jacobs vehicle systems safety policy · participation in audits and inspections, reporting and...

Jacobs Vehicle Systems Safety Policy

Revised - October 6, 2004

JACOBS VEHICLE SYSTEMS SAFETY POLICY

Revision: 10/6/2004

TABLE OF CONTENTS I. Management Commitment to Safety ……………………………………………………… pg. 4 II. Duties ………………………………………………………………………………………... pg. 5 III. Safety Program Responsibilities …………………………………………………………… pg. 5

- Staff Responsibilities - Manufacturing Managers’ and Engineering Group Leaders’ Responsibilities - Duties of the Operations Manager and Engineering Lab Manager

- Employee’s Responsibilities

IV. Safety Audits ………………………………………………………………………………... pg. 7

- Departmental Audits V. Safety Committee ………………………………………………………………………... pg. 8

- Safety Steering Committee Role - Voluntary Protection Program/Star Points - Contractor Safety Committee - Incident Review Team - Safety Committee Authority

VI. Medical and First Aid ………………………………………………………………….… pg. 10

- General Treatment - Serious Injury - Lost Time Incidents and Illnesses

VII. Incident Reporting/Investigation ……………………………………………………….. pg. 12

- Reporting of Incidents - Forms Used for Reporting Injuries - Major Incident Procedure


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VIII. Safety Rules …………………………………………………………………………….… pg. 13

- Rules - Application

IX. Bloomfield Facility Visitor Safety and Security Policy ……………………………….. pg. 16 X. Safeguarding against Hazards …………………………………………………………. pg. 17

- Selection and Placement - Orientation - Training - Job Safety Analysis - Machinery Safeguarding

XI. Evacuation Plan ………………………………………………………………...……….. pg. 19

APPENDIX: 1. Risk Assessment Severity Matrix …………………………………………………………… pg. 21


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I. Management Commitment to Safety Date 10/6/2004

The Management of Jacobs Vehicle Systems is committed to achieving the highest possible levels of

health and safety protection for all employees, contractors, and visitors to the site through the development of safety programs that encourage training and education for our personnel, and hazard prevention and control within our facility.

The Management of Jacobs Vehicle Systems is committed to the empowerment of all employees, such that any employee may report an unsafe condition, safety hazard, or unsafe act without fear of reproach. We welcome all such reports, as they afford us the opportunity to correct these hazards before they can cause an injury or illness to anyone in the facility.

The Management of Jacobs Vehicle Systems is committed to identifying and eliminating all safety

hazards through the performance of regularly scheduled safety audits, systematically tracking the assignment and closure of action items, and by providing hazard recognition education to all of our associates.

The Management of Jacobs Vehicle Systems is committed to providing several meaningful ways for

our employees to become actively involved with our safety programs, through service on safety committees, participation in audits and inspections, reporting and investigation of near misses and accidents, and other safety programs.

The Management of Jacobs Vehicle Systems is committed to maintaining performance standards that have as a minimum requirement, 100% compliance with all relevant Federal and State regulations.

The Management of Jacobs Vehicle Systems is committed to achieving and maintaining the Star Certification awarded by the Occupational Safety and Health Administration’s (OSHA) Voluntary Protection Program (VPP). To that end, we will strive to create a world class safety culture committed to continuous improvement. In compliance with the regulations of the Voluntary Protection Program, we agree to submit Injury and Illness Logs, records documenting training, and safety inspections, and other pertinent information as requested. We welcome representatives of OSHA to perform on-site audits in conjunction with our quest to achieve and maintain the VPP Star.


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II. Duties

The safety and health of our employees is the number one concern of the Jacobs Vehicle Systems teams.

A. In order to meet the safety goals established by the various Safety Committees, we must all

work together, management, supervision, and employees. B. All employees will be held directly responsible for maintaining a safe and orderly

operation throughout the facility and for the prevention of accidents within it. The implementation and maintenance of an effective Safety Program will be part of the job standards by which each Manager will be appraised.

