15 May When You Least Expect It…Lessons Learned!

When You Least Expect It…Lessons Learned!

No one expects to be injured at work. We hear reminders every day to work safely, follow procedures, stay alert, and wear required personal protective equipment (PPE). The challenge is remembering that these precautions apply every time—even during familiar or routine tasks.

Work procedures and PPE requirements exist because incidents have shown what can happen when hazards are overlooked. The following examples demonstrate how quickly an ordinary task can result in a serious injury.

Lesson #1 – Protect Your Eyes

Two mechanics were repairing the rear roll-up door of a step van. The work required them to tension a large spring by inserting metal rods into the spring mechanism.

During the work, one of the rods slipped from the spring catch. The stored energy in the spring caused the rod to rebound violently and strike the second mechanic in the eye, resulting in a serious injury requiring immediate medical attention.

Lessons Learned:

• Identify stored-energy hazards before beginning work.
• Use established procedures for controlling or releasing stored energy.
• Keep employees out of the potential line of fire.
• Use the correct tools for the task.
• Wear appropriate eye and face protection.

A task involving springs, tensioned components, compressed materials, or other stored energy should never be treated as routine.

Lesson #2 – PPE Can Save Your Life

A construction superintendent was observing work when a piece of heavy equipment drove over a piece of concrete. The tire propelled the concrete from beneath the equipment, turning it into a high-speed projectile.

The concrete traveled across the work area and struck the superintendent in the head. Fortunately, he was wearing a hard hat, which helped protect him from a potentially fatal head injury.

Lessons Learned:

• Wear required PPE even when you are only observing work.
• Maintain appropriate separation from operating heavy equipment.
• Keep travel paths and work areas free of loose materials when practical.
• Recognize that equipment can throw rocks, concrete, and other debris without warning.
• Stay alert to hazards created by nearby operations.

PPE cannot eliminate a hazard, but it can significantly reduce the severity of an injury when unexpected events occur.

Lesson #3 – Keep Your Attention on the Task

An employee was using a bench grinder equipped with a wire wheel to polish a piece of metal. While the wheel was operating, the employee turned to speak with a coworker and took his attention away from the work.

The material became caught between the wheel and tool rest, pulling the employee’s finger into the rotating wheel and causing a serious injury.

Lessons Learned:

• Keep your attention on operating machinery.
• Do not allow conversations or other distractions to interfere with equipment operation.
• Inspect grinders and tool rests before use.
• Maintain required clearances and adjustments.
• Keep hands away from rotating wheels and other points of operation.
• Turn equipment off before making adjustments or addressing problems.

Learn Before Someone Gets Hurt

Incidents rarely occur without contributing factors. Unsafe conditions, improper procedures, distractions, inadequate planning, failure to recognize hazards, or failure to use required PPE can turn a routine task into a serious event.

Before beginning work:

• Think about what could go wrong.
• Identify line-of-fire and stored-energy hazards.
• Inspect tools and equipment.
• Follow established safe-work procedures.
• Wear required PPE.
• Stay focused on the task.
• Stop work when conditions change or something does not look right.

Near misses and previous incidents should also be discussed and used as opportunities to improve procedures and prevent recurrence.

Remember

Do not wait until an injury occurs to recognize the importance of a safety rule. Learn from previous incidents, apply those lessons to your own work, and never assume that an accident cannot happen simply because you have performed the task safely before.