1. IENG 475: Computer-Controlled Manufacturing Systems
IENG Lab 01
Manufacturing Safety
5/22/2019
IENG 475: Computer-Controlled Manufacturing Systems
(c) 2006, D.H. Jensen

2. Academic Lab Safety History
Some background:
19th Century: “Swashbuckling researcher” Richard Bunsen has a series of explosions in his laboratory, finally leaving him blind in one eye (Yet you still use his “Bunsen Burner” in school chemistry classes!)
2009 UCLA: A research assistant dies from burns caused in a chemistry lab because she was not wearing the appropriate, req’d cotton lab coat.
2010 Texas Tech: A graduate student is critically injured in a chemistry lab explosion because simple lab procedures (typically taught in high school) were not followed.
2011 Yale: A physics major about to graduate strangles to death when her hair gets caught in a lathe while finishing her senior project. She violated PPE protocols and worked alone in lab until about 2:00 AM …
2011 U.S. Chemical Safety Board: identifies more than 120 academic laboratory safety incidents over the past decade.
2015 Kentucky: All active NSF grants suspended as sanction for major safety violations.
ASEE Prism (2016 Jan). pp.35-37
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IENG 475: Computer-Controlled Manufacturing Systems

3. IENG 475: Computer-Controlled Manufacturing Systems
Safety Regulation
The Occupational Safety & Health Act of 1970 created:
NIOSH (National Institute for Occupational Safety and Health) which develops standards, performs research, and conducts education and training
OSHA (Occupational Safety & Health Administration) which enforces standards to ensure safe and healthy working conditions
5/22/2019
IENG 475: Computer-Controlled Manufacturing Systems

4. OSHA Requirements for Employers
“Each employer shall furnish to each of his or her employees employment and a place of employment free from recognized hazards that are causing or likely to cause death or serious harm to his employees and shall comply with occupational safety and health standards under this Act”.
5/22/2019
IENG 475: Computer-Controlled Manufacturing Systems

5. OSHA Requirements for Employees
Employees have the responsibility to “…comply with occupational safety and health standards and all rules, regulations and orders issued pursuant to this Act that are applicable to his or her own actions and conduct”.
5/22/2019
IENG 475: Computer-Controlled Manufacturing Systems

6. IENG 475: Computer-Controlled Manufacturing Systems
Liability
Employers ARE strictly liable for compliance with OSHA regulations
Employees ARE NOT strictly liable for OSHA regulation violations
BOTH employers and employees may be held to account for safety under general liability
Know or could have reasonably foreseen of a problem and did not take appropriate action
“Deep Pockets” legal theory applies
Professional censure for engineers applies
5/22/2019
IENG 475: Computer-Controlled Manufacturing Systems

7. Safety Theory – Domino Theory
Herbert Heinrich Study (1920s & 1930s):
88% caused by unsafe acts
10% caused by unsafe conditions
2% caused by unavoidable “acts of God”
Sequence of Factors (dominos):
Ancestry & Social Environment – predisposing factors
Fault of Person (character flaw) – poor choice made
Unsafe Act and Physical Hazard – action taken in the presence of a hazard
Accident – unexpected result
Injury – outcome of unexpected result
Removing any domino prevents the accident!
5/22/2019
IENG 475: Computer-Controlled Manufacturing Systems

8. Safety Theory – Human Factors Theory
Humans are error prone – accident is a chain of events that lead to a human error
Three factors that lead to the error:
Overload – limitations on amount of stress that individuals can handle
Working environment
Health & physical condition
Personal commitments & problems
Job responsibilities
Inappropriate Response – (lack of) experience, training, proper demeanor
Inappropriate Activities – action taken based on incorrect judgement
Prevent all three to avoid the accident!
5/22/2019
IENG 475: Computer-Controlled Manufacturing Systems

9. Safety Theory – Multiple Causation Theory
Extension of Domino Theory – accidents may have multiple causes (more than one domino) but eliminating either one of two categories of causes will prevent an accident
Behavioral – human elements contrary to safe operations, such as:
Inadequate skill or training
Fatigue or inattentiveness
Environmental – physical elements contrary to safe operations, such as:
Inadequate lighting, housekeeping, noise control
Inadequate safeguards, personal protective equipment
5/22/2019
IENG 475: Computer-Controlled Manufacturing Systems

10. IENG 475: Computer-Controlled Manufacturing Systems
Four Tools for our Lab
Cause & Effect Diagrams
Check Lists
Supervised Training
Practice (and assessment)
5/22/2019
IENG 475: Computer-Controlled Manufacturing Systems

11. IENG 475: Computer-Controlled Manufacturing Systems
Fishbone Diagram
Preliminary Analysis for potential hazards:
Head of the Fish is the problem statement
An accident in the lab leads to injury
Five major bones of the fish: (4 M’s and an E)
Man
Material
Method
Machine
Environment
Use these as prompts to organize and brainstorm more specific causes …
5/22/2019
IENG 475: Computer-Controlled Manufacturing Systems

12. IENG 475: Computer-Controlled Manufacturing Systems
Questions
Be ON TIME to lab next week, with EP paper and / or a LAB engineering notebook.
Lab instructions will be provided, but you can preview the instructions on the Schedule Page.
Activities:
Safety Equipment
Safety Practices
Safety Analysis (individual & team)
You may not use the lab / equipment until this assignment is complete!
5/22/2019
IENG 475: Computer-Controlled Manufacturing Systems