Expanding the maintenance toolkit for 2015 OSHA standards

Effective as of January 1, the new OSHA standards are designed to help improve workplace safety, in light of statistics showing more than 4,000 workers killed on the job in 2013.

03/04/2015


Effective on January 1, 2015, the new OSHA standards are designed to help improve workplace safety, in light of statistics showing more than 4,000 workers killed on the job in 2013. Courtesy: Smartware GroupJanuary 1, 2015 marks the starting date for a new set of regulations from the Occupational Safety and Health Administration (OSHA) that will affect many maintenance professionals throughout the United States. The new OSHA standards are designed to help improve workplace safety, in light of statistics showing more than 4,000 workers killed on the job in 2013.

Not only are workplace accidents devastating to employees and families, it is estimated that for every dollar paid for an OSHA violation, companies could spend an additional $50 in increased insurance premiums, lost productivity, retrofitting expenses, or re-training costs. Worse, major corporations may stop doing business completely with certain vendors if OSHA fines cause those vendors to earn an unacceptable rating from insurance companies.

To avoid such problems, first take a look at OSHA’s new regulations for 2015:

  • Employers must notify OSHA of work-related fatalities within eight hours, and work-related in-patient hospitalizations, amputations, or losses of an eye within 24 hours. Previously OSHA’s regulations required an employer to report only work-related fatalities and in-patient hospitalizations of three or more employees – not a single employee, as will be necessary under the new regulations.
  • The new rules maintain the exemption for any employer with 10 or fewer employees, regardless of their industry classification, based on the requirement to routinely keep records of worker injuries and illnesses.
  • All employers covered by the Occupational Safety and Health Act, even those who are exempt from maintaining injury and illness records, are required to comply with OSHA’s new severe injury and illness reporting requirements. To assist employers in fulfilling these requirements, OSHA is developing a Web portal for employers to report incidents electronically, in addition to the phone reporting options.

Now, how can maintenance professionals comply with the new rules?

One of the best strategies to achieve true safety in the workplace is through the use of a modern CMMS in support of persistent preventive maintenance (PM). A CMMS with expanded reporting capabilities can also make it easier for maintenance professionals to comply with OSHA regulations, while helping companies avoid the hidden costs of non-compliance.

For one, an Occupational Safety & Health-enabled CMMS allows maintenance managers to create, track, review, and record incidents while they can also monitor safety programs, including drills, evacuations, Job Safety Analysis (JSA), historical safety meeting notes, and Material Safety Data Sheets (MSDSs). In addition, CMMS users can document and archive worker safety measures, including incidents and accidents linked to employees, employee trainings, and certification.An OSH solution within CMMS can aid maintenance professionals in managing safety programs, employee certifications, and more.

Further, a CMMS that offers flexible data views can create safety reports that are sorted according to asset, repair technician, safety standard, or other criteria. If an auditor then questions an incident or exposes a safety risk, the maintenance record can prove that PMs were performed on schedule, and that the incident was a one-time occurrence, where applicable.

Most importantly, using a CMMS to integrate safety protocols into PMs and work orders makes it far simpler to keep safety in its rightful position as a workplace priority – and that, in turn, can keep workers from experiencing injuries and illnesses that can be prevented easily.

A CMMS with all of these capabilities can simplify the job of reporting to OSHA or other governing body in the event of an injury/illness, as well as for a regulatory inspection. If an OSHA inspector follows up on an incident or identifies a safety risk, a CMMS-generated maintenance report will prove that the PM was performed on schedule and new preventive PMs are put in place to prevent future incidents. And as Benjamin Franklin once said, “An ounce of prevention is worth a pound of cure.”

This article originally appeared on Smartware Group Bigfoot Maintenance Software blog. Smartware Group is a CFE Media content partner. Edited by Joy Chang, digital project manager, CFE Media, jchang@cfemedia.com



Top Plant
The Top Plant program honors outstanding manufacturing facilities in North America.
Product of the Year
The Product of the Year program recognizes products newly released in the manufacturing industries.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
October 2018
Tools vs. sensors, functional safety, compressor rental, an operational network of maintenance and safety
September 2018
2018 Engineering Leaders under 40, Women in Engineering, Six ways to reduce waste in manufacturing, and Four robot implementation challenges.
July/Aug
GAMS preview, 2018 Mid-Year Report, EAM and Safety
October 2018
2018 Product of the Year; Subsurface data methodologies; Digital twins; Well lifecycle data
August 2018
SCADA standardization, capital expenditures, data-driven drilling and execution
June 2018
Machine learning, produced water benefits, programming cavity pumps
Spring 2018
Burners for heat-treating furnaces, CHP, dryers, gas humidification, and more
October 2018
Complex upgrades for system integrators; Process control safety and compliance
September 2018
Effective process analytics; Four reasons why LTE networks are not IIoT ready

Annual Salary Survey

After two years of economic concerns, manufacturing leaders once again have homed in on the single biggest issue facing their operations:

It's the workers—or more specifically, the lack of workers.

The 2017 Plant Engineering Salary Survey looks at not just what plant managers make, but what they think. As they look across their plants today, plant managers say they don’t have the operational depth to take on the new technologies and new challenges of global manufacturing.

Read more: 2017 Salary Survey

The Maintenance and Reliability Coach's blog
Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
One Voice for Manufacturing
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Maintenance and Reliability Professionals Blog
The Society for Maintenance and Reliability Professionals an organization devoted...
Machine Safety
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
Research Analyst Blog
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Marshall on Maintenance
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
Lachance on CMMS
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
Material Handling
This digital report explains how everything from conveyors and robots to automatic picking systems and digital orders have evolved to keep pace with the speed of change in the supply chain.
Electrical Safety Update
This digital report explains how plant engineers need to take greater care when it comes to electrical safety incidents on the plant floor.
IIoT: Machines, Equipment, & Asset Management
Articles in this digital report highlight technologies that enable Industrial Internet of Things, IIoT-related products and strategies.
Randy Steele
Maintenance Manager; California Oils Corp.
Matthew J. Woo, PE, RCDD, LEED AP BD+C
Associate, Electrical Engineering; Wood Harbinger
Randy Oliver
Control Systems Engineer; Robert Bosch Corp.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
Design of Safe and Reliable Hydraulic Systems for Subsea Applications
This eGuide explains how the operation of hydraulic systems for subsea applications requires the user to consider additional aspects because of the unique conditions that apply to the setting
click me