Professional Documents
Culture Documents
7 Steps to
Industrial Hygiene Success
www.EHS.com
Contents
STEP 1: Similar Exposure Groups (SEGs): The Foundation for a Great IH Program....................................................4
STEP 2: Q
ualitative Exposure Assessment (QEAs): Essential Risk Assessment Methodologies for
IH Program Management...............................................................................................................................................5
STEP 5: IH Data Analysis: Defining Your Goals and Selecting the Best Metrics...........................................................12
STEP 6: Medical Surveillance: Strengthening Your Last Line of Defense for Worker Health..................................14
STEP 7: E valuating and Communicating Performance: The Keys to Engagement with Your IH Program........15
For non-IH professionals just stepping into the role, it can be intimidating. No bones about it,
IH is a scientific, highly technical discipline that relies on complex calculations and exposure Dave Risi, CIH, CSP
Principal Solution Strategist
data to drive critical decisions about workplace health and compliance. Even if the previous IH
for IH | VelocityEHS
program manager maintained organized data and records, where do you even begin?
For seasoned IH professionals still in the program management role, you might be struggling with how to maintain
and improve IH program performance in the face of dwindling staff and resources. You might also be wondering what
IH program strategies and best practices are out there today to help you lighten your load, reduce costs and boost
program performance.
This e-Book is a compilation of some of the most valuable insights and best practices I've gathered over more than 30
years as both a Certified Industrial Hygienist (CIH) and developer of IH software technologies. It’s intended for both the
seasoned IH professional and those new to IH program management, and offers a unique, outside-the-box approach
to IH program management that will not only help you focus and refine your program, but help you minimize program
costs, simplify compliance and improve the health of your workers.
In the following sections, we’ll take an in-depth look at each of the seven IH program elements and give you, the reader,
practical guidance on how to build, maintain, refine and integrate those elements to form a highly effective IH program.
Since then, AIHA has published several updates to the text It provides you with a more extensive risk profile compared
and QEAs are now widely considered a best practice for to sampling only the higher-risk SEGs.
industrial hygiene around the world.
Prioritization
The ultimate result of performing QEAs is a risk rating Once completed, QEAs make it easier to identify SEGs that
that can be used to prioritize resources for IH sampling, require additional investigation and monitoring. SEGs with
implementation of controls and inclusion of workers in sufficient data and a high degree of confidence showing
medical surveillance programs. QEAs can also help you they do not require a significant investment in additional
identify high-risk potential exposures that require immediate monitoring can be more effectively prioritized.
corrective actions, rather than taking the time and effort to
perform IH sampling and waiting for analytical results to Improved Communication
be returned from the lab before you implement controls to QEAs ultimately help you create a well-developed risk
protect worker health. matrix that standardizes risk visualization across disciplines.
They also provide a valuable tool to show workers and
In this section, we’ll cover several of the most common management your IH program activities and the value they
methods used to perform QEAs and help you set up a bring to the company.
simple risk matrix report that can be used to easily prioritize
exposure risks and communicate those risks to workers Litigation Support
and management. Well-documented QEAs, along with other IH program
information, provide faster access to supporting data without
QEAs as Part of Your IH Program needing to recall files from storage or spend weeks going
If SEGs are the foundation of a good IH program, QEAs are through old reports if requested by regulators or stakeholders.
the actionable insights which drive your IH program forward.
Once performed, they provide a comprehensive and visual Knowledge Transfer
breakdown of the potential risks in your workplace so you QEAs provide a great way to capture the knowledge gained
can get to the important work of protecting your people. through your EHS professionals’ years of experience and
integrate that knowledge into your IH program for future
Here are some of the greatest benefits of performing QEAs: IH leaders.
