Presentation on theme: "Elimination of Heat Stress in the Glass Manufacturing Environment PPG Industries, Inc. Presented by Pat Pride PPG Industries, Inc. Environmental Manager,"— Presentation transcript:
Elimination of Heat Stress in the Glass Manufacturing Environment PPG Industries, Inc. Presented by Pat Pride PPG Industries, Inc. Environmental Manager, Fiber Glass & Flat Glass
Background and Objective Problem: A PPG float glass plant experienced 3 heat stress cases in one year (7 cases total for this business unit) Objective: Eliminate heat stress - focus on furnace Hot Repair. Use a technology aimed at prevention. Assessment Tools: Six Sigma statistical evaluation; catalyst assigned. QUESTemp III Monitor (heart rate & body temp) Polar Monitor (heart rate)
Methodology Develop a Working Group: Plant healthcare representatives: Facility nurse, facility doctor Production representatives Persons to collect, maintain, and evaluate data Identify facility “hot work” areas: Areas, jobs, and employees where potential for heat stress exists. Initially focused on Furnace hot work areas. 15 hot-work employees involved in the assessment; 57 samples.
Methodology Develop a baseline personal heart rate (HR) profile for each hot-work employee using QUESTempIII monitor: All hot repair and back-up hot repair personnel. Others that may be exposed to high-heat jobs. Use profile to establish each individual’s normal HR baseline. Collect HR data trend during heat up/cool down cycle periods while performing hot-work job duties.
Methodology Identify individuals with health risk. Investigate cause of health risk before allowing the person to perform high-risk activities. Work with facility doctor to determine what is required to allow person to resume hot work activities. Institute special requirements, if necessary (i.e., required to wear monitor).
Examples of QUESTemp III Data Alarm sounds at the highest heart pulse and the cooling process aids in the reduction of pulse rate. Not extreme hot repair work scheduled
Results and Conclusions Heart rate (HR) indicated reaction to heat much sooner than body temperature response (leading indicator). Employees routinely exposed to heat become acclimated to it. This assessment indicated that Hot Repairmen can work longer than other furnace employees. Cool down and recovery are faster. While HR monitors have been in use, no one experienced heat stress, therefore no data is available during a heat- stress occurrence.
Results and Conclusions Cool-Down between work cycles to resume employee’s individual normal baseline HR averts heat stress. Availability and use of a Cool Room facilitated recovery time to normal HR (allows resuming duties sooner). Rule of thumb: 15 minutes IN followed by 15 minutes OUT for Hot Repairmen. Important to note this is site, job and employee specific. Guideline for maximum allowable HR: 220 minus age (or as determined by facility doctor)
Results and Conclusions Other contributing factors to HR response to hot work conditions: Individual variation – 2 employees experienced unexplained rapid HR. General health, medications, etc. Determine individually if fit for duty Once baseline is established with QUESTempIII, a HR monitor such as that marketed for exercise (i.e., Polar), is adequate for ongoing monitoring during hot work activity.
Implementation Purchase each Hot Repairman a person HR monitor (using Polar brand). Nurse sets alarm level for each (220 – age). Hot repairmen pace themselves through use of personal baseline HR and ongoing use of monitor during hot work. Cool vests (gel type), various beverages (Gatorade, Propel, water etc.), and other preventive measures are also used in conjunction with HR knowledge to prevent heat stress.
Heat Stress Preventive Program Summary Establish HR baseline for applicable employees (QUESTempIII) Screen for at-risk employees Use HR monitor during hot-work activities (Polar) Use work/rest cycle (15 min ea or as indicated by HR response) Use cool room & A/C areas, cool vests Provide suitable beverages & specific diet meals Use “observers” of worker behavior; blood pressure.
Program Summary - continued Annual training – symptom recognition, prevention, procedures, etc. Procedures requiring use of HR monitors If anyone experiences heat stress- requires plant doctor to approve return to hot work. Plan jobs during cooler periods of day/year if possible Have extra manpower for long jobs
DISCLAIMER Guidelines and protocols described in this presentation have been established based on conditions specific to one facility and its specific operations. It is recommended that other facilities not rely solely on these results but should develop data and programs applicable to their unique operations, work conditions, personnel, and climates.