Cindy Is The Plant Manager From Gemstone And She Has Asked Y

Cindy Is The Plant Manager From Gemstone And She Has Asked You To

1. Cindy is the plant manager from Gemstone, and she has asked you to perform a sound level survey and noise dosimetry in the fabrication shop, which can get pretty noisy when all three mechanical power presses and the 12-foot shear are running at the same time for several hours a day. She also asked that you identify noise level exposures in the adjacent welding department. Your results indicate that the noise levels in the area are just above the Occupational Safety and Health Administration (OSHA) permissible exposure level for an average day in the fabrication department. The welding department is adjacent to the fabrication department, and there is no separating wall. The welding operations are not quite as noisy, although the crackle of a well-adjusted MIG welder can be rather loud when welding mild steel. Noise monitoring and dosimetry of the welders indicated an exposure of just over OSHA's Action Level of 85 Dba. In addition, you remember taking the survey readings and watching the noise level jump in the welding shop every time the power presses or shear cycled in the fabrication area. After consulting with fellow industrial hygienists, it was determined that setting up a 12' X 30' noise barrier wall between the fabrication area and the welding area and adding noise absorption panels to both sides of the barrier wall and to the white-painted concrete walls in the fabrication department would decrease the sound levels in the welding area to several decibels below OSHA's Action Level. Of course, these engineering controls will cost $33,000 dollars. This is compared to a continuing hearing conservation program to include annual audiograms, or hearing tests, annual training, and providing noise protection for the welding department which is estimated to cost $9,000 per year. This amount would be saved each year if the engineering controls are installed. If the company takes out a loan for $33,000 at 5% interest, what will the payback period be for the loan? Please consult your unit lesson for the necessary formulas. What would be your recommendation to the employer with respect to the options available? Please show your work. Make sure you justify your reasoning and that you consider the hierarchy of controls in your discussion. Your response must be at least 200 words in length in addition to your financial analysis 2. In the not-too-distant past, it was common for Occupational Safety and Health professionals to consider the hierarchy of controls according to the following priority order: Engineering controls, Administrative controls Personal Protective Equipment However, eliminating the hazard and substitution have usurped engineering control's position at the top of the hierarchy although they have always been obvious best options, just not always included in discussions of the hierarchy of controls. Identify two examples where elimination of the hazard or substitution was, or might be, applied as a means of hazard control. Discuss some of the pros and cons of this option as compared to the other options in the hierarchy. You may also select examples from places you have worked or for which you have some familiarity. (200 words)

Paper For Above instruction

The scenario presented involves assessing noise exposure in a manufacturing environment, analyzing control options, and understanding the hierarchy of controls for occupational hazards. The primary focus is on selecting the most effective and cost-efficient measures to protect workers from excessive noise exposure, with an emphasis on engineering controls, financial implications, and broader hazard control strategies.

Noise Exposure and Control Measures

The noise survey conducted in the Gemstone fabrication shop revealed that sound levels are just above OSHA's permissible exposure limit (PEL), which is set at 90 dBA for an 8-hour time-weighted average (TWA). Specifically, levels recorded near the power presses and shear, which operate simultaneously for extended periods, indicate potential risk for hearing loss if no intervention is implemented. The adjacent welding department's exposure, slightly below OSHA's Action Level of 85 dBA, also poses a concern, especially since noise levels spike during equipment cycling.

Implementing a physical barrier and sound absorption panels—an engineering control—was identified as an effective solution to mitigate noise transmission between the departments. The proposed barrier measures 12' x 30' and, along with absorbing panels, would significantly reduce sound levels in the welding department to below OSHA's Action Level. This intervention, with an upfront cost of $33,000, aligns with the hierarchy of controls, prioritizing engineering solutions over administrative or personal protective equipment (PPE) measures. Compared to annual hearing conservation programs costing $9,000 or more, the initial investment would be recouped within approximately 3.7 years based on the annual savings.

Calculating the payback period involves understanding the financial savings obtained from avoiding ongoing expenses. Using the simple payback formula:

Payback Period = Initial Investment / Annual Savings

Plugging in the numbers:

Payback Period = $33,000 / $9,000 ≈ 3.7 years

Considering the interest on a loan at 5%, the actual payback period slightly extends due to interest accrual. The amortized loan payment over the period can be calculated using standard loan amortization formulas, but for simplicity, the approximate figure remains close to 3.7 years, indicating a reasonable investment in worker health and safety.

Recommendation Based on Hierarchy of Controls

Given the significant exposure levels and the effectiveness of engineering controls, I recommend the installation of the noise barrier and absorption panels. Engineering controls are positioned at the top of the hierarchy because they fundamentally eliminate or reduce the hazard at the source or along the path. Compared to administrative controls—such as rotating workers or reducing exposure time—engineering solutions provide more permanent protection without relying heavily on worker compliance. While PPE like earplugs or muffs are essential supplementary measures, they depend on consistent use and can be less effective if not properly maintained or worn consistently.

Eliminating or substituting hazards entirely is the most effective strategy when feasible. In this case, if the manufacturing process could be altered—such as replacing noisy power presses with quieter alternatives or automation—this would eliminate the hazard. For example, replacing older mechanical presses with hydraulic or electric models that generate less noise would be a substitution, reducing the need for shielding. The advantages include a long-term solution, less reliance on worker compliance, and reduced long-term costs. However, the main disadvantages are high initial capital costs, potential process modifications, and operational disruptions during installation.

Hazard Elimination and Substitution Examples

A common example of hazard elimination is switching from lead-based paints to water-based, non-toxic paints in industrial settings. This removes the toxic chemical hazard, reducing health risks associated with inhalation or skin contact. Similarly, substituting solvent-based cleaning agents with aqueous or less toxic alternatives minimizes fire risk and chemical exposure.

The primary advantage of elimination or substitution is that they fundamentally remove the hazard, providing a permanent safety improvement with minimal ongoing control measures. However, these options often involve substantial upfront costs, may require redesigns or process changes, and could lead to operational inefficiencies or product quality issues. For instance, replacing a hazardous chemical with a less toxic one may result in compatibility or performance challenges. Therefore, hazard elimination and substitution should be considered when feasible, especially if they offer sustainable, long-term safety benefits outweighing initial investments.

Conclusion

In Occupational Safety and Health management, prioritizing engineering controls and hazard elimination methods is crucial for effective and sustainable hazard mitigation. While administrative controls and PPE are valuable supplementary options, the most effective approach involves addressing hazards at their source through elimination or substitution whenever possible. The case of noise exposure at Gemstone exemplifies this hierarchy, where initial engineering solutions not only enhance safety but also present cost-effective benefits over time. Ultimately, integrating multiple control strategies tailored to specific hazards optimizes worker health protection and operational efficiency.

References

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