Once you have gathered this information, list all of the Step 3: Conduct Your QEAs
potential stressors for each SEG. An example of this is shown Break up Table 2 so each SEG and stressor are listed in a
in Table 2 above (this should be familiar from our previous unique row. Then, add columns for your Exposure Rating
section on SEGs). and Health Effect Rating variables, and one column for the
calculated Risk Rating. Table 3 on page 8 below shows how
Step 2: Define Your QEA Strategy/Formula to apply the AIHA strategy for the SEGs identified in the
After 30 years in the field of IH, I have seen some companies Houston Refinery example.
spend years perfecting their QEA model. Some spend a lot
of time modeling their QEAs around variables such as Based on information in Table 3, we see the highest risk is
frequency, duration, control technology factors, vapor benzene exposure during liquid sampling by Operators
pressures and even particle size distributions. These can at the Reformer Unit, while the lowest risks are benzene
be useful variables, but most companies do not have the exposure to Operators at the Coker Unit when performing
resources or expertise to be that thorough, especially when routine work duties.
just beginning their QEA program.
Step 4: Display Your QEA Data in a Risk Matrix
Just like when setting up your SEGs, you need to avoid The QEAs in Table 3 contain a lot of great data but are
“analysis paralysis” and just start the process. After you’ve not recommended for use when presenting QEA findings
established your baseline assessments and ultimately to workers or management. Let me explain: it can easily
accumulate years of data to help validate your model, you become overwhelming and confusing when applied to a site
may find it necessary to change your QEA model by adding containing 50-100 rows of QEA data. Instead, we recommend
additional variables that provide an even more precise summarizing the data using a standard risk matrix.
assessment. Until then, start simple.
Risk matrices are already widely used by safety, quality and Step 5: Prioritize Next Steps
other departments across the organization to illustrate the After you and your stakeholders understand the exposure
status of their programs and related risks. So, why not use risks in the workplace, you can then begin an informed
the same tools to convey IH information, right? Far too many discussion about what to do next. If the risk rating is low
IH professionals believe they need to show a ton of complex (green), you should track for potential exposure risk changes,
data, statistics and fancy graphs to effectively communicate and no additional sampling may be needed. If the risk rating
exposure risks. IH practitioners should, as a whole, get out of is moderate (yellow), sampling is likely needed and controls
this “black box” mentality and simplify our messaging for both should be implemented (PPE, training, engineering controls,
employees and management. etc.). If the risk rating is high (red), immediate action is required
(typically PPE to start, then engineering and other controls,
Risk matrices also take advantage of peoples' existing visual medical surveillance, additional sampling, etc.).
and psychological cues: when presenting this data, viewers’
eyes will be almost instinctively drawn to the red items, right? We’ll talk more about taking the right actions and
They will inevitably ask: implementing controls later on.
To help you answer these questions with confidence, we Items with a zero rating have the lowest priority but should be
recommend the following three-step process you can use to periodically re-evaluated to confirm the exposure potential
define a sampling plan. This method focuses your resources hasn’t changed.
to get the most out of your sampling effort, while supporting
the overall IH program. Step 3: Document Your Sampling Plan
Once you have the regulatory-required sampling and the
How Do I Develop a Sampling Plan? prioritized list of SEGs that require additional sampling, you
Step 1: Identify any Regulatory-driven Periodic can combine them in a single table and determine the number
Sampling Requirements of samples to take and the scheduled completion date(s).
OSHA and other agency standards include regulatory-required
periodic sampling that must be considered when developing Q: How many samples are needed?
your sampling plan. One example is the Coke Oven Emissions A: There are a lot of different strategies and methods that can
Standard, 29 CFR 1910.1029. Paragraph (e)(1)(iii) of the be used to determine the appropriate number of samples
Standard requires the full-shift personal sampling for each to take—too many to discuss all of them here in this article.
battery and job classification on each shift. This sampling is Ultimately, most of these methods recommend between 3 and
to be conducted quarterly. 9 samples for each SEG/stressor. We will go into more detail on
this in the section on Data Analysis.
