Transcript Developing a Part 46 Training Plan - MCET

Developing a Part 46
Training Plan
Welcome
Feb. 20-24, 2006 “Focus on
Safety Week” for Metal and
Nonmetal Mines Nationwide
Session Agenda
I.
Welcome and Introductory Remarks
II. Part 46 Regulatory Review
III. Writing a Training Plan
IV. Training Resources
V. Session Wrap-up
Regulatory
Overview
Under Part 46 Who Has to be
Trained?
Miners and other persons at:
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Shell dredging
Sand
Gravel
Surface Stone
Surface Clay
Colloidal phosphate AND
Surface Limestone mines
Who is Considered a “Miner”?



Any person, including any operator or
supervisor, who works at a mine and who is
engaged in mining operations;
Includes independent contractors and
employees of independent contractors who are
engaged in mining operations; AND
Any construction worker who is exposed to
hazards of mining operations.
What is the Minimum Information
Required for a Training Plan?
1.
2.
Name of production operator or independent
contractor, mine name(s), MSHA mine ID
number(s) or independent contractor
number(s).
Name and position of person designated who
is responsible for health & safety training.
What is the Minimum Information
Required for a Training Plan?
3.
General description of teaching methods, course
materials, subject areas and approximate time
for each subject area.
4.
List of persons and/or organizations who will
provide training and subject area each is
competent to instruct.
5.
Evaluation procedures used to determine
effectiveness of training.
Who Can Conduct Training?

Competent Person – means a person
designated by the production-operator or
independent contractor who has the ability,
training, knowledge or experience to provide
training to miners in his or her area of expertise.
Must be able to effectively communicate the
training subject to miners and to evaluate
whether the training given to miners is effective.
Who Can Conduct Training?
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You may conduct your training
State or federal agencies
Associations of production-operators or
independent contractors
Miners’ representatives
Consultants
Manufacturers’ representatives
Private associations
Educational institutions
How Should the Training Be
Conducted?
Classroom instruction
 Instruction at the mine
 Interactive computer-based instruction
 Alternative training technologies
 Any combination of training methods

What are the Categories of Training
Required by the Standard?
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New miner training
Newly hired experienced miner training
New task training
Annual refresher training
Site specific hazard awareness training
Contractor training
New Miner Training

New Miner – person who is beginning
employment as a miner with a productionoperator or independent contractor and
who is not an experienced miner.

No less than 24 hours of training is
required for new miners.
New Miner Training: Before Beginning
Work at the Mine (No Less Than 4 Hours)
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Introduction to work environment;
Recognition and avoidance of electrical and other hazards;
Review of the emergency medical, escape and emergency
evacuation plans, firewarning and firefighting;
Health & safety aspects of assigned tasks;
Statutory rights of miners;
Authority and responsibility of supervisors and miners’
representatives
Introduction to rules and procedures of reporting hazards
New Miner Training: No Later Than 60
Calendar Days After Beginning Work at
Mine

Instruction in use, care and maintenance of selfrescue and respiratory devices (if in use)

Review of first aid methods
New Miner Training: No Later Than 90
Calendar Days After Beginning Work at
Mine

Provide with balance, if any, of the 24
hours of training on any other subjects that
promote health & safety for miners.
Newly Hired Experienced Miner Training

Experienced Miner – person employed
as a miner on or after October 2, 2000
who has completed 24 hours of new miner
training under Sect. 46.5 of this part or
under Sect. 48.25 of this title and who has
at least 12 cumulative months of surface
mining or equivalent experience.
Newly Hired Experienced Miner: Before
Beginning Work at the Mine
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Introduction to work environment;
Recognition and avoidance of electrical and other
hazards;
Review of the emergency medical, escape and
emergency evacuation plans, firewarning and
firefighting;
Health & safety aspects of assigned tasks;
Statutory rights of miners;
Authority and responsibility of supervisors and
miners’ representatives
Introduction to rules and procedures of reporting
hazards
Newly Hired Experienced Miner: No
Later Than 60 Calendar Days After
Beginning Work at Mine
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Instruction in use, care and maintenance of selfrescue and respiratory devices (if in use)
New Task Training
To be provided to any miner who is
reassigned to a new task in which he/she
has no previous work experience
 Train in the health & safety aspects and
safe work procedures specific to that new
task
 Provide before the miner performs the new
task

