Passive Learning Methods

Passive learning methods include lecture, reading, audiovisual, and demonstration. Retention rates for passive learning:

• Lecture – 5%
• Reading – 10%
• Audiovisual – 20%
• Demonstration – 30%

Safety training often is delivered using the passive learning approach. Instructors typically lecture and use supporting materials such as informational handouts, PowerPoint presentations, video, and hands-on demonstration. As you can see by the average retention rates, a combination of the four methods provides for a greater level of retention.

Participatory Learning Methods

The Learning Pyramid indicates that participatory learning methods achieve greater retention levels. Participatory learning methods include group discussion, practice, and teaching others. The average retention levels for participatory learning:

• Group discussion – 50%
•  Practice – 75%
• Teaching others – 90%

The challenge to the instructor is to incorporate participatory learning methods into routine safety training sessions. Using these methods will require adequate preparation prior to the training delivery. This may include up to two hours of preparation for each hour of training.

Group Discussion 

As an instructor, there are days when you feel like you have to pull teeth to get employees to participate in training. This can be overcome by preparing for the class adequately and using small group exercises.  For instance, divide the class into small groups of two or three persons. Provide them with a case study relating to the topic being covered. Consider using OSHA Fatal Fact Sheet scenarios from OSHA’s website, www.osha.gov, as the case study. The Fatal Fact Sheets summarize fatalities in the workplace for all types of industries and situations (mobile equipment, falls, scaffolding, confined space, lockout/ tagout, etc.).

Case studies also can include incidents from the past, theoretical situations, or personal experiences. Provide the employees with the description of the task and ask them to identify the steps of the task, potential hazards, and the recommended safe work practices or controls. Each group can review their work with the larger group. Once all groups have discussed their efforts, review the outcome from the situation described in the Fact Sheet.  Using this approach fosters teamwork, collaboration, and active group participation.

Practice

The word practice is often equated to team sport participation.  Teams can study the playbook extensively, but they will not master the playbook, until they hit the field and practice.  The  field is the work environment. There are many situations where we can practice what we learn in the classroom. For instance, locking out a complicated piece of equipment, entering a confined space, responding to a chemical spill, loading a railcar properly, and rigging a fall protection/restraint system are just a few.  There has been a shift in recent years to the hands-on training approach. This approach, as demonstrated in the Learning Pyramid, provides for maximum information retention. However, just like in sports, employees can be injured during practice. Make sure that the practice scenarios do not place employees in danger.

Teaching Others

I once worked with a CEO who told me, “If you truly want to learn something, teach it.” He was right. In order to instruct on a topic, you have to know it inside and out. Consider the teaching-others method for your training.  The possibilities for having employees instruct on certain topics are endless. In fact, in many instances, operations employees are more knowledgeable on how to work safely than the instructor is. Consider having your employees instruct or demonstrate some of the practice activities that were referenced earlier. You may even want to have them cover a particular example or real-life experience during classroom training.  This can influence their coworkers greatly and increase their retention and awareness.

Summary

In this article, we have discussed both passive and participatory learning activities. Work toward including participatory training methods into your routine safety training. Strive to get out of the classroom and into the work environment. That is where the real work is done.

Written by:  Joe Mlynek CSP, OHST – Progressive Safety Services LLC

What is Hot Work?

OSHA defines hot work as any work involving welding, cutting, brazing, or other flame-producing activities. While not mentioned in OSHA’s definition, many companies expand this definition to include grinding of ferrous metals. This spark-producing activity poses an additional ignition source that is often overlooked. Consider including grinding activities in your company’s hot work program.

All in the Approach

Prior to performing hot work, consider alternatives to eliminate potential ignition sources in the operating facility. Alternatives may include using powered saws instead of a cutting torch or relocating the work to a designated area such as a maintenance shop. As a team, identify ways to eliminate, control, or reduce exposure.

The Permit Process

Each facility needs to establish a process for coordinating and approving hot work activities. It is common for managers, supervisors, or maintenance personnel to coordinate the process. All opportunities for eliminating, reducing, or controlling the hazards should be discussed prior to issuing the permit. Hot work permits should be specific to each job or project. Complete permits frequently for longer-term projects. Conditions change quickly in our industry. Therefore, we must continually evaluate the work environment.