Start your sampling plan by making a list of the sampling
required for each SEG, stressors that must be assessed, Q: What should I set as the scheduled completion date?
how many samples are required, and the date(s) they need A: December 31st is the most common date, since most
to be completed. sampling plans are annual. However, make sure you meet
the time requirements/deadlines for any regulatory-required
Step 2: Identify Samples Necessary to Increase Confidence sampling. For example, if quarterly monitoring is required,
with Your QEAs show the line item 4 times with the end of each quarter as
AIHA has developed a simple formula that we recommend your scheduled completion date.
to our customers when determining priority for additional
investigation, including additional sampling activity. The You may also set the date earlier in the year if there is a high
formula is: potential for exposure that is not well understood, or to match
up with your production calendar when the task/process is
Info Gathering Priority Rating = Risk Rating x Uncertainty Rating being performed.
Information-
Exposure Health Effect Uncertainty
Location Job Task Stressors Risk Rating Gathering
Rating Rating Rating
Priority Rating
Hydrogen
Coker Unit Operator Routine Work Duties 2 2 4 2 8
Sulfide
Hydrofluoric
Alky Unit Operator Routine Work Duties 1 3 3 1 3
Acid
Maintenance Gasket
Maintenance Asbestos 2 3 6 0 0
Technician Replacement
Liquid
Reformer Unit Operator Benzene 4 3 12 0 0
Sampling
# Sampled Scheduled
Location Job Task Stressors # Samples Taken % Complete
Planned Completion Date
One or Multiple Labs? Additional accreditations are available for specific stressors
Based on analytical requirements, you may ultimately need to including lead (ELLAP), mold and other microbiological
use multiple labs. Using the methodology prescribed below, samples (EMLAP). If you are a global corporation, consider
you will ensure you address the highest priorities with respect looking for laboratories that are also ISO/IEC 17025 accredited.
to your annual budget for monitoring.
Depending on the state(s) you operate in, you may also need
Price to consider state accreditations. Some states that have their
Sampling effort should be focused on the items that need own accreditations include Louisiana, New York, New Jersey
additional data and investigation. For example, those annual and Texas.
noise surveys you conduct every year that show noise levels
are consistently above 95 dBA can be removed or greatly Streamline Your Process
reduced. Remember, the overall number of samples you One of the most intensive administrative tasks when working
collect should be minimized over time, saving you money and with IH labs is creating your chain of custody (COC) form. It
giving you back time to focus on more important projects. can be a time-consuming task, one that most of us don’t look
forward to at the end of a long day of sampling. However,
On-Staff CIH several IH laboratories are now offering online services to
Several of the larger labs offer free or low-cost consultation complete your COCs online. Some labs like SGS Galson even
with their on-staff CIHs. This comes in handy if you need provide a convenient web portal to help you easily complete
additional support to determine the best sampling methods and submit your COCs.
or just want an IH expert to review your work.
Several labs also offer direct access to their sampling and
Equipment Loan and Rental analysis guides (SAGs). Your lab’s SAG is essentially a catalog
Several labs offer air sampling pumps for free and will often of the analytical services they offer and includes information
rent noise dosimeters and other direct reading equipment. such as analysis methods, limits of detection, flow rates and
This offers a great cost-saving option if you’re not taking required sample volumes. Having SAG information readily
enough samples to justify purchasing your own equipment. available helps ensure your planned sampling is performed
according to proper procedures, and it helps minimize
Location questions or the need to resample.
For most, lab location is not an issue. Sample media can easily
be shipped next day air to and from most places. However, Challenges with Lab Interfaces
location becomes important if you need to swing by their Most IH software systems include interfaces that provide the
office to pick up sampling media on short notice, or when ability to send COCs to labs and upload analytical results.
analyzing a highly volatile agent and you don’t want to deal However, the challenge with many of these lab interfaces
with packing it in dry ice or some other cooled packaging. is implementing them properly and keeping them working
as analytical parameters and methods change. It can be an
Accreditation administrative nightmare requiring months to set up, plus
Most IH laboratories are AIHA LAP accredited. We recommend additional support every time there is a change with the lab
this level of accreditation for analysis of most stressors. SAGs or any time you add a new stressor to your database.
