ALLIANCE ANNUAL REPORT
Occupational Safety and Health Administration
and the
Society of Plastics Industry, Inc. (SPI)
December 12, 2004

1. Alliance Background

   Date Signed

   September 19, 2002

   Date Renewed

   March 4, 2004

   Overview

   The OSHA and SPI Alliance continues to focus on providing SPI's members and others with information, guidance and access to training resources to promote machine safety and ergonomic awareness. OSHA and SPI are identifying machinery hazards and provide potential solutions to reduce injuries (e.g., lacerations, burns, and amputations) and providing potential solutions for ergonomics problems.

   Implementation Team Members

   OSHA:

   Brett Besser

   Salt Lake Technical Center (SLTC)

   Cathy Cronin

   Office of Training and Education (OTE)

   Bob Curtis

   SLTC

   John Hermanson

   Region V

   Chuck Lorish

   Michigan OSHA

   Lisa Ramber

   Office of Outreach Services and Alliances

   Tom Ripberger

   Indiana OSHA

   Doug Simon

   OTE

   Jack Standard

   OTE

   Jim Washam

   Region V, Cincinnati Area Office

   SPI:

   Susan Howe

    

   Suzanne Riney

   Spartech Corporation

   Brian Schell

   Buckell Plastics Company

   Wayne Wilson

   Corporate Director, United Southern Industries, Inc

   Contributors

   Lisa Brown

   SLTC Contractor

   Kym Pond

   SLTC Contractor

   Evaluation Period

   September 19, 2003 - September 18, 2004

2. Implementation Team Meetings

   October 14-16, 2003

   Team meeting

   December 9, 2003

   Team meeting

   February 23-24, 2004

   Team meeting

   May 3, 2004

   Team meeting

   July 15, 2004

   Team meeting

3. Results

   1. Events and Products

      Training and Education Goal

      • Develop and deliver training addressing machine safety, to be delivered in conferences, meetings, OSHA Training Institute (OTI) Ed Centers, and through distance learning.

      Events

      Injection Molding Machine Safety Training Course, November 18, 2003, OSHA Training Institute, Sinclair Community College, Dayton, Ohio

      The OSHA/SPI Alliance presented the course entitled "Injection Molding Machine Safety Training Course." This course was taught by Jim Washam, Machine Guarding Coordinator, Cincinnati, Ohio Area Office and Wayne Wilson of United Southern Industries and focused on the injuries that may occur in the plastics processing industry, in particular amputations. Course participants received a package of training materials, including PowerPoint presentations and other resource materials so they can then deliver the course at their own workplaces.

      Rollstock and Sheet Extrusion Machine Safety Training Course, April 28, 2004, Doubletree Hotel & Conference Center, Chesterfield, Missouri

      Presented by Jim Washam, Region V, OSHA-DOL and Wayne Wilson, United Southern Industries, Inc. During this train-the-trainer course, over 40 participants from the plastics industry and OSHA's Region IV St. Louis and Kansas City Areas Offices and Michigan OSHA learned about the types of injuries that may occur in the rollstock and sheet extrusion process, discussed the possible causes of the injuries and identified possible ways for employees to protect themselves by recognizing the hazards. In addition, the group discussed requirements for guarding machines and implementing solutions for identified problems.

      Roll-Fed and Inline Thermoforming Machine Safety Training Course, July 16, 2004, Placon Corporation, Madison, Wisconsin

      More than 40 safety and health professionals and OSHA staff from Region V, including Federal, State Plan State and Consultation Program representatives, attended the Roll-Fed and Inline Thermoforming Machine Safety Training Course at Placon Corporation in Madison, Wisconsin. During the workshop, the attendees heard from Jim Washam, Region V, OSHA-DOL and Wayne Wilson, United Southern Industries, Inc. who discussed the types of injuries that may occur in plastic roll-fed and inline thermoforming manufacturing, the possible causes of the injuries and identified possible ways for employees to protect themselves by recognizing the hazards. In addition, the group discussed requirements for guarding machines and implementing solutions for identified problems.

      Products

      Rollstock and Sheet Extrusion Machine Safety Training Course
      Roll-Fed and Inline Thermoforming Machine Safety Training Course

      The OSHA and SPI Alliance implementation team developed the Rollstock and Sheet Extrusion Machine Safety Training Course and the Roll-Fed and Inline Thermoforming Machine Safety Training Course. Both courses have modules on machine guarding and lock-out/tag-out and identify the types of injuries that can occur while operating the machines and ways to avoid those injuries. (See above for details on the course offerings.)

