Establishing a Safety Culture

I have been reading the many recent threads on safety but have been too busy to reply. I finally have a few minutes so here goes. Sorry if this sermon like and too long but I live these issues every day.

First the disclaimer.I am a safety guy. With 35 years experience in engineering, I have spent much of the last ten years managing large field exploration programs and I am often assigned to be the project site safety officer. In business, our focus on safety is primarily on maintaining the well being of our workers but there are financial implications as well. A single incident resulting in even a minor injury or lost time can shut down a large project for extended periods or worse yet get you removed from the project.

One of the lessons I have learned is that thinking and acting safely is a learned skill. The difference in safety attitude between folks that have been on multiple projects with me compared to newcomers is very evident. It is not a question of experience - it is all about accepting safety culture. We have more problems with crusty veterans who are set in their ways (I have been doing it this way for 30 years and never had a problem!) than we do with some less experienced folks. We begin every day with a safety brief and reward ideas and suggestions. After time, most people adopt and endorse the safety culture. Those who do not do not last long on the project.

A few key points from my work life that carry over to turning safely.

1. We must accept the assumption that every injury is preventable. If not, why would we knowingly put ourselves in harms way.
2. In industry, we evaluate each and every activity, identify the steps required, the hazards associated with the actions, and the ways to mitigate that hazards. I do this so often during my work day that it has become second nature in my shop. There is rarely an action I do that I do not think about this process.
3. Use the two minute rule take two minutes before an activity to evaluate the task at hand, the work environment, hazards and PPE. Do it again if things change.
4. Trust your gut. I am often called upon to assist in an investigation of an incident. Almost without fail, when I interview those involved, they say they were uncomfortable with the task prior to the incident but still elected to proceed. If in doubt, stop and re-evaluate!
5. Evaluate all Near Misses as if there were injuries. A near miss that is evaluated can prevent a major injury in the future. A severe catch or an item dismounting from a chuck while turning are good opportunities to stop and evaluate even if there were no major consequences. What can be done to prevent it next time? Accidents Happen is not an acceptable conclusion. In industry we do a root cause analysis. Ask yourself why at least five times to get to a root cause. The answer may surprise you.
6. Use the correct PPE. Some of the statements I have read in this forum against face shields are the same ones I hear about PPE every day on the job. A hard hat is not designed to prevent injury from a 100 pound weight falling from height but that is not a reason not to wear one. There may not be PPE on the market to completely protect us from a heavy blank coming apart at speed but there is equipment that will minimize injury, dissipate energy and protect us well from less severe events. To reject face shields because they give a false sense of security or that they cannot protect from the most sever event, or they are hot or I am standing out of the line of fire or they are bulky or .. is , in my view, dangerous rationalization.
7. I absolutely, 100% agree with the discussion of understanding the Line of Fire. It should be part of the hazard evaluation mentioned above. I have learned from this discussion and have altered my methods. I do not believe however that it mitigates the need for proper PPE. A blank that comes free from a chuck or a platter that comes apart at speed can easily be deflected by a tool, a tool rest, or other obstructions and travel in an unanticipated direction.
8. Finally, I think it is important to recognize and mitigate other hazards associated with turning. In my opinion, wood dust, can be just a s deadly as a dismounted platter. The effects of dust are subtle and therefore easily overlooked but can be cumulative and devastating. There are also potential hand injuries, fumes, fires and a host of others but that is for another day.

My personal bottom line Shortly after I started turning, I evaluated hazards and PPE. I elected to purchase a 3M Airstream based on a conversation with Bill Grumbine (he was wearing one while doing demos in the vendor area at a symposium). I my view, the Airstream provides adequate head, face and lung protection for the turning I was doing. It also cost more than my first lathe. While it was painful to have to spend that kind of money, I made it a priority and have not regretted it for a moment.

Others may make different choices. The important thing is that your choices be based on a sound and reasonable evaluation of what you are doing, the hazards associated with it, and the limitations of the PPE to mitigate the risk. Learn good technique but know that technique alone cannot protect you from the unexpected. PPE is essential. There is no single right answer but if we all embrace a safety culture, set good examples, and do thoughtful evaluations of our processes, we can make a difference.