Annual Refresher Training
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No less than 8 hours
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No later than 12 months after the miner
begins work at the mine
Annual Refresher Training
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Changes at the mine that could
adversely affect miners’ health or
safety;
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Other relevant health and safety topics.
Other Relevant Topics
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Applicable health and safety
requirements
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Ground conditions and control
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Traffic patterns and control
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Working in areas of highwalls
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Water hazards
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Prevention of accidents
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Explosives
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Respirators
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Working around moving objects
(machine guarding)
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Fall prevention and protection
Hazard Communication
Transportation controls and
communication systems
Escape and emergency evacuation
plans
Firewarning and firefighting
Use of hand-tools and welding
equipment
Material handling
Other Relevant Topics: Equipment Specific Training
Haulage and service trucks
 Front-end loaders and tractors
 Conveyor systems
 Cranes
 Crushers
 Excavators
 Dredges
 Maintenance and repair

Site-Specific Hazard Awareness
Training (SSHAT)
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Must be provided before any person specified is
exposed to mine hazards
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SSHAT is information or instructions on the
hazards a person could be exposed to while at
the mine and emergency procedures.
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Not required for any person who is accompanied
at all times by an experienced miner familiar with
the hazards.
Who Must Receive SSHAT?
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Office or staff personnel
Scientific workers
Delivery workers
Customers, including commercial over-the-road
drivers
Construction workers
Maintenance or service workers
Vendors or visitors
Independent Contractor Training