      Outreach and Communication Goals

      • Speak, exhibit, or appear at SPI conferences, including Plastics USA 2004, local meetings, or other industry events.

      Events

      SPI Sheet Producers Division, Spring Technical Conference, April 27 - 28, 2004, Doubletree Hotel & Conference Center, Chesterfield, Missouri

      Susan Howe, Senior Technical Director for Worker and Product Safety at SPI presented "OSHA/SPI Alliance Overview" and shared details of the Alliance between SPI and OSHA with more than 60 representatives from the plastics industry who produce plastic resins, manufacture sheet and/or roll stock, or manufacture machinery for use in the extrusion of plastic material.

      2004 OSHA Compliance Assistance Training Sessions, June 15-16, 2004, Falls Church, Virginia

      Susan Howe, Senior Technical Director, Worker and Product Safety, SPI, was a workshop speaker on June 15-16, 2004 during the 2004 OSHA Compliance Assistance Training Sessions in Falls Church, Virginia. During the workshop titled, "Writing a Successful Alliance Agreement," Ms. Howe shared OSHA and SPI Alliance success stories and best practices. SPI also had an exhibit at the 2004 OSHA Compliance Assistance Training Sessions.

      • Develop and disseminate information through print and electronic media, including electronic assistance tools and links from OSHA's and SPI's Web sites.

      Products

      OSHA Assistance for the Plastics Industry, OSHA Safety and Health Topics Page

      The OSHA and SPI Implementation team reviewed and shared comments with OSHA's SLTC regarding the content of OSHA's Safety and Health Topics page; OSHA Assistance for the Plastics Industry. The following OSHA staff and SPI members and staff are members of the page's editorial board:

      • Susan R. Howe, SPI
      • Loren Mills, Demag Plastics Group
      • Bob Monteith, Milacron Inc.
      • Lisa Ramber, OSHA
      • James Washam, OSHA, Region V, Cincinnati Area Office

      • Wayne Wilson, United Southern Industries

      OSHA and SPI, Alliance Web Site

      OSHA developed an OSHA and SPI Alliance Web site on the Agency's Web page that includes the OSHA and SPI Alliance agreement, renewal agreement, news releases, and milestones and successes. This Web site is kept up-to-date on a regular basis.

      SPI Web Site

      SPI's Web site has a Worker Health and Safety section that includes information on the Alliance and its accomplishments and the training tools and electronic assistance products developed by the Alliance.

      Publications and Newsletters

      Information and news releases on the OSHA and SPI Alliance signing and the activities of the Alliance have appeared in a number of publications produced by OSHA. In addition, information on the OSHA and SPI Alliance has been published in a number of safety and health publications. Please see the chart in this report under "Alliance Program Reach" for additional information.

      • Work with other Alliance participants on projects on ergonomics that are addressed and developed through the Alliance Program.

        The OSHA and SPI Alliance continues to look for and evaluate opportunities to work with other Alliance participants to address ergonomics.

      • Promote and encourage SPI members' participation in OSHA's cooperative programs such as compliance assistance, the Voluntary Protection Programs, and Consultation and its the Safety and Health Achievement Recognition Program, and Consultation.

      SPI Occupational Health and Environmental Issues Committee, Washington, DC, October 22, 2003

      Dr. John Engler, Pennsylvania Consultation, spoke to twenty-five members of SPI's Occupational Health and Environmental Issues Committee on October 22, 2003 in Washington, DC. SPI also distributed Dr. Engler's presentation to a number of SPI's members and wrote an article for SPI Link that was sent to 8,000 people.

   2. Executive Summary

      During the Alliance's last year OSHA and SPI continued their excellent working relationship that was established when the Alliance was originally signed in 2002. Both organizations' commitment to work on compliance assistance projects and programs through the Alliance Program was demonstrated with the signing of the Alliance renewal agreement on March 4, 2004.

      The OSHA and SPI Alliance continued its efforts to reduce injuries in the plastics industry and developed additional training courses that address lock-out/tag-out and machine guarding issues for extrusion and thermoforming machinery. The Alliance also held training courses, using the materials it developed, for plastics industry employers and staff from OSHA's National, Regional and Area Offices, and State Plan State and Consultation Programs.

