Safety Management

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 Accident Definition
An "accident" is an unplanned, undesired event which may or may
not result in injury or property damage that interferes with the
completion of an assigned task
An accident at work = a discrete occurrence in the course of work
which leads to physical or mental harm.
This includes cases of acute poisoning and wilful acts of other
persons, as well as accidents occurring during work but off the
company’s premises, even those caused by third parties.

It excludes accidents having only a medical origin and occupational

diseases. The phrase "in the course of work" means whilst
engaged in an occupational activity or during the time spent at
work.
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Heinrich Pyramid

FATALITY

SEVERE

INJURY LTI

RECORDABLE INJURY / ILLNESS

FIRST AID CASES

NEAR MISSES

UNSAFE CONDITIONS

UNSAFE ACT
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 Accident Pyramid
For every:
1 - Major Accident
1

3 There were 3 Lost Time Accidents

30
30 First Aid Accidents

300 300 Near Misses

3,000
And 3,000 “At Risk” Behaviors

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 Injury Classification
• Fatal Injury: This is an injury resulting in death from an
accident or from complications arising from the accident.
• Permanent Total Disability: These are nonfatal
injuries that, in the opinion of competent
medical authority, permanently and totally
incapacitate a person so that he or she cannot follow
any gainful occupation.
• Permanent Partial Disability: Injuries that do not result
in death or permanent total disability, but,
in the opinion of competent medical authority, do
result in permanent impairment or loss of any part of the
body.

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 Injury Classification

• Lost Work Day:

– An injury that does not result in
death, permanent total disability, or permanent
partial disability, but results in 5 or more lost
workdays (not including the day of the injury).
– Lost workday level injuries are further divided into
major and minor categories.
• Major: results in 5 or more lost workdays and requires
admission to a hospital for 5 or more days
• Minor: An injury less than major that results in 1 to 4 lost
workdays.

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 Injury Classification

• First Aid Injury:

– This injury involves bodily harm requiring only
first aid or no treatment.
– Lost workday level injuries are further divided into
major and minor categories.
• Major: results in 5 or more lost workdays and requires
admission to a hospital for 5 or more days
• Minor: An injury less than major that results in 1 to 4 lost
workdays.
• No Injury: A "near miss" is a form of an accident that does not
result in injury or property damage.
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 Traditional classification of Accidents
Mortality Fatal or non fatal
Absence from Accidents with less or more than 3 days’ (at least 4 calendar
work days) absence at work
 Accidents within the premises of the victim’s company
 Accidents occurring outside the premises of the victim’s
Place of company
occurrence  Road traffic accidents in the course of work
 Accidents in a public place in a journey in the course of work
 Commuting accidents (on the way to and from work)

Link to  Accidents linked to occupational activity

occupational
activity  Accidents from strictly natural causes (medical disorders)

Consciousness  Unintended accidents

of involved  Accidents due to wilful acts of other persons
persons  Deliberate self-inflicted injuries
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 Industrial accidents & workplace accidents

Industrial accidents involving

harm to personnel

Industrial accidents
due to failures of engineering systems

Workplace accidents
occurring without system failures

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 Workplace accident

Presence of
Error made by Workplace
active, “armed”
personnel accident
hazard

Immediate
Hot surface (e.g., Worker spills
ignition, worker
electrical heater) flammable liquid
is injured

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 Industrial accident
On-site consequences
Initiation of accident Damage to
personnel

Damage to plant
Escalation of adverse
System failure
events
Damage to public

Damage to
environment
Off-site consequences

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 Example of industrial accident

Failure of electricity
On-site consequences
supply
Intoxication of
workers
Loss of control of
pressure in tank Contamination of
site
Failure to
Increase of pressure contain Intoxication of
in tank toxic gas, general public
release of gas
Contamination of
environment
Off-site consequences

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 Basic Accident Types
• Struck Against: force impact is key factor and
employee has no chance of defending himself
• Fall from above: mostly occurs in construction
side, stairways without railing
• Fall on the same level: slipping because of
untidy floor.
• Caught in under or between objects: Struck in
a collapsing building

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 Basic Accident Types
• Rubbed or abraded: rubbing or abrading by
kneeling or leaning
• Bodily reaction: heat stroke / seizure due to
dehydration
• Overexertion: lifting, carrying, pushing objects
that are too heavy to handle without machine
assistance causing a back injury.

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 Basic Accident Types
• Contact with Electric Current:
• Contact with caustic, Toxic and Noxious
Substances:
• Exposure to radiation: power plant, battery
manufacturing
• Public Transportation: overturns, goes out of
control
• Drowning: logging, ship building and working
in dam
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 Key Accident Data
1. Nature of injury:
2. Part of the body:
3. Source of injury:
4. Accident type:
5. Hazardous condition:
6. Agency of accident:
7. Agency of accident part:
8. Unsafe act:

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 Example
• The operator of a circular saw reached over
the running saw to pick up a piece of scrap.
His hand touches the blade, which was not
covered, and his thump was severely
lacerated.