Precautions

The person issuing the permit is responsible for ensuring that all necessary precautions are taken prior to and during hot work activities. Prior to hot work, take the following precautions where applicable:

• Ensure that sprinkler systems, fire hydrants, fire hose, and detection systems remain in service during the work.
• Ensure that welding and cutting equipment is in good repair. This means that all equipment including gas hoses, flashback arresters, fire resistive tarps or curtain, torch heads, regulators, leads, grounds, etc. are in acceptable condition.
• Ensure that adequate precautions are taken within 35 feet of hot work activities. This may include removing or wetting down areas that have combustible dust that cannot be removed completely, removing flammable and combustible liquids, covering combustible materials with fire-resistive tarps or metal shields, covering all floor openings, and suspending  fire resistive tarps below overhead work, where sparks may travel to areas below.
• Ensure that wall or ceiling construction materials are not combustible.
• Purge and clean all enclosed equipment of all flammable and combustible liquids and vapors.

One precaution that typically is not present on most generic hot work permits is isolating all conveyance, bucket elevators, or other moving equipment, This equipment can transport smoldering materials to other areas of the facility. Picture sparks igniting dust or material on a conveyor or in a bucket elevator. The equipment is started. The smoldering material ignites suspended dust inside the equipment or is conveyed to a storage bin, tank, or silo. The outcome could be catastrophic.

Fire Watch

Assign a person to fire watch detail during and after hot work activities. The fire watch must have a suitable fire extinguisher, charged hose, or other means to put out smoldering material or incipient fires. He or she will need sufficient training on how to use the equipment and initiate an evacuation of the area, if needed.  Fires may start during and several hours after hot work activities are completed. A fire watch should be provided for at least 60 minutes after the work has been completed. Therefore, it is best to plan hot work activities to allow adequate time for fire watch and inspection.

Contractors

Contractors have caused fires in the workplace. It is imperative that they are educated on the company requirements. It is helpful to conduct a pre-project planning session with contractors to discuss opportunities to eliminate, reduce, or control the hazards associated with the work. You also may consider reviewing their hot work program prior to allowing them to perform hot work within the facility.

Summary

Whether performed by company employees or outside contractors, hot work has the potential to cause fires, explosions, and flash fires. Pre-planning is a critical component of managing hot work activities. Continually evaluate each scenario to identify, eliminate, control, or reduce its hazards. Ensure that employees and contractors know the procedures and requirements at your facility. Respect the exposure that hot work creates. Do not play with fire.

Written by:  Joe Mlynek CSP, OHST – Progressive Safety Services LLC

The hierarchy consists of five control methods:

• Elimination
• Substitution
• Engineering controls
• Administrative controls
• Personal protective equipment (PPE)

The idea behind the hierarchy is that the controls at the top of the list are more effective at reducing employee exposure to workplace hazards than those at the bottom. Let’s look at each control method in more detail starting at the top of the list.

Elimination

Elimination is the preferred method to address workplace hazards. I recently had a discussion with a client regarding the cleaning of residual grain in the facility’s concrete bins. I was pleasantly surprised that the employees had been working to eliminate completely the need for entry by purchasing specialized reclaim equipment.By eliminating the need for entry, they have eliminated the potential for employees to be exposed to numerous hazards. While an expensive alternative, this allows for the higher level of safety. Elimination may not be feasible for all types of hazards, but should be evaluated regardless. In addition to improved safety, the investment often can be justified by increased productivity and efficiency.

Substitution

Substitution is a control measure that utilizes less hazardous materials, processes, or equipment. An example would be substituting a hazardous chemical used in the workplace with one that is less hazardous.Another example would be using a self-retracting lifeline (SRL) rather than a lanyard for fall protection. By substituting the SRL for the lanyard, the free fall distance and the potential for severe injury is reduced. Substitution requires leaders to be vigilant in looking for new products, processes, and equipment that allow for a greater level of safety.

Engineering Controls

Engineering controls are used to remove a hazard or place a barrier between the worker and the hazard. While engineering controls can be expensive to implement, they often provide a greater level of protection than administrative controls and personal protective equipment.Examples of engineering controls include machine guards, interlocks, and ventilation. For example, dust collection systems often are used at the head and boot sections of elevator legs, to reduce suspended dust in the leg to levels below the minimum explosive concentration.

