Manufacturing Safety Training Tips: How to Get It Right

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Looking for some manufacturing safety training tips? If so, that makes sense. There’s a lot to be said in favor of working in manufacturing, but it does pose a set of hazards to the workers.

However, safety managers and other safety professionals work tirelessly to create safer, healthier workplaces for manufacturing employees (and of course, in a good safety culture, they’re working hand-in-hand with the employees themselves), and part of that involves safety training for the manufacturing workforce.

In this article, we’re going to walk you through some key aspects of safety and safety training in manufacturing facilities, and give you tips to help create a safer, healthier workplace.

Before we begin, though, know that you can download a free guide to Effective Safety Training by clicking the download button at the end of this article, or just download any of the free guides and/or watch any of the free webinars listed below.

And with all that said, and with those free resources made available, let’s get to listing some manufacturing safety training tips.

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What Is a Hydraulic System? Definition, Design, and Components

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With a variety of applications, hydraulic systems are used in all kinds of large and small industrial settings, as well as buildings, construction equipment, and vehicles. Paper mills, logging, manufacturing, robotics, and steel processing are leading users of hydraulic equipment.

As an efficient and cost-effective way to create movement or repetition, hydraulic system-based equipment is hard to top. It’s likely your company has hydraulics in use in one or more applications for these reasons.

We’ll provide more information about hydraulic systems in this article, including covering the definition and basic designs and components.

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OSHA Personal Protective Equipment (PPE) Standards and Requirements

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Many years ago, before the PPE Final Rule, OSHA determined that there were an extensive number of injuries related to workers not wearing effective personal protective equipment. In fact, in the Preamble to the Final Rule, OSHA cited various studies indicating there were 320,000 hand and finger injuries, 70,000 eye injuries, 70,000 head and face injuries, and 110,000 foot and toe injuries in 1987. (Roughly 31 percent of the total disabling injuries for that year.) Rightly so, OSHA decided these numbers merited a Standard (CFR 1910.132) to protect workers from these hazards.

Indeed, PPE does work to safeguard workers. Experts estimate that approximately ninety percent of related injuries could be prevented or minimized by wearing the proper equipment. PPE is a vital and necessary tool in the employer’s arsenal to protect workers.

Fast forward to today. Even with PPE Standards fully in place for decades, we still have an alarming number of eye, face, foot, hand and head injuries. For example, NIOSH states, “Each day about 2,000 U.S. workers sustain a job-related eye injury that requires medical treatment. About one-third of the injuries are treated in hospital emergency departments, and more than 100 of these injuries result in one or more days away from work.”

In addition to the effects injuries have on workers, these events can be financially devastating to the organization. Excessive or serious injuries can trigger numerous employer headaches, from high-risk insurance costs to OSHA inspections and penalties. And of course, each injury incident carries indirect costs related to downtime, replacing injured workers, and various related issues.

Given the importance of PPE, let’s look at OSHA’s PPE regulations more closely in this article.

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What To Teach Employees about Confined Spaces

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Few workplace areas present as many potentially serious hazards as a confined space. Without dedicated procedures for safe entry and monitoring employees within the confined space, catastrophic events can occur. According to OSHA, approximately ninety workers die in confined spaces every year. OSHA cites failure to recognize and control the hazards as contributing factors in most confined space injuries and fatalities.

This means training is critical to protecting workers if they will enter a confined space.

But it can be challenging for employers to understand the requirements for confined space training, as the hazards of these areas are often very complex or unique to each facility. You’ll have a solid training program if you know the fundamental aspects of the confined space standard and how to apply it to your workplace.

But where to begin? We’ll walk you through the OSHA confined space training requirements in this article and give you some tips for getting started.

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Delivering Safety Training: Read Our Tips in ASSE’s “Professional Safety” Magazine’s July Issue

We’ve got another in a series of articles related to safety training in the July issue of Professional Safety, the official magazine of the American Society of Safety Engineers (ASSE).

The series of articles provides tips for better safety training, and takes as a starting point some key parts of the ASSE/ANSI Z490.1 standard on effective EHS training. This article focuses on delivering effective EHS training (as opposed to designing it, or developing it, etc.).