Production-operator has responsibility for
providing SSHAT and information
regarding the contractor’s responsibility to
comply with MSHA training requirements:
 New
miner training
 Newly hired experienced miner training
 New task training
 Annual refresher training
Developing a Part 46
Training Plan
Five Steps to Compliance
2005 Metal / Nonmetal
Fatal Accident Review
www.msha.gov/stats/review/2005/2005review.asp
MNM Fatals
Contractors
2
Mine
Employees
33
MNM Fatalities by Commodity
Other*, 26%
Cement, 6%
Sand &
Gravel, 28%
Crushed
Stone, 32%
Gold, 8%
* Trona, Lime, Platinum, Pumice,
Phosphate, Iron Ore, Sandstone,
Potash, Copper
MNM Fatalities by Classification
Machinery,
29%
Falling
Material, 8%
Fall of
Person, 8%
Electrical, 6%
Powered
Haulage, 46%
Exploding
Vessel, 3%
MNM Fatalities by Mine Size
1-5
Employees,
14%
100+
Employees,
34%
5-10
Employees,
20%
50-100
Employees,
9%
25-50
Employees,
11%
20-25
Employees,
3%
10-20
Employees,
9%
MNM Fatalities by Age
60+, 14%
17-25, 11%
25-30, 11%
50-60, 11%
30-35, 18%
45-50, 20%
40-45, 6%
35-40, 9%
MNM Fatalities by Mining Experience
25-30
Years, 9%
30+
Years,
11%
20-25
Years, 3%
0-1 Years,
29%
15-20
Years, 3%
10-15
Years, 3%
5-10
Years,
11%
2-5 Years,
14%
1-2 Years,
17%
MNM Fatalities by Activity
Maintenance
, 51%
Production,
49%
MNM Fatalities by Occupation
Machinery/
Plant
Operator,
20%
Mobile
Equipment
Operator,
26%
Supervisor,
8%
Laborer/
Utility,
20%
Repairman/
Technician,
26%
Root Causes
Risk
Assessment,
16
Inadequate
Procedures,
23
Training,
6
LO/TO,
4
PPE,
15
Note: Fatalities may have
several root causes.
No Inspection,
5
MNM Fatalities – 1995-2005
70
60
61
53
50
51
55
47
47
42
40
30
30
26 27
35
20
10
0
1995
1997
1999
2001
2003
2005
METAL/NONMETAL DAILY FATALITY REPORT
FATALITIES CHARGEABLE TO
2001
2002
-
End of Year - 2005
2003
2004
2005
THE MNM MINING INDUSTRY
U
G
S
U
G
S
U
G
S
U
G
S
U
G
S
ELECTRICAL
0
1
1
1
0
2
0
1
1
1
EXP VESSELS UNDER
PRESSURE
0
0
0
1
0
0
0
0
0
1
EXP & BREAKING AGENTS
0
0
0
0
0
0
0
0
0
0
FALL/SLIDE MATERIAL
0
0
1
1
0
3
0
4
0
3
FALL OF FACE/RIB/HIGHWALL
0
0
0
1
0
0
0
1
0
0
FALL OF ROOF OR BACK
4
0
0
0
0
0
0
0
0
0
FIRE
0
0
0
0
0
0
0
0
0
0
HANDLING MATERIAL
0
0
0
0
0
0
0
0
0
0
HAND TOOLS
0
0
0
0
0
1
0
0
0
0
NONPOWERED HAULAGE
0
0
0
0
0
0
0
0
0
0
POWERED HAULAGE
3
1
3
1
1
4
0
6
1
6
5
1
1
HOISTING
0
0
0
1
0
0
0
0
0
0
IGNITION/EXPLOSION OF
GAS/DUST
0
1
0
0
0
1
0
0
0
0
INUNDATION
0
0
0
0
0
0
0
0
0
0
MACHINERY
0
2
0
1
3
1
7
1
5
2
8
SLIP/FALL OF PERSON
0
4
0
2
1
2
0
6
0
3
STEP/KNEEL ON OBJECT
0
0
0
0
0
0
0
0
0
0
STRIKING OR BUMPING
0
0
0
0
0
0
0
0
0
0
OTHER
0
2
2
3
0
2
0
2
0
0
Fatalgrams and Fatal Investigation Reports
Metal and Nonmetal Mines
www.msha.gov/fatals/fab.htm
METAL/NONMETAL MINE FATALITY - - On January 27, 2006, a 60-year old
heavy equipment operator with 10 years mining experience was fatally injured at a
crushed stone operation. He was operating a dozer to prepare a bench for drilling.
The dozer traveled over the edge of a 50-foot highwall and fell to the quarry floor,
submerging the cab in several feet of mud and water.
METAL/NONMETAL MINE FATALITY - - On
January 27, 2006, a 60-year old heavy
equipment operator with 10 years mining
experience was fatally injured at a crushed
stone operation. He was operating a dozer to
prepare a bench for drilling. The dozer
traveled over the edge of a 50-foot highwall
and fell to the quarry floor, submerging the
cab in several feet of mud and water.
Best Practices
Stop, Look, Analyze, and Manage (SLAM) each task to identify all potential hazards
before performing work. Maintain and wear seat belts when operating machinery. Always
keep the blade between yourself and the edge of the highwall when operating a dozer on
the highwall bench.
Operate equipment so that control is maintained. Reduce the throttle position and know
how to immediately stop the dozer when working near the edge of the highwall. Provide
adequate illumination when work is performed during non-daylight hours.
METAL/NONMETAL MINE FATALITY - On January 6, 2006, a 39-year old mechanic with 12
years mining experience was fatally injured at a sand and gravel operation while working on a
front-end loader. The front and rear sections of the loader had been separated at the articulation
joint and each section was independently supported with jack stands. The victim was positioned
between the left rear tire and frame to remove a hydraulic hose. The frame of the loader tipped
forward on the tires and swiveled to the left on the rear axle oscillation trunnion, pinning him.
METAL/NONMETAL MINE FATALITY - On January 6, 2006, a 39-year old mechanic with 12
years mining experience was fatally injured at a sand and gravel operation while working on a
front-end loader. The front and rear sections of the loader had been separated at the articulation
joint and each section was independently supported with jack stands. The victim was positioned
