Abstract: Early in the morning of November 18, 1999, Employee #1, a 19-year-old temporary worker, was on the graveyard shift as a parts washer at Textron Aerospace. At the start of the shift, his supervisor told him to add caustic soda to dip tank #1, which contained heated, 150 to 160 degrees F, aqueous sodium hydroxide, to adjust the liquid pH into the range between 11and 12. He weighed out approximately 49 lb of solid sodium hydroxide into a plastic container and then manually poured it directly into the tank. A chemical reaction occurred, and Employee #1's chest, face, and eyes were splashed with chemicals. Coworkers immediately helped him to flush himself with water from a nearby chemical safety shower and eye wash, and then he was transported to a local hospital for medial treatment. Employee #1 sustained chemical burns over approximately 15 percent of his body. Subsequent investigation revealed that he had been involved in a similar incident two months earlier that had not resulted in injury. Textron Aerospace had provided him with additional training to supplement previous training on the proper method and precautions of adding caustic soda to the tank. These precautions and procedures included remotely adding the caustic soda using a conveyor system, something he did not follow in either instance. The cause of this accident appears to be Employee #1 failing to follow proper procedures. The employer was cited for an accident-related violation for failing to ensure that proper body protection was worn.