Ioe/mfg 539 safety engineering methods


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IOE/MFG 539 -- SAFETY ENGINEERING METHODS

COURSE SYLLABUS (Vers. 1.0) -- FALL 2016
Instructor -- W. Monroe Keyserling, Ph.D.


Date

Topic(s)

Reading(s)










Sep. 6

Introduction to Course

ILO - Andreoni,

Adams (scan),
NSC – 1 (Note: All NSC readings are optional)

Sep. 8

Case Presentation: “A Confined Space Fatality”
HW #1 Due

North Carolina Guide,
ILO – McManus (scan)

Sep. 13

Confined Spaces, OSHA Confined Spaces Standard
HW #2 Due

OSHA Compliance Summary,
CSB Video (watch)

Sep. 15

Confined Spaces (wrap-up),
Electrical Safety

ILO – Folliot,
WMK Notes,
NIOSH 1998 (scan),
NSC – 8 (scan pp 221-228)

Sep. 20

Electrical Safety, cont’d.

ILO – Menguy (skim)

Sep. 22

Electrical Safety, cont’d.




Sep. 27

Fire Safety: Flammable Liquids

ILO – Banky (scan)

ILO – Drysdale (skim)

NFPA Ordile (skim)
ILO – Johnson (scan),

ILO – Taylor,

Artim Readings (scan),
Hayden, 2004,
NSC – 10 (scan)

Sep. 29

Fire Prevention and Protection, Halons




Oct. 4

Building Design and Life Safety


ILO – Anderberg (scan),
Lathrop 1997 (scan)

Oct. 6

EXAM I (coverage T.B.A.)




Oct. 11

Misc. Fire Topics (wrap up),




Oct. 13

Machine Guarding, Gen. Principles

ILO – OSHA-Gerecke,
ILO – Backstrom and Dos,
Sorock, et al. 2001,
OSHA e-tool (scan),
North Carolina (skim)
NSC - 6, 20 (scan)

Oct. 18

NO CLASS: FALL RECESS




Oct. 20

Machine Guarding, Metal Forming

OSHA e-tool,
NIOSH Bulletin (skim)
NSC -21 (scan pp. 621-649)




Oct. 25

Machine Guarding, Metal Cutting

ILO – Retsch (scan),
ILO – Welinder (scan),

Ndana

Oct. 27

Machine Guarding, Robots, AGVs and wrap-up

ILO – Marty, et al. “Robots”,

ILO – Schreiber,

Murashov, et. al.,

New York Times

ILO – Marty, et al. “CNC”) (scan),
NSC – 22 (scan)

Nov. 1

Energy Control: Power Lock-out and Tag-out

OSHA Manual (skim),
Mutawe, et al., 2002,
NIOSH 1999,
OSHA e-tool (ref)

Nov. 3

Introduction to Systems Safety,
Failure Modes & Effects Analysis
*** Assignment of Course Project ***

Univ. of Leeds (scan),
WMK Qualitative Rankings,
U.S. Army Qualitative Rankings
Coast Guard FEMA (Chap. 9)

Nov. 8

EXAM II (coverage T.B.A.)




Nov. 10

Job Safety Analysis
Case Study: Power Press

OSHA (ref),
JSA Template

Nov. 15

Fault Tree Analysis, Process Safety
*** Project Proposal Due ***

Coast Guard FTA (Chap. 11)
Weibull.com

Nov. 17

Walking and Working Surfaces

Lehtola, et al., 2009,
NIOSH, 2010,

Brit. Health & Safety Exec.,
LeClercq, 1999, (skim)
OSHA Slips e-tool,

Nov. 22

Control of Slip/Fall Hazards

ILO – Arteau (scan),
OSHA: Stairs/Ladders (scan),

OSHA e-tool,

Keyserling, et al. 1999(scan),
ATL report (REF)

Nov. 24

NO CLASS – THANKSGIVING BREAK





Nov. 29

Pressure Vessels and Material Testing

Brit.Health & Safety Exec.
ILO: Mathisen, et al. (scan),

Dixson, 2001,
ILO – Kindwall (scan),

NSC -5 (scan)

Dec. 1

Accident Modeling/Investigation





Stromgren, et al. 2015,
OSHA 300 series forms

Kjellan and Larsson (scan)

Dec. 6

Accident Modeling/Investigation, cont’d.