between the left rear tire and frame to remove a hydraulic hose. The frame of the loader tipped
forward on the tires and swiveled to the left on the rear axle oscillation trunnion, pinning him.
Best Practices
•Stop, Look, Analyze, and Manage (SLAM) each task to identify all potential hazards before
performing maintenance work. Practice safe work habits during the entire task.
•Consult and follow the manufacturer's recommended safe work procedures for the maintenance
task.
•Train miners in safe work procedures before beginning repairs.
•Securely block equipment against all hazardous motion at all times while performing
maintenance work. If the equipment being blocked has multiple degrees of movement of
freedom, exercise extreme caution because some instability modes may not be obvious.
METAL/NONMETAL MINE FATALITY - On November 18, 2005, a 52-year old repairman with
33 years mining experience was fatally injured at a crushed stone operation. A rubber-tired
boom truck was being used to lift a motor from its mounting base. The victim, who was
attempting to pry the motor free, was struck by the motor when it unexpectedly swung against
the crusher as it came free.
METAL/NONMETAL MINE FATALITY - On
November 18, 2005, a 52-year old repairman
with 33 years mining experience was fatally
injured at a crushed stone operation. A rubbertired boom truck was being used to lift a motor
from its mounting base. The victim, who was
attempting to pry the motor free, was struck by
the motor when it unexpectedly swung against
the crusher as it came free.
Best Practices
Stop, Look, Analyze, and Manage (SLAM) each task to identify all potential hazards.
Practice safe work habits during the entire task.
Disassemble all tensioned components to prevent a sudden release of energy before
dismantling equipment.
Position yourself only in areas where you will not be exposed to hazards resulting from a
sudden release of energy.
Train miners in safe work procedures and ensure they are familiar with manufacturer's
recommendations before beginning
METAL/NONMETAL MINE
FATALITY - On November 4,
2005, a 21-year old laborer with 5
weeks mining experience was
fatally injured at a crushed stone
operation. The victim was being
task trained to operate a haul
truck. While backing down a ramp,
he lost control of the truck. The
truck went through a berm,
overturned, and fell to the bench
below.
METAL/NONMETAL MINE
FATALITY - On November 4,
2005, a 21-year old laborer with
5 weeks mining experience was
fatally injured at a crushed stone
operation. The victim was being
task trained to operate a haul
truck. While backing down a
ramp, he lost control of the truck.
The truck went through a berm,
overturned, and fell to the bench
below.
Best Practices
Task train new miners in all phases of mobile equipment operation at locations designated for
training only. Provide classroom training that includes a thorough review of the Operator's
Manual before hands-on training of operating mobile equipment.
Experienced miners providing task training must be knowledgeable of all safety requirements
and proficient in the safe operation of mobile equipment.
Conduct pre-operational checks to identify any defects that may affect the safe operation of
mobile equipment before placing it into service.
METAL/NONMETAL MINE FATALITY - On October 28, 2005, a 32-year old crusher
foreman with 7 years mining experience was fatally injured at a sand and gravel
operation. The victim and another miner were moving a radial stacking conveyor to a
new position. The victim was positioned on the ground while a front-end loader was
used to move the unit. He was caught by one of the wheels of the stacking conveyor.
METAL/NONMETAL MINE FATALITY - On October 28, 2005, a 32-year old crusher
foreman with 7 years mining experience was fatally injured at a sand and gravel
operation. The victim and another miner were moving a radial stacking conveyor to a
new position. The victim was positioned on the ground while a front-end loader was
used to move the unit. He was caught by one of the wheels of the stacking conveyor.
Best Practices
•Stop, Look, Analyze, and Manage (SLAM) each task to identify all potential hazards.
Prior to starting the task, jointly discuss steps that will be taken to safely perform the
job.
•Ensure that miners communicate clearly with each other.
•Ensure that miners are not positioned in areas where they are exposed to hazards.
Most Frequently Cited Standards by Mine Type for 2004
www.msha.gov/STATS/Top20Viols/top20home.htm
Metal / Nonmetal Mines
 Mills – Metal
 Mills – Nonmetal
 Mills – Stone
 Sand and Gravel
 Surface Metal
 Surface Nonmetal
 Surface Stone
 Underground Metal
 Underground Nonmetal
 Underground stone
Coal Mines
 Plants – Coal
 Surface Coal
 Underground Coal
Most Frequently
Cited Standards
2004
Sand and Gravel
Standard Title
Number of
Violations
Percent
(%)
Standard