      OSHA and SPI also promoted the Alliance and the products it has developed to a number of audiences at conferences and meetings through workshops and panel presentations, including the SPI Sheet Producers Division, Spring Technical Conference, April 27 - 28, 2004 in Chesterfield, Missouri and the 2004 OSHA Compliance Assistance Training Sessions, June 15-16, 2004 in Falls Church, Virginia. In addition, SPI and OSHA experts are using their expertise to review and provide ongoing comments on the OSHA Assistance for the Plastics Industry Safety and Health Topics page.

   3. Alliance Program Reach

      Type of Activity (Conference, Training, Print and Electronic Distribution, etc.)	Number of Individuals Reached or Trained
      October 22, 2003 , OSHA Consultation Program, SPI's Occupational Health and Environmental Issues Committee, Washington, DC Speaker: Dr. John Engler, Pennsylvania Consultation	25
      November 18, 2003, Machine Safety for Injection Molding Machines, OSHA Training Institute, Sinclair Community College, Dayton, Ohio Speakers: Jim Washam, Region V, OSHA-DOL Wayne Wilson, United Southern Industries, Inc.	40
      March 4, 2004, OSHA, Society of the Plastics Industry Renew Alliance, Focus continues on reducing amputations, ergonomic hazards, OSHA News Release	25 News Services
      March 4, 2004, SPI/OSHA Renew Strategic Alliance, Partnership Will Continue to Foster Safer, More Healthful Workplaces, SPI News Release	8,000
      March 4, 2004, OSHA, Society of the Plastics Industry Renew Alliance; Focus Continues on Reducing Amputations, Ergonomic Hazards, www.usnewswire.com	25,000
      March 15, 2004, Society of Plastics Industry Renews Alliance with OSHA, QuickTakes	50,000
      March 19, 2004, OSHA Renews Plastics Alliance, BNA Occupational Safety and Health Reporter	25,000
      April 27, 2004, SPI Sheet Producers Division, Spring Technical Conference, Doubletree Hotel & Conference Center, Chesterfield, Missouri Speaker: Susan Howe, Senior Technical Director for Worker and Product Safety, SPI	100
      April 28, 2004, OSHA/SPI Machine Safety Extrusion Class, Doubletree Hotel & Conference Center, Chesterfield, Missouri Speakers: Jim Washam, Region V, OSHA-DOL Wayne Wilson, United Southern Industries, Inc.	40
      June 15-16, 2004, 2004 OSHA Compliance Assistance Training Sessions, Falls Church, Virginia Speaker: Susan Howe, Senior Technical Director, Worker and Product Safety, SPI	30
      June 15-16, 2004, 2004 OSHA Compliance Assistance Training Sessions, Falls Church, Virginia SPI Exhibited	200
      July 16, 2004, OSHA/SPI Machine Safety for Plastic Roll-Fed and Inline Thermoforming Class, Placon Corporation, Madison, WI Speakers: Jim Washam, Region V, OSHA-DOL Wayne Wilson, United Southern Industries, Inc.	40
      OSHA Assistance for the Plastics Industry, OSHA Safety and Health Topics Page	18,000
      Machine Guarding eTool, Horizontal Injection Molding Machines Module	40,000
      OSHA and SPI Alliance Web page on OSHA's Web site	3,600
      SPI Alliance Web page on SPI's Web site	Data No Available
      TOTAL	154,075

4. Upcoming Milestones

   OSHA and SPI will continue its training and outreach efforts and development of compliance assistance tools and resources. For example, OSHA will be part of the SPI exhibit booth during Plastics USA 2004, September 28-30, 2004 in Chicago, Illinois. Members of the OSHA and SPI Alliance implementation team will distribute OSHA safety and health information. In addition, the Alliance plans on developing and distributing a CD during the conference with the Alliance-developed train-the-trainer courses and the OSHA Assistance for the Plastics Industry Safety and Health Topics page.

   The implementation team plans to develop a thermoforming machinery module for OSHA's Machine guarding eTool, using the Roll-Fed and Inline Thermoforming Machine Safety Training Course as the basis for the module. The tool will address thermoforming machinery hazard areas and possible solutions to the hazards and include a 360-degree tour of a thermoforming machine.

   In addition, a number of opportunities for presenting the machine safety train-the-trainer courses will be explored in the upcoming year, including presenting the course in OSHA's Region I, Region II, California (a State Plan State) or the southern region of the United States. The OSHA and SPI Alliance will also be working on the development of a 10-hour OSHA course for the plastics industry.

Report prepared by: Lisa Ramber, OSHA and SPI Alliance Coordinator, December 12, 2004