Dec. 8

EXAM III (coverage T.B.A.)




Dec. 13

Oral Presentations of Term Project




Dec. 14

Wednesday -- Written Projects due at 5:00 P.M.





GENERAL INFORMATION



WEB PAGE:

Canvas: IOE 539 Fall 2016







CLASS MEETS:

Tuesday/Thursday 1:30--3:00, Room 1680 IOE







GRADING:

Exam I

20%

Exam II

30%

Exam III

30%

Project

20%

Oral Presentation

Up to 2 points added to final grade







INSTRUCTOR:

W. Monroe Keyserling, Ph.D.
IOE Building, Rm. G620







Office Hours:

Tuesday and Thursday: 3:00 – 4:00 PM
Also by appointment













E-MAIL:

wmkeyser@umich.edu













TEXTS:

ILO (required):

International Labor Organization: ILO Encyclopaedia of Occupational Health and Safety (5th edition), Geneva: International Labor Organization, 2011.

Available online at:

http://www.iloencyclopaedia.org/

NSC (optional):

National Safety Council: Accident Prevention Manual for Industrial Operations, Engineering and Technology Aspects (14th edition), Chicago: The National Safety Council, 2015.


(Note: This is a good desk reference for anyone with professional OSH responsibilities. The 14th edition was just released, July 2015.)

HONOR CODE ISSUES AND POLICIES

GENERAL:

All students, regardless of their home department or degree program, are required to follow the Engineering Honor Code. Suspected violations will be investigated by the Engineering Honor Council.

HOMEWORK AND TERM PROJECT:

Homework #1 (Biosketch): Discussion with other students is permitted, but is unlikely to help complete the assignment.

Homework #2 (Power Plant Case Study): This is an individual assignment equivalent to an examination. Discussion with other students is NOT permitted.

Homework #3 (Circuit): This is a voluntary homework and the answer is posted on the course web site. Students are encouraged to work together and to compare their answers to the posted solution.

Term Project: This is a team assignment equivalent to an examination. Discussion with students other than members of your own team is NOT permitted. Discussions with the instructor are permitted.

EXAMINATIONS:

Availability of Old Exams: Copies of old examinations are posted on the course web site. Students are encouraged to use old exams as a study guide and to work together in study groups well ahead of scheduled exams. Answers to old exam questions are NOT posted on the web site. Instead, study groups are encouraged to compare answers and to debate the approaches used to solve problems.

Taking the Exam: Examinations are “open book, open notes.” Students are allowed to bring textbooks, course packs, lecture outlines, lecture notes and other reference materials to all examinations. Students are not permitted to utilize any outside resources during the exam, including any type of wireless communication.

Students must sit in alternate seating during the examination. Once the exam has started, no discussions or exchange of information of any type is permitted among students or with anyone outside the classroom (except for the instructor). If necessary, students may ask the instructor to explain or clarify a question. At the end of the exam, each student must sign the Honor Code statement.

Early/Late Exams: Students are expected to take the exam at the scheduled time. Under extraordinary circumstances, an exam may be give early or late. Sharing of information among students taking the exam at different times is considered non-authorized collaboration. Any student who either gives or receives information regarding exam content will be reported to the Engineering Honor Council.