IHSTAT
IHSTAT is a free Microsoft Excel worksheet that checks for log-
normalcy and provides several common statistical analyses of
IH data and compliance testing. This commonly used tool was
developed by AIHA and is available for free.
EAS Bayesian
Dr. Paul Hewett of Exposure Assessment Solutions developed Unfortunately, the formulas used for ANOVA can be
the market-leading Bayesian analysis tool. He provides intimidating, let alone the time it takes to perform one.
training sessions and webinars throughout the year on the Alternatively, the scatter diagram can be quickly generated
software and other statistical topics. The Bayesian software using Excel.
has a free version (IHDA-Student), which is intended for use by
students or EHS professionals in training. The IHData Analyst Example of a Scatter Diagram
Professional version is intended for organizations looking to
use it in their IH programs. Both versions are available here.
BWStat
BWStat is a Microsoft Excel tool developed by Tom Geens
and hosted by the Belgium Society of Occupational Hygiene.
It allows the estimation of compliance with OELs, taking
into account the intra- and inter-individual variation in
repeated measurements. It was built to help facilitate the
implementation of the BOHS-NVvA Guidance. You can
download BWStat here.
Before diving into best practices for medical surveillance, let’s Methods for Setup and Maintenance of Medical
first have a quick refresher of the basics. Surveillance Programs
There are a few fundamental steps necessary to set up and
What Is a Medical Surveillance Program (MSP)? maintain your MSPs and ensure workers are enrolled in the
An MSP is defined as the set of medical activities that must be right programs based on exposures.
performed on workers when exposures to workplace stressors
exceed a certain level. The program will list what the stressor of Step 1: Define Applicable MSPs and Their Required
concern is, the threshold at which workers need to be tested, Medical Activities
and the medical activities and their frequencies that need to Looking at your locations and assessment of potential
be conducted. exposures, you can determine which MSPs may be required
under any applicable regulations. For example, a list of
Why Are MSPs Needed? potential stressors at your locations may include noise,
benzene and silica, all of which are regulated by OSHA
The purpose of the MSP is to evaluate workers exposed
and have MSP requirements.
to stressors above a set threshold and quickly identify any
adverse health effects early-on, so they may be removed from
Risk Ratings
These are obtained through your qualitative exposure
assessments. If the risk rating is above the threshold set
by the MSP, all members of the SEG should be enrolled.
IH Sample Data
At a minimum, all persons for which sampling shows
exposures exceeding the defined threshold should be enrolled
in the MSP. An important determination is whether to enroll
all workers that do the same job (i.e., are in the same SEG) or
to assess each worker’s potential exposure independently.
Most professionals would apply the enrollment to the entire
SEG. However, you may be able to justify individual worker If you were to ask business managers what the status of their
enrollments/de-enrollments if you can reliably demonstrate business is, they would discuss their profit margin, EBITA,
that those workers experience different exposures due to percent growth in revenue or other common financial metrics.
unique work procedures and conditions.
If you were to ask safety managers, they’d probably tell you
Step 4: Automate Enrollment and De-enrollment of about the number of days without a recordable injury or their
workers in MSPs incident rate and how it compares with last year.
