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ALLIANCE ANNUAL REPORT

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

I. 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
Cathy Cronin
Bob Curtis
John Hermanson
Chuck Lorish
Lisa Ramber
Tom Ripberger
Doug Simon
Jack Standard
Jim Washam
Salt Lake Technical Center (SLTC)
Office of Training and Education (OTE)
SLTC
Region V
Michigan OSHA
Office of Outreach Services and Alliances
Indiana OSHA
OTE
OTE
Region V, Cincinnati Area Office
   
SPI:  
   
Susan Howe
Suzanne Riney
Brian Schell
Wayne Wilson

Spartech Corporation
Buckell Plastics Company
Corporate Director, United Southern Industries, Inc
   
Contributors  
   
Lisa Brown
Kym Pond
SLTC Contractor
SLTC Contractor

Evaluation Period

September 19, 2003 - September 18, 2004

II. Implementation Team Meetings

 
October 14-16, 2003
December 9, 2003
February 23-24, 2004
May 3, 2004
July 15, 2004
Team meeting
Team meeting
Team meeting
Team meeting
Team meeting

III. 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

IV. 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