After the Exam -- Appeals and Re-grades: There will be a brief in-class review and discussion of exam questions and answers on the day that the exam is returned. Students who discover scoring errors or disagree with the grading of any question may file a written appeal. This appeal, along with the original examination must be submitted within two weeks of the in-class review. Students are bound by the Honor Code during the appeal process. Specifically, students may not alter any answer on the original examination. A small number of examinations will be randomly selected for photocopying before they are returned to students. If exam alteration is discovered during the appeal process, the violation will be reported to the Engineering Honor Council.

Frivolous Appeals: Students are discouraged from filing frivolous appeals strictly for the purpose of trying to gain extra points. While students are strongly encouraged to challenge scoring errors or grading outcomes that they disagree with, excessive use of the appeal process may result in an oral examination on all appealed questions. Performance on the oral exam may result in points either being added to or subtracted from the original grade. Students have the option of declining an oral exam by retracting their entire appeal.

MISCELLANEOUS ISSUES AND POLICIES
Class Start Time: Class begins promptly at 1:40 PM. Students are expected to arrive on time. If you must be late, please get to your seat as quietly as possible.
Mobile Phones: Please put your phone into “silent” or “vibrate” mode. If your phone rings audibly in class, you will be asked to leave the lecture room and will not be permitted to return for the balance of the class period.

READINGS
Note: All readings available on Canvas, unless otherwise noted.
Adams, P. – “Establishing a Safe Design Process,” Professional Safety, November, 1999, 29-32.
North Carolina Dept. of Labor -- A Guide to Safety in Confined Spaces, Raleigh, NC: NCDOL, 2008.
OSHA Compliance Summary (https://www.osha.gov/Publications/osha3138.pdf)
NIOSH 1998 – Worker Deaths by Electrocution: A Summary of NIOSH Surveillance and Investigative Findings, U.S. Department of Health and Human Services, NIOSH Publication Number 98-131, Cincinnati, OH: National Institute for Occupational Safety and Health, May 1998.
Ordile, Anthony M. -- “Storage of Flammable and Combustible Liquids,” Section 6, Chapter 21 in Fire Protection Handbook (19th edition), pp. 6:297-314, Quincy: MA: National Fire Protection Association, 2002.
Artim, Nick. – “An Introduction to Automatic Fire Sprinklers, Part I,” WAAC Newsletter, Volume 16, Issue 3, September 1994.
Artim, Nick. – “An Introduction to Automatic Fire Sprinklers, Part II,” WAAC Newsletter, Volume 17, Issue 2, May 1995.
Puchovsky, M.T. – “Automated Sprinkler Systems,” Section 10, Chapter 11 in Fire Protection Handbook (19th edition), pp. 10:185-211, Quincy: MA: National Fire Protection Association, 2002.
Hayden, Donald K. – “Secondary Dust Explosions: Lessons from the plastics processing industry, Professional Safety, pp. 27-30, November, 2004.
Lathrop, James K. -- “Concepts of Egress Design,” Section 4, Chapter 3, in Fire Protection Handbook (19th edition), pp. 4:57-82, Quincy: MA: National Fire Protection Association, 2002.
Sorock, G.S., Lombardi, D.A., Hauser, R.G., Eisen, E.A., Herrick, R.F., and Mittleman, M.A. -- “A Case-Crossover Study of Occupational Traumatic Hand Injury: Methods and Initial Findings,” Am. J. Ind. Med., pp. 39:171-179, 2001.
OSHA e-tool “Introduction to Machine Guarding,” (http://www.osha.gov/SLTC/etools/machineguarding/intro.html)