We encourage you to check out the ASSE, their Professional Safety magazine, and of course their ANSI Z490.1 standard for environmental, health, and safety training. Also, be aware that ANSI and ASSE are beginning the process of creating ANSI Z490.2, which will deal with online or “virtual” EHS training. We’re on the committee to create that standard and you can read more about that here, here, and here.

To download our free guide to effective EHS training, based on ANSI Z490.1, scroll down to the bottom of this article.

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Paper Manufacturing Safety Tips: Hazards, Controls, and Safe Work Practices

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If you’re a paper manufacturer, we probably don’t need to tell you that (1) paper manufacturing comes with its own unique set of hazards, (2)  controlling those hazards and keeping employees safe on the job is important and worthwhile, and (3)  not only is creating a safe workplace the right thing to do, it pays off in terms of better operational efficiency and higher revenues too. So you may be looking for some paper manufacturing safety tips.

We partner with many paper manufacturers to make online paper manufacturing training videos, both custom and off-the-shelf. And all our customers see the value in online paper manufacturing safety training courses as well.

In the article below, we give a few tips about safety issues when working around a paper machine. The images are taken from our Paper Machine General Safety online course. We’ve included a sample video of that course immediately below, and throughout the article, you’ll see other sample videos from other related courses.

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ANSI Z490.2–Another Update on National Standard for Virtual Occupational Safety, Health, and Environmental Training

As you may remember, I’m part of a group of people helping to create the upcoming ANSI/ASSE Z490.2 standard on “virtual occupational safety, health, and environmental training” and I’ve been writing periodic blog articles with updates on the status and little behind-the-scenes views of how a standard is created.

I wrote an earlier article that explains Z490.2 is in creation and that explains some base-level details, such as what is its relation to Z490.1, and a second article as we began working on Z490.2.

In this article, we’ll tell you of the most recent developments, which came about as a result of a phone conference the group members had to discuss the new safety training standard.

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Wire Rope: Lay, Classification, and Construction

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Working safely with wire rope, for rigging and other purposes, requires an understanding of some of the characteristics of wire rope. Characteristics you should understand include lay, classification, and construction. We’ll explain each in this article.

For even more information about wire rope, please see our wire rope online training video and wire rope safety online training video courses.

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MSHA Part 46 Training Certification Process

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In this article, we’re going to explain the MSHA Part 46 certification process for miners, and tell you what kind of MSHA Part 46 training certificate you should get when you’re training’s complete.

To set the scene, MSHA is the Mine Safety and Health Administration. It’s the mining equivalent of OSHA. And MSHA’s 30 CFR Part 46 are MSHA’s regulations for safety training provided to miners and other employees at surface mines. And we describe what a surface mine  and surface mining are here.

And with those starters covered, let’s learn more about MSHA Part 46 certification.

 

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Visuals for Better Paper Manufacturing Training

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Pulp and paper manufacturing is a competitive business (that’s true of tissue and corrugated board as well). You’ve got to be an expert in many things–operations excellence, health and safety, environmental regulations, training, and more.

That’s true no matter where in the world you’re doing business.

In addition, American pulp and paper manufacturers have one arguable competitive disadvantage: they have to pay their workers more than workers in many other nations are paid. As a result, it’s important to provide the best possible training to this pulp and paper manufacturing workforce so they will have advanced skills that allow them to create a product, including value-added products, with more efficiency.

That’s where we come in. We’re experts in pulp and paper training and we’ve been doing it for more than 15 years.

With our training, you can onboard new hires more rapidly, efficiently, and effectively than you can otherwise. And that’s going to matter as the experienced Baby Boomers at your company are retiring and they’re being replaced by intelligent, capable, even college-educated millennials who have a lot to offer but don’t have a lot of relevant job experience.

Our training will help you cross-train workers so they know how to perform multiple different jobs. This will ease succession planning but will also spark motivation, creativity, and innovation from your workers.

It will, as a customer of ours who’s a training lead at a major American paper products manufacturing company has said to me, “turn your machine operators into machine engineers.”