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 Key Accident Data
1. Nature of injury: laceration
2. Part of the body: thumb
3. Source of injury: circular saw
4. Accident type: struck against
5. Hazardous condition: unguarded
6. Agency of accident: circular saw
7. Agency of accident part: blade
8. Unsafe act: cleaning when an object is moving
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 Exercise
• A warehouse employee jumped from the
loading platform to the ground instead of
using steps. As he landed, he sprained his
ankle. Inspection found that stairs cannot be
used because of some materials are stored in
the staircase.

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 Key Accident Data
1. Nature of injury: sprain
2. Part of the body: ankle
3. Source of injury: ground
4. Accident type: fall from above
5. Hazardous condition: material kept in the stairway
6. Agency of accident: none indicated
7. Agency of accident part: none indicated
8. Unsafe act: jumping from elevation

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 Measuring Injury Statistics
• Safety performance is relative. Only when a
company compares its injury experience with
that of its entire industry, or with its own
previous experience, can it obtain a meaningful
evaluation of its safety accomplishments.
• To make such comparisons, a method of
measurement is needed that will adjust for the
effects of certain variables contributing to
differences in injury experience.

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 Measuring Injury Statistics
• Injury totals alone cannot be used for two
reasons.
– First, a company with many employees may be
expected to have more injuries than a company with
few employees.
– Second, if the records of one company include all the
injuries treated in the first aid room, while the records
of a similar company include only injuries serious
enough to cause lost time, obviously the first
company's total will be larger than the second
company's figure.

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 Measuring Injury Statistics
• Frequency Rate (or incident rate): based on
– Total number of deaths
– Permanent total, permanent partial and
temporary total disabilities in the period covered
by the frequency rate
– 500 employees working 2000 hours in a year
𝑛𝑜 𝑜𝑓 𝑑𝑖𝑠𝑎𝑏𝑙𝑖𝑛𝑔 𝑖𝑛𝑗𝑢𝑟𝑖𝑒𝑠 × 100000
𝐹𝑅 =
𝑒𝑚𝑝𝑙𝑜𝑦𝑒𝑒 𝑕𝑜𝑢𝑟𝑠 𝑒𝑥𝑝𝑜𝑠𝑢𝑟𝑒
A rate of 20 means that 20 disabling injuries per year for each 500
employees or 1 disabling injuries per 20 employees.
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 Measuring Injury Statistics
• FR can also based on the exposure of 100 full-time workers using
200,000 employee-hours as the equivalent (100 employees
working 40 hours per week for 50 weeks per year).
𝑛𝑜 𝑜𝑓 𝑑𝑖𝑠𝑎𝑏𝑙𝑖𝑛𝑔 𝑖𝑛𝑗𝑢𝑟𝑖𝑒𝑠 × 200000
𝐹𝑅 =
𝑒𝑚𝑝𝑙𝑜𝑦𝑒𝑒 𝑕𝑜𝑢𝑟𝑠 𝑒𝑥𝑝𝑜𝑠𝑢𝑟𝑒
• Severity Rate (SR) or lost work day incident rate: rate at which
the days are lost
𝑛𝑜 𝑜𝑓 𝑙𝑜𝑠𝑡 𝑑𝑎𝑦𝑠 × 100000
𝑆𝑅 =
𝑒𝑚𝑝𝑙𝑜𝑦𝑒𝑒 𝑕𝑜𝑢𝑟𝑠 𝑒𝑥𝑝𝑜𝑠𝑢𝑟𝑒
• A severity rate of 500 may be interpreted as 500 days lost for
every one million employee hours worked.
𝑛𝑜 𝑜𝑓 𝑙𝑜𝑠𝑡 𝑑𝑎𝑦𝑠
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑙𝑜𝑠𝑡 𝑤𝑜𝑟𝑘𝑑𝑎𝑦𝑠 =
𝑇𝑜𝑡𝑎𝑙 𝑙𝑜𝑠𝑡 𝑤𝑜𝑟𝑘 𝑑𝑎𝑦𝑠 𝑐𝑎𝑠𝑒

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The INCIDENCE rate is really a general term. In addition to the
total injury-illness incidence rate, we have the following;

1. Injury incidence rate

2. Illness incidence rate
3. Fatality incidence rate
4. Lost-workday-cases incidence rate (LWDI)
5. Number-of-lost-workdays rate
6. Specific hazard incidence rate

• Rate 4 counts cases in which one or more workdays were lost

or in which the worker was transferred to another job.

• Rate 5 counts the total number of workdays lost or days in

which the worker was transferred to another job.
CASE STUDY

A metal products fabrication and assembly plant employs 250 workers and has the following injury-
illness experience for the year.

• File 1/January 31: Press-blanking operator scratches hand from punch press; first aid received, no
medical treatment; worker remains on the job.
• Analysis: File 1 - The key word is “first aid.” This case is not recordable.