North Carolina Department of Labor – “A Guide to Machine Safeguarding, Raleigh, NC: NCDOL, Division of Occupational Safety and Health, 2001.
OSHA e-tool – “Presses.” (http://www.osha.gov/SLTC/etools/machineguarding/presses/mechanical.html)
NIOSH – “Injuries and Amputations Resulting from Work with Mechanical Power Presses, Intelligence Bulletin #49, May 1987.
Ndana, J. “Working Safely with Grinders – 10 Proven Best Practices,” Professional Safety, pp. 27-30, November, 2004. pp. 26-29, November 2015.
Murashov, V., Hearl, F., and Howard, J. “Working Safely with Robot Workers: Recommendations for the New Workplace, Journal of Occupational and Environmental Hygiene, 13:D61-71, 2016.
OSHA. – “Control of Hazardous Energy: Lockout/Tagout (revised),” Publication No. 3120, 2002 (INTERNET)
Mutawe, A.M., Tsunehara, R., and Glaspey, L.A., – OSHA’s Lockout/Tagout Standards: A Review of Key Requirements, Professional Safety, February, 2002, 20-24.
NIOSH 1999 – Preventing Worker Deaths from Uncontrolled Release of Electrical, Mechanical, and Other Types of Hazardous Energy, U.S. Department of Health and Human Services, NIOSH Publication Number 99-110, Cincinnati, OH: National Institute for Occupational Safety and Health, July 1999. (INTERNET, 15 pages in PDF format)
OSHA e-tool – “Lockout/Tagout Interactive Training Program.” (http://www.osha.gov/dts/osta/lototraining/index.htm)
University of Leeds, Risk Assessment Guidance (INTERNET)
Geronsin, R. – “Job Hazard Assessment: A Comprehensive Approach, Professional Safety, Dec. 2001, 23-30.
University of Leeds: Faculty of Engineering – Guidelines for Risk Assessment (INTERNET)
Nomogen, Ltd. – “Failure Modes and Effects Analysis: Methodology” (INTERNET)
OSHA. – “Job Hazard Analysis (revised),” Publication No. 3071, 2002
Lehtola, C.J. et al. – “Preventing Injuries from Slips, Trips, and Falls,” University of Florida Extension Service, Circular 869, 2001
OSHA e-tool – “Slips, Trips, and Falls” (http://www.osha.gov/SLTC/etools/hospital/hazards/slips/slips.html)
LeClercq, S. – “The Prevention of Slipping Accidents: A Review and Discussion of Work Related to the Methodology of Measuring Slip Resistance,” Safety Science, 31:95-125, 1999.
OSHA. – “Stairways and Ladders: A Guide to OSHA Rules,” Report 3124-12R, 2003.
OSHA e-tool – “Ladder Safety.” (http://www.osha.gov/SLTC/etools/construction/falls/4ladders.html)
Keyserling, W.M., Monroe, K.A., Woolley, C.B. and Ulin, S.S. – “Ergonomic Considerations in Trucking Delivery Operations: An Evaluation of Hand Trucks and Ramps,” Am Ind. Hyg. Assoc. J., 60:22-31, 1999. (INTERNET, 10 pages in PDF format)
ATL: Advanced Technologies and Laboratories International. – “Current Status and Knowledge Gaps of Fall Protection Technologies/Research for Falls from Ladders,” 2003.
Dixson, D.P. “Compressed Gases and Systems,” Professional Safety, Nov. 2001, 29-34.
Stromgren, M., Bergvist, A., Andersson, R., Harms-Ringdahl, L. “A Process-Oriented Evaluation of Nine Accident Investigation Methods,” Safety Science Monitor, 19 (1):1-14; 2015.
OPTIONAL COURSEPACK: Lecture notes
You have the option of downloading outlines for each lecture from the C-tools site. These outlines are very old and do not always match the content of the Power Point slides. A few students in last year’s class said that the outlines were useful, so I’m making them available. However, I would classify these materials as “unsupported.”
Lecture Outlines:


Confined Spaces

Electrical Safety

Fire Safety

Halon Alternatives

Machine Guarding

Robot Safety

Power Lock Out

Systems Safety Analysis

Failure Modes and Effects Analysis (FMEA)

Qualitative Ranking of Probability and Seriousness

Job Safety Analysis (JSA)

Fault Tree Analysis and Cut Sets

Working Surfaces/Slips and Falls

Pressure Vessels

Accident Investigation



9/3/15


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