Administrative Controls

Administrative controls are procedures or policies used to manage exposure to hazards. Let’s return to our example of entering grain bins to reclaim the residual grain. We have identified that the best option would be to eliminate the need to enter the bin through the use of specialized equipment or other means. This may not be feasible in every situation for various reasons (bin characteristics, cost, etc.).  n example of an administrative control would be developing a procedure for safe entry into the bin. It would require the use of a confined space entry permit, atmospheric monitoring, lockout of internal moving parts, etc. Employees need to be trained on the procedure, and management must ensure that procedures are followed.

Personal Protective Equipment

PPE is the last resort when addressing exposure to hazards. Let’s use our example of entering the grain bin once more. Entry into bins for cleaning may expose employees to respirable dust. It’s very difficult to eliminate dust inside of a grain bin; therefore, PPE may be an effective alternative. In this case, the proper form of respiratory protection would need to be determined, employees would need to be trained on its use, limitations, etc., and management would need to ensure that respiratory protection is used as required.

Summary

The Hierarchy of Controls provides a methodology for addressing exposure to workplace hazards. We have looked at five separate control methods within the hierarchy. I encourage you to share this information with your team.  The next time a hazard is identified, start at the top, and work your way through the five control methods identifying which are most feasible both short and longer term. Using this method will take your hazard identification program to the next level.

Written by:  Joe Mlynek CSP, OHST – Progressive Safety Services LLC

JSA is a process that provides a proactive approach to identifying, eliminating, and reducing workplace hazards. JSA also provides a valuable tool for analyzing the relationship between the worker, his or her tasks, tools, and the work environment. Even more importantly, the JSA process engages employees at all levels to work to gether toward the goal of creating an injury-free workplace. Let’s begin to explore the JSA process.

Select the Job

The first step in the JSA process involves selecting the job to be analyzed. It’s helpful to focus efforts on those jobs that have contributed to multiple injuries or near misses. Once these jobs have been analyzed, begin focusing efforts on those activities employees feel have the greatest risk or potential for severe injuries. This can be accomplished through engaging employees during safety meetings, informal discussions, or by conducting surveys.

Assemble the Team

Once a job has been selected, it’s time to select the team of employees who will analyze the job. This team should have representation from both management and operations. Employees who perform the job being analyzed must be involved. They are the experts. One person will need to take on the role of team leader. The team leader should have training in the process to ensure success. The remaining participants should have basic knowledge of the JSA process.

Observation

After the team has been assembled, it’s time to observe the job being done in the workplace.  It’s important that those employees being observed are aware of the purpose of the observation. The purpose is to observe the job, not the person performing it.  The job should be observed during normal work conditions such as the time of day, number of employees typically assigned, etc. Videotaping the job is highly recommended. This allows the team to view the job multiple times providing a greater depth of analysis.

Break into Steps

Once the job has been observed, the team needs to break the job into steps. The JSA should be limited to no more than 15 steps. If there are more than 15 steps, consider breaking the job into several separate tasks.  After completing the sequence of job steps, they can be entered into the “Job Step” section of the JSA form.

Identify Hazards

After the job steps have been identified, the hazards associated with each step need to be identified.  The team should analyze each step asking the following question: “Can this step increase exposure leading to an injury or accident?” Common types of hazards may include falls, being struck by an object, contact with electrical equipment, becoming caught in machinery, overexertion, chemical exposure, engulfment, etc. Once the hazards of the step have been identified, they can be entered in the “Hazards” column on the JSA form.

Controls/Safe Work Practices

Now that the hazards have been identified, the team needs to work to eliminate, reduce, or control the hazards. For those instances where the hazard cannot be eliminated completely, safe work practices can be developed.  For example, if an employee were entering a confined space, the safe work practice may be: “Fill out confined space entry permit to include atmospheric monitoring and lockout/ tagout prior to entry.” Once the safe work practice has been developed, enter it into the “Safe Work Practice” section of the JSA form.

Be Consistent

Once the JSA is completed, it is important that a program be implemented to promote its use on a consistent basis. JSA documents can be reviewed during safety training, daily pre-shift safety meetings, or any instance where safety should be reinforced. JSAs need to be reviewed with employees on a regular basis to promote safety and to ensure that the document remains accurate.

Summary

Job Safety Analysis is a powerful tool for identifying, eliminating, and reducing hazards in the workplace. Even more importantly, it allows employees to work together to identify and address exposure in the workplace. JSA is a useful tool for increasing employee involvement in the safety process.
Written by:  Joe Mlynek CSP, OHST – Progressive Safety Services LLC