers to ergonomic hazards; shoulder, elbow, back, and chest were the main areas of the body that were of concern.
The innovation drops down and encloses the parts in a steel frame. The frame slides the product off the conveyor and into the basket. Rather than manually raking the parts, workers complete the process with the push of a button.
This innovation significantly reduced the ergonomic risks by eliminating the raking motion and reduced the workers’ heat exposure because the operator’s panel is about 5 feet farther away from the hot parts than the original operating position.
thyssenkrupp Bilstein of America (Hamilton) – Near Miss Reporting App
thyssenkrupp Bilstein of America manufactures shock absorbers for high-performance automobiles, motorsports, and off-road vehicles in Hamilton, Ohio.
In a manufacturing facility that works 24/7, with nearly 700 employees, unsafe acts and unsafe conditions were happening. Unfortunately, they were often not being reported, nor addressed. Before implementation, the site had an average of about four near misses being reported per month, and they were coming from the same few supervisors. It was a cumbersome reporting process that required the worker to download a four-page document from the intranet, complete it, print it, and then have it signed by multiple people. The process was slow; often the Safety Department was not aware of a near miss until it landed in its mailbox, days later.
The innovation changed the near miss reporting process from a tedious, long paper document to a short, quick, and easy electronic submission method called the “Near Miss App.” The app was developed through web-based software called Smartsheet. Anyone can submit the online form, and it puts the information into a database similar to an Excel spreadsheet.
Near miss reports have increased from approximately 48 per year to more than 500 per year. The resulting investigations helped them reduce their Occupational Safety and Health Administration recordable rate from 3.03 to .91, and their lost-time accident rate from 3.61 to 0.
The five finalists will be on hand at the Safety Innovation Awards booth at the 2020 Ohio Safety Congress & Expo (OSC 2020) March 11-13 in Columbus. Stop by to learn more about the innovations and vote for your favorite when you’re at OSC 2020.
We will present awards and monetary prizes to the finalists during OSC 2020, but the real winners are the employees of these companies. Innovations like the ones above help workers stay safe and healthy, increase productivity and morale, and produce long-term cost savings.
Click on the image below to register for #OSC2020.