Guarding of Moving Machine Parts
2,988
13.3
56.14107(a)
Horns and Backup Alarms
1.377
6.1
56.14132(a)
Safety Defects
1.234
4.5
56.14100(b)
Electrical Conductors
829
3.7
56.12004
Preparation and Submission of MSHA
Report Form 7000
662
3.0
50.30(a)
Parking Brakes
642
2.9
56.14101(a)(2)
Berms or Guardrails
609
2.7
56.9300(a)
Guard Construction
565
2.5
56.14112(b)
Inspection and Cover Plates
515
2.3
56.12032
Insulation and Fittings for Power
Wires and Cables
514
2.3
56.12008
Testing Grounding Systems
496
2.2
56.12028
Safe Access
477
2.1
56.11001
Housekeeping
407
1.8
56.20003(a)
Handrails and Toe Boards
388
1.7
56.11002
Warning Signs
336
1.5
56.4101
Inspection
299
1.3
56.4201(a)(2)
First Aid
283
1.3
56.18010
Workplace Safety Records
282
1.3
56.18002(b)
Correction of Dangerous Conditions
251
1.1
56.12030
Requirements for Container Labels
246
1.1
47.41(a)
MSHA's Accident Prevention Program:
Tips and Ideas by Mine Type
www.msha.gov/Accident_Prevention/minetypes.htm
Surface Mines
Coal
Metal
Nonmetal
Stone
Sand and
Gravel
MSHA's Accident Prevention Program
Safety Ideas and Tips
By Mine Type
Sand and Gravel
Safety Ideas
Miner's Tips
•Blocking Against Motion
•Ask Someone Who Knows
•Chutes and Bins: Access
Without Spillage
•Avoid Dump-Point Hazards
•Cleaning Equipment Steps
•Bulk Truck Maintenance
•Conveyor Belts Move Faster
Than You Can
•Buried Gas Line Hazards
•Conveyor Belt Skirt Boards
•Conveyor Clean-up
•Conveyor Safety Features
Should Not Be Options
•Dump Point Warning Light
•Effective Annual Refresher
Training
•Electrically Insulated Matting
•Battery Safety
•Conditioning
•Contractor Safety
•Creating Understanding
•Designate Someone
•Don’t Get Caught In A Moving
Conveyor
•Downed Power Line
•Driller / Blaster
Communications
MSHA's Occupational Illness and Injury Prevention Program
Miner's Tips and Health Ideas by Category
www.msha.gov/Illness_Prevention/ippcategories.htm
Confined Space
Cold Stress
Disease
Dust Control
General Safety
Health
Heat Stress
Hygiene and Housekeeping
Knee Injury
Noise
Personal Protective Equipment
Remember
Your Health Comes First!
Previous MSHA Webcasts
Remember -- "Safety and Health are Values!"
www.msha.gov/webcasts/Webcasthistory.asp
For 2004
Metal/Nonmetal
Mine Safety and
Health
"SLAM" Stop Look - Analyze Manage"
October 12, 2004
See
Material
Metal/Nonmetal
Mine Safety and
Health
"Industry Needs U
in the Middle to
Reduce Fatalities"
January 22, 2004
See
Material
Stakeholder Best Practices
www.msha.gov/stakeholderbp/stakeholderbp.htm
Automated
Adding
Pipeline on a Dredge
Building
Can
External Defibrillator (AED)
A Safety Culture
You See What You're Breathing?
Changing
Cold
Screening
Weather Hazards
Contractors
Ensure
are Miners, Too
A Healthy Workplace
Fatigue
Heat
Caustic Soda *
Road Housekeeping
Stress - Summer Alert
Improving
Is
Your Pre-shift Inspection
that Cell Phone conversation worth the Price?
Keeping
the Truck Driver in the Cab
Maintaining
Mentoring
the Bank Edge
and Dismounting Equipment
Noise
Reduction in the Cab
Open
Pit Traffic Control
Oxygen-Acetylene
Plan
Recognizing
Red
Cutting Operations
Your Work and Work Your Plan
Work Zones
Flags of Substance Abuse
Reducing
Signs,
Handling
Haulage
Mounting
Silica Exposure
Signs, Everywhere There's Signs
Substance
Support
Abuse
the IRS (Increased Roof Support)
Suspended
Loads
Underground
Air Quality
Wellness
Windshield
Workboat
Access
Safety *
Equipment Safety and Health Concerns
Equipment Related Accidents
www.msha.gov/equipmentsafety/equipmentaccidents.asp
The following pages contain equipment related
accident data from 1995 - 2004. Searches can
be done for a particular year or by listed
equipment type, which then are linked to
fatalgrams and accident reports. Our goal is to
educate equipment operators and the mining
community about the hazards associated with
operating a specific type of equipment.
SLAM Risks
Stop - Look - Analyze - Manage
www.msha.gov/FocusOn/SLAM2004/SLAM2004.asp
The majority of fatal accidents have
these common root causes
•Failure to identify hazards
SLAM Risks the SMART Way!
•Failure to manage risks
Miners:
Stop
Look
Analyze
Manage
Mine Operators:
Stop
Think through the task
Identify the hazards for each job step
Determine if you have the proper knowledge, training, and tools
Remove or control hazards and use proper equipment
Isolate each step in a task and identify past and potential accidents,
injuries, and violations.
Measure Evaluate the risks associated with the task and barriers that have
allowed hazards to cause injuries
Act
Implement controls to minimize or eliminate any hazards that make
the risk unacceptable
Review Conduct frequent work site visits to observe work practices and audit
accidents, injuries, and violations to identify root causes
Train
Develop a human factor-based action plan and then involve and train
the miners
When Miners & Mine Management are
Risk SLAMMERS
together they
Make the RIGHT Decision and…