In this article, we’re going to demonstrate a few visual design techniques that make our paper manufacturing training materials so compelling, engaging, and effective. This is actually the second of a two-article series looking at how to design visuals for effective paper manufacturing training. You may also want to check our earlier article, Better Paper Manufacturing Training Through Visual Learning.

Feel free to watch the short sample video, which shows some highlights of our online job training courses, before you begin. You’ll see we make online training materials for pulp, paper, tissue, and corrugated board manufacturing, but also for things like environment, health, and safety; HR and soft skills; general manufacturing; and more.

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ASSE Safety 2017 Day Three Summary (Thursday, June 22)

This is our third and final daily summary of the ASSE’s Safety 2017 conference.

You can also read our summary of ASSE Safety 2017 Day One and ASSE Safety 2017 Day Two.

Here’s a quick overview of some of the presentations I was lucky enough to catch on Thursday. Feel free to use the comments section at the bottom to talk about sessions you attended.

ASSE Training & Communications Practice Specialty Leadership Meeting

I’m not a member of the leadership for this practice specialty, but current head Michael Coleman was nice enough to shoot me an email and invite me to sit in.

A lot of things were discussed, including news on potential ASSE name and logo changes (stay tuned for more on that), and some things going on to make communications and knowledge share within ASSE and this practice specialty easier and more efficient.

I also learned that Michael Coleman’s preparing to step down as leader of this practice specialty and that Morgan Bliss of Central Washington University is preparing to step into the leadership role. I met Morgan and she seemed great, so I wish her luck in her new role.

Insights from Leadership Development Training for Frontline Supervisors

Lori Guasta presented data from training she helped design, develop, and deliver to frontline supervisors in mines. The purpose was to help these supervisors develop leadership skills so they could lead employees more effectively.

In doing so, Lori presented a lot of interesting information about how people see the world, communicate, and otherwise interact.

Her training breaks workplace relationships down into three parts:

  1. Person–the kind of person you (as a leader) are and/or want to be
  2. People–interacting with and leading others
  3. Environment–how your organization, including its culture, affects the two items above

And, if I wrote this all down quickly enough, here’s the outline of her 2-day course:

  1. Embracing differences
  2. Values, motivation, attitudes, and personality
  3. Generational differences
  4. Adult learning styles
  5. Communication
  6. Team building
  7. Motivation, feedback, and recognition
  8. Mentoring/coaching
  9. Accountability and vision
  10. Strategies to promote positive safety culture

Closing General Session–Why We Make Mistakes

Joseph Hallinan explained some features of human psychology that are often very helpful but sometimes cause us to make mistakes, including safety mistakes at work.

His primary message is that there’s an element of “mistake-making” that’s baked into humans, and as a result we should design systems that are safe even with those mistakes occurring.

He explained three traits that cause humans to sometimes make mistakes:

  1. Inattentional blindness–“If you don’t see something often, you often don’t see it”
  2. Selective memory–Memory is not an “exact science,” but is instead constantly being reshaped, pruned, and reinterpreted, sometimes to create a narrative that’s not objectively true
  3. Blind spots–Things we’re prone to overlook

Given this, he suggested the following:

  • Know your limitations
  • Realize humans are fallible and build that expectation into design
  • Impose constraints, including things like checklists

What about You?

What sessions did you see? Let us know in the comments section below. And we hope to see you today!

And help yourself to the free guide below, which is based in large part on ASSE/ANSI Z490.1.

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Effective EHS Training: A Step-by-Step Guide

Learn how to design, create, deliver, and evaluate effective EHS training by following these best practices with our free step-by-step guide.

Download Free Guide

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What Is Surface Mining?

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Ever wonder to yourself: what is surface mining?

If so, this is the article for you. We’re going to explain what surface mining is and give you some information about the MSHA Part 46 training requirements for surface mines to boot.

If you read through this and are still wondering about the surface mining definition, leave a note in the comments below.

And let us know if you’d like some additional information about online safety training for surface mining too (MSHA Part 46 training).

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