Mr. John Smith, the plant manager for Acme Automotive Parts (AAP    

Answer

Occupational Safety and Health Final Report

1.0 Introduction 

AAP is a manufacturer of support parts for new automobiles and serves as a small supplier to Nissan, Honda, and Volkswagen facilities in the United States. The plant consists of 8 sections from which their processes are performed. These include shipping/receiving, hydraulic presses, metal working lines, robotic welding stations, hand-welding stations in rework areas, two small paint booths, a quality assurance/quality control (QA/QC) laboratory, and a final inspection area. Industrial hygiene sampling is performed to demarcate the level of exposure on a full shift – typically 8 hours or less – of air sample (Paik & Zalk, 2019).

2.0 Hazard Assessment

This section identifies six health hazards identified each area at the facility and are subsequently tabulated:

3.0 Sampling Plan

This section covers four hazards for which sampling was done:

Manganese Fume

Personal sampling method was used for the Manganese Fumes. A personal sample was collected and analyzed for three parameters, namely, concentration, flow rate, and minimum sample time (Hulo et al., 2014). The concentration of the fumes was measured using an electrochemical sensor, while flow rate, and sample time were determined using the rotameter.

Toluene (Paint)

Using coconut charcoal adsorbent tube media and toluene for calibration of sampling train, the minimum sample time for Toluene was calculated. The area sampling method was used by dividing the exposure area into small sub-areas from which small portions of the as is collected for analysis (Esmaelnejad et al., 2015).

Metal Working Fluids

.           Thoracic particulate, a type of representative fraction of inhaled particles was. Ternary solvent was used as sampling media and the sample train was calibrated using the National Institute of Standards and Technology Class S-1.1 weights. A personal sampling method was also executed as sample collection tools were obtained from individuals.

Noise Exposures

A personal sampling method was used to evaluate noise levels in the facility.  Using the dosimeter- calibrated sampling train, noise samples were obtained in strategic places specifically adjacent to the grinding and welding areas.

4.0 Sample Results

This section presents sampling results for each of 7 hazards. Subsequently, he sampling location, the sampled employee, duration of sampling, and results are tabulated as shown:

Table 2

hydraulic press, metalworking line, robotic welding, and paint booth

5.0 Evaluation of Sample Results

From the tabulated results, only copper fumes obtained from calculations as 0.1344mg/m3 concentration, exceeds the set Occupational Safety Health Association permissible limit (OSHA PEL) of 0.1 mg/m3 TWA. Inferentially, potential hand welding locations such as the hydraulic press, metalworking line, robotic welding, and paint booth have the greatest risk of copper fume exposure. However, hazards from manganese fume, 1, 2, 4 Trimethylbenzene, Lead fume, Toluene, metal working fluid, xylene are well below OSHA PEL limits as shown in the table. It also means that locations such as shipping and receiving, QA/QC laboratory and final inspection are all within the OSHA PEL recommended range.

However, when perceived in terms of the recommended OSHA action level of 8 hours, it is observed that activities at the hydraulic press, metalworking line, robotic welding, and paint booth all last 12 hours. By inference the preceding activities have high concentrations are considered to be more than the OSHA permitted action level of 8 hours (US Department of Labor, 2020). Such a period, as well as the results that emanated from such periods, are over OSHA action level.

6.0 Recommendations

Assessment of Hazards at AAP confirms the presence of risk in all stages of operation. As such at a basic level, the firm can implement measures to control hazards. Some recommendations are subsequently tabulated:

• The firm should ensure that workers are adequately trained operation of mechanical load shifting devices such as cranes, hoists, hand trucks and forklifts) can avoid awkward loads.
• The firm should also provide personal protective equipment (PPE) and grinders. Similar equipment should have guarding of machinery guidelines such as Barrier guards, two-hand tripping devices and electronic safety devices. Additionally PPEs should guarantee safety during grinding, machining, sanding, and riveting by providing safety goggles spectacles fitted with side shields. Face shields should also be provided to shield against splashing of liquefied metal (Automotive Respirators and Safety Products, 2020). Welders should also be provided with helmets, preferably fitted with lift-front window, to provide cover from liquid metal splashes and possible burns. For particulate and chemical protection, particularly during grinding and welding operation should be fitted with exhalation valve on respirators (Automotive Respirators and Safety Products, 2020).

• The firm should also implement a strict rotation policy that ensures that employees do not engage in monotonous tasks for extended durations. The firm should also institute internal mechanism for continuous risk-assessments and pre-operational assessments. Additionally, the firm should ensure that Lockout-Tag out(LOGO) procedures are executed carefully particularly during routine maintenance of machines.
• Finally, evacuation drills in preparation for fire outbreaks should be conducted at least twice monthly.

7.0 Future Needs

Success of the IH sampling approach will invariably depend on preparations undertaken prior to the sampling process. Accordingly a study by Day, Boss, Miller and Wrenn (2016) recommends a three-step process for improvement to the sampling process. First, the firm should conduct a “walk-through investigation” focusing on present state of the buildings, open spaces, and machining areas. Secondly, improvements to the sampling process should be instigated. These changes should be targeted at individuals such as customers and visitors so as to obtain a wider perspective of the risks involved. Finally, interviews focused on employees should be conducted to gather their experiences with regard to internal work spaces and buildings (Day, Boss, Miller and Wrenn, 2016).