Manually updating the lists of workers that are enrolled and
As an IH professional, how would you answer the question:
de-enrolled in MSPs is a time-consuming task. IH software
“What’s the status of your IH program?” Would you pull up a
can make this job not just easy, but virtually effortless. The
bunch of statistics? A list of SEGs? Perhaps you would show
key is to be able to get accurate employee data from your HR
them your sampling plan for the year?
department and map it to the requirements for who needs to
be included in each MSP. If you are having a hard time identifying the best data points,
statistics, tables or diagrams to show, you’re not alone. This
The best method is to map HR information specifying workers’
has been a long-running challenge for IH professionals and a
jobs and locations on to each SEG. With HR data being
big reason, I believe, why most stakeholders don’t understand
continually updated in the background, workers can be moved
what IH is or the value we bring to the business.
in and out of SEGs automatically as job roles and locations
change. If you define who is required for your MSPs at the
SEG level, workers will automatically move in and out of MSP
Documentation and Communication
enrollment as they move in and out of SEGs. Industrial hygienists are very good at documentation, but
most of us need to improve our communication. We generate
Unfortunately, there are limitations to most HR systems and employee notification letters, tables and charts of sample
records, and getting a 100% accurate, real-time account of all results and include them in quality reports that are sent to
workers’ job roles and locations is very difficult. That said, even management, but is there any two-way communication?
a 50% automation of MSP enrollment saves enough time and Do we present our findings in person and make time for
resources to make it worth the effort. dialogue, discussion or Q&A? What happens with the reports
we generate for data users? Are they just filed and eventually
shipped to a salt mine for long-term storage without providing
any real value for the business?
If It Ain't Broke, Don't Fix It! • The current number of risk assessments and what level of
I am big believer in leveraging what works within your risk they each have (e.g., high, medium, low)
company’s culture. For most companies, important safety, • Details of the jobs, tasks, location and stressors that make up
quality and other risk information is already being summarized the health risks
using a standard risk matrix, and stakeholders are likely
• The degree of certainty with our health risk ratings
accustomed to referencing other types of risk matrices to
quickly understand the presence of risks in the workplace. • Where additional resources are needed to improve the
degree of confidence in the health risk ratings
As we talked about earlier, a risk matrix is a valuable tool
already in your toolbox that can also be used to summarize To ensure effective communication of risks, these values
exposure and worker health risks. In the case of IH risks, rather should be discussed with workers and management, giving
than using severity and likelihood as our key risk variables, the them ample opportunity to ask questions and have an
IH risk matrix uses health effect ratings and exposure ratings to open dialogue on the data. Ideally, this will instill greater
rank and prioritize risks. understanding and appreciation of what IH is and its value
to the business, and ultimately strengthen engagement with
your IH program.
Health Information-
Exposure Uncertainty
Location Job Task Stressors Effect Risk Rating Gathering
Rating Rating
Rating Priority Rating
Tank Farm Operator Gauging Benzene 3 3 9 2 18
Looks great, huh? But it’s never quite that simple. You must Present a Financial Analysis
be armed with data to show what it takes to reduce those Most of us are not experts on financial analysis, but we still
red items. When communicating control activities and should be able to provide some basic information about
effectiveness, we strongly recommend the following: control alternatives, including:
Benefits of VelocityEHS
Simplicity
We believe that well-designed, intuitive software ultimately
gets used, and when your people are engaged, you get the
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capabilities, but our implementations require less time, cost
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on the market. VelocityEHS Industrial Hygiene solutions help you
assess and control workplace stressors, automate
Unparalleled Customer Support time-consuming IH tasks and maintain a world-class
Our in-house IH experts and Customer Support Team IH program, no matter what your level of IH expertise.
stand ready to deliver the guidance, consultation and best- Contact us to learn more!
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IH management challenges. VelocityEHS
Toll free: 1.866.919.7922
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VelocityEHS gives you a comprehensive IH program Australia: +61 2 9098 4332
management platform that integrates your IH sampling
data, SEGs, QEAs, sampling plans, database of stressors and United Kingdom: +44 (0) 1737 812718
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Learn more at www.EHS.com
Value
The IH experts at VelocityEHS are continuously developing the
system enhancements and innovative new features you need
to achieve greater levels of IH program efficiency throughout
the life of your purchase.