• File 2/February 19: Maintenance worker, not wearing eye protection, operating grinding machine
in tool room, incurs eye injury from flying chip; medical treatment required; injury occurs on
Tuesday, employee returns to regular job at regular time on Thursday.
• Analysis: File 2 - This is a lost-workdays injury case. Do not count the date of injury (Tuesday). Do
not count Thursday either because the worker returned to work at the regular time. Only one day
was lost.

• File 3/February 27: Assembly worker becomes “ill” due to noxious odors from remodeling
operation in the assembly area; receives permission from supervisor to take the rest of the day
off; does not go to a doctor or clinic; reports to regular work on time the next day.
• Analysis: File 3- This case is not recordable. The worker felt “ill,” but there was no medical
treatment, and although the worker left work one afternoon. The worker returned to work on
time the next day, so no lost time is counted.

• File 4/March 2: Sewing machine operator’s right ring finger pulled into unguarded drive belt pulley
on sewing machine; small fracture revealed by X ray; splint applied; worker returns to regular
work at regular time the next day.
• Analysis: File 4 - This is a recordable injury, as the X ray was positive, revealing a fracture, which is
always recordable. The worker returned to her regular work at the regular time the next day,
however, so no time was lost.
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CASE STUDY

A metal products fabrication and assembly plant employs 250 workers and has the following injury-
illness experience for the year.

• File 5/March 19: Dockworker sprains ankle on loading dock; moved to office job for two
workweeks.
• Analysis: File 5 This is a lost time injury. Even though the worker returned to work, he was
assigned to a different job, so OSHA’s position is that the days at the restricted work activity count
as lost workdays.

• File 6/May 2: Maintenance worker entangles finger in rope as winch is released; taken to clinic for
X ray; no fractures found; no treatment; worker returns to regular work the next day.
• File 6 Unlike File 4, the X ray in this case was negative. Since there was no fracture and no medical
treatment and the worker returned to the same job the next day on time, this case is not
recordable.

• File 7/June 7: Yard worker exposed to poison ivy while clearing weeds in tank-farm area behind
plant; Rash develops; treated with steroid drug by prescription; no time lost.
• File 7 Poison ivy from on-the-job exposure is classified as an occupational illness and is identified
“Skin Disorder.”

• File 8/July 6: Assembly worker loses two workdays getting better from severe allergic reaction to
stings incurred while cleaning out his attic at home; medical treatment with prescription drugs.
• File 8 Incidents occurring off the job are not recordable.

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CASE STUDY

A metal products fabrication and assembly plant employs 250 workers and has the following injury-
illness experience for the year.

• File 9/August 4: Maintenance worker using ungrounded portable electric drill to repair equipment
in assembly area is electrocuted. Date of death: August 4.
• File 9 This is an injury-type fatality and should be recorded.

• File 10/August 7: Loaded pallet in loading dock area falls from forklift on dock- worker’s left foot;
worker examined in hospital emergency room and X ray revealed no fractures or other injuries;
worker receives therapy and goes home; worker reports back to his regular job on time the next
day and wears his company-issued safety shoes.
• File 10 The negative X ray and whirlpool therapy during the first visit to medical personnel are
both considered first aid not medical treatment. This case is not recordable.

• File 11/August 9: Maintenance worker in the tool room incurs injury from foreign object in the
eye; irrigation method used to remove foreign object, worker returns to regular job.
• File 11 Since the irrigation method was used and the object was not embedded in the eye, this
eye injury is considered a first-aid case and is thus not recordable.

• File 12/September 11: Worker in final assembly diagnosed with carpal tunnel syndrome (CTS) from
repetitive work; surgery prescribed; worker misses three weeks of work before returning to
regular job with engineering improvements to the workstation.
• File 12 Because CTS is due to “repeated motion,” it is classified as a illness. This is a recordable lost
time illness. The lost time is in the days-away-from-work category.

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Calculation of Incidence Rates:

2 x 200,000
LWDI (injuries only) = ------------------------------ = 0.8
250 x 2000

3 x 200,000
Injury incidence rate = ------------------------------- = 1.2
250 x 2000

2 x 200,000
Illness incidence rate = ------------------------------ = 0.8
250 x 2000

1 x 200,000
Fatality incidence rate = ----------------------------- = 0.4
250 x 2000

26 x 200,000
Number-of-lost-workdays rate = ---------------------- = 10.4
250 x 2000

Specific-hazard 1 x 200,000
incidence rate (eye injuries) = ------------------------- = 0.4
250 x 2000
Some explanation for the Case Study
• The LWDI is calculated in a prescribed way that excludes all fatalities
and all illnesses, regardless of whether time was or was not lost.
• Remember that the LWDI is an incidence rate and should not be
confused with the number-of-lost-workdays rate.
• In the specific-hazard incidence rate calculation, only one eye injury
(File 2) was included in the calculation. The File 11 eye injury satisfied
the definition of first aid and thus, as a non recordable injury, was
excluded from the calculation.
• The 250-employee firm in Case Study provides sufficient data to show
meaningful calculations for the various incidence rates. But many
firms are much smaller.
• For very small firms, the calculations are obviously inappropriate.
Recognizing that the general injury-illness recordkeeping system was
designed for larger firms.