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  • Food Manufacturing Industry

    Safety and Health Management Program

    Occupational Safety and Health Division

    N.C. Department of Labor

    1101 Mail Service Center

    Raleigh, NC 27699-1101

    Cherie Berry

    Commissioner of Labor

    �������� ��� ������ ��

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    104

  • N.C. Department of Labor

    Occupational Safety and Health Program

    Cherie Berry

    Commissioner of Labor

    OSHA State Plan Designee

    Allen McNeely

    Deputy Commissioner for Safety and Health

    Kevin Beauregard

    Assistant Deputy Commissioner for Safety and Health

    Wanda Lagoe

    Author

    This guide is in a series of industry guides focused on the Special Emphasis Programs. It is intended to be consistent

    with all existing OSHA standards; therefore, if an area is considered by the reader to be inconsistent with a standard,

    then the OSHA standard should be followed.

    To obtain additional copies of this guide, or if you have questions about North Carolina occupational safety and health

    standards or rules, please contact:

    N.C. Department of Labor

    Education, Training and Technical Assistance Bureau

    1101 Mail Service Center

    Raleigh, NC 27699-1101

    Phone: 919-807-2875 or 1-800-625-2267

    ____________________

    Additional sources of information are listed on the inside back cover of this guide.

    ____________________

    The projected cost of the NCDOL OSH program for federal fiscal year 2011–2012 is $17,841,216. Federal funding pro vides approximately 31 percent ($5,501,500) of this total.

    Original 03/2012

  • Table of Contents Foreword and Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11v

    Special Emphasis Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i1vi

    Section 1: Safety and Health Program Management . . . . . . . . . . . . . . . . . . . . . . .111

    Management Commitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Safety and Health Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 Employee Participation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 Recordkeeping and Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

    l Access to Employee Exposure and Medical Records . . . . . . . . . . . . . .115 Accident/Incident Investigation Policy . . . . . . . . . . . . . . . . . . . . . . . . . . .117

    l Employee’s Incident Report Form . . . . . . . . . . . . . . . . . . . . . . . . . .118 l Supervisor’s Incident Investigation Form . . . . . . . . . . . . . . . . . . . . . .119 l Incident Investigation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

    Safety and Health Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . .114 Hazard Prevention and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 Disciplinary Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Alcohol and Drug Use Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

    Section 2: Safety and Health Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118

    Bloodborne Pathogens, Exposure Control Plan . . . . . . . . . . . . . . . . . . . . . . . . . .119 l Hepatitis B Vaccine Declination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

    Combustible Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 Confined Space Entry Program (Permit Required) . . . . . . . . . . . . . . . . . . . . . . .128

    l Confined Space Entry Permit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 Electrical Safety-Related Work Practices Program . . . . . . . . . . . . . . . . . . . . . . .134

    l Electrical Safety-Related Work Practices Program Self-Audit Checklist . .141 Emergency Action Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142 Ergonomics Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144 Fall Protection Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149 Fire Prevention Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

    l Fire Prevention Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159 l Identified Fire Hazards and Responsible Personnel . . . . . . . . . . . . . . . . . .160 l Fire Extinguisher Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160

    First Aid, CPR and AED Response Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161 Fleet Management and Vehicle Safety Program . . . . . . . . . . . . . . . . . . . . . . . . .162 Forklift Safety Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167

    l Forklift Inspection Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172 Hand and Powered Tools Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176 Hazard Communication Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181 Hearing Conservation Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183

    l Notification of “Quiet Period” Prior to Baseline Hearing Test . . . . . . . . . .189 Hexavalent Chromium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190 Hot Work Permit Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191

    l Hot Work Permit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192 Housekeeping Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193 Ladder Safety Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195 Lockout/Tagout Program (Control of Hazardous Energy) . . . . . . . . . . . . . . . . .196

    l Types/Locations of Energy-Isolating Devices . . . . . . . . . . . . . . . . . . . . . . .197 l LOTO Training Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

    iii

  • Machine Guarding Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 l Machines and Machine Guarding Inspection Form . . . . . . . . . . . . . . . . . . .106

    Personal Protective Equipment Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 l PPE Hazard Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

    Process Safety Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 l Notification of Process Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

    Respiratory Protection Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 l Appendix C—Medical Questionnaire (Mandatory) . . . . . . . . . . . . . . . . . .125 l Appendix D—Voluntary Use—Filtering Facepieces . . . . . . . . . . . . . . . . .130

    Walking and Working Surfaces Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131

    Section 3: Training and Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135

    Employee Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 Job Progression Training and Skills Assessment . . . . . . . . . . . . . . . . . . . . .138 Periodic Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 Employee Training Roster/Certificate of Training . . . . . . . . . . . . . . . . . . .141 Management Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142 Supervisor Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

    Section 4: Reference Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144

    N.C. Department of Labor, Occupational Safety and Health Division . . . . . . .144 Federal Occupational Safety and Health Administration . . . . . . . . . . . . . . .144

    Section 5: Facility Inspection Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145

    l Comprehensive Safety Inspection Form . . . . . . . . . . . . . . . . . . . . . . .146 l Monthly Inspection Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170

    iv

  • Foreword In North Carolina, the N.C. Department of Labor enforces the federal Occupational Safety and Health Act through

    a state plan approved by the U.S. Department of Labor. NCDOL offers many educational programs to the public and

    produces publications to help inform people about their rights and responsibilities regarding occupational safety and

    health.

    When reading this guide, please remember the mission of the N.C. Department of Labor is greater than just regula-

    tory enforcement. An equally important goal is to help citizens find ways to create safe workplaces. Everyone profits

    when managers and employees work together for safety. This booklet, like the other educational materials produc

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