C. The Safety Engineer will oversee the Safety Committees and coordinate the Safety

Program and measure their effectiveness. D. All members of management shall be responsible for implementation of relevant parts of

the Loss Prevention Program within their area of responsibility. E. Each employee is expected to cooperate with management's efforts to proactively prevent

and eliminate accidents and make the company a safe place to work. The company will not tolerate willful disregard of safety rules or unsafe practices, which endanger people and/or company property.

F. There is no room for compromise in dealing with unsafe acts, unsafe tools, unsafe

conditions and unsafe equipment. All safety rules, practices and procedures are strictly enforced as a condition of employment.

G. It is a fundamental responsibility of managers to create and maintain an environment

within the facility in which all employees are encouraged to actively participate in this Health and Safety Program without fear of negative consequences.

III. Safety Program Responsibilities A. Staff

1. Drive top-level policy deployment initiatives and take the responsibility for over seeing and implementing the Safety Program.

2. Perform monthly safety audits with Star Points.

B. Managers and Engineering Lab Group Leaders


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1. It is the responsibility of managers (including Engineering Lab Group Leaders) to lead the safety program in their respective areas.

2. Safety Audits

a. Participate in all scheduled safety audits in their assigned areas utilizing the established safety audit checklist twelve times a year.

b. All open compliance items must be placed on KPI boards and acted upon within thirty days or have an action plan for timely completion.

3. Incident/Accident Reports

a. Initiate and be in charge of a thorough investigation of each incident.

Complete the Incident Review Report within one business day of an incident even if investigation is not complete.

b. Attend incident review meetings and take ownership for completion of corrective actions.

c. Communicate OSHA Recordable incidents and corrective actions to their respective teams as soon as possible after the event, to prevent future recurrence.

4. Safety Training

a. On the job safety orientation with all new hires in their area. (JSA, MSDS,

evacuation, and job specific hazards) b. Be in attendance with their team members at all OSHA required safety

training as scheduled by the Safety Committee. Lead weekly safety talks. c. Review the team’s safety performance, discuss and elicit teams safety

suggestions to improve safety during the teams weekly meeting. (i.e. safety KPI/data, OSHA recordables and open audit items)

d. Communicate all OSHA recordable incidents to team members and explain the corrective action taken.

5. KPI

a. Track, post and improve annual safety KPI’s in the manufacturing cells. 6. Operations Review a. Report KPI metrics, at monthly Operations Review. Review targets and

measurements at least annually, and as determined by the Safety Committee.


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7. Complete a Job Safety Analysis (JSA) on all new equipment, and every process in their area. These will be amended and changed as needed, at a minimum JSA’s must be reviewed annually. JSA’s must be written prior to the start of production (excluding prototype) of any new equipment.

8. Correct all safety hazards in their work area in a timely manner. (see Hazard

Assessment Matrix for severity rating)

C. Operations Managers and Engineering Lab Manager

1. Meet with their Managers and discuss safety within his/her area of responsibility, weekly and after each OSHA recordable incident.

2. Ensure that all open items noted on the safety audits are corrected under the direction of the Manager in a timely manner.

3. Work with the Safety Committee to monitor and act upon recognized safety issues. 4. All Operations Managers (or his/her designee when absent) must report in person

to the Company President, or via email/voicemail in his absence, all OSHA recordable incidents and the appropriate corrective actions that have been or will be taken within 24 hours of occurrence.

D. Employee Responsibilities

1. All injuries no matter how minor must be reported to the employee’s supervisor and medical department immediately. The employee must aid the supervisor in completing a supervisor’s incident investigation and report.

2. All employees must comply with Jacobs established safety rules. Each individual is responsible for their own safety and the safety of their surroundings. All employees must work in a manner that will not compromise the safety of themselves or their co-workers. All employees must report all unsafe conditions or acts to their manager immediately.

IV. Safety Audit

A. Departmental Audits

1. A Manufacturing Manager (Lab Manager) and a star point (see section V. B.) will perform a minimum of 1 safety audit per month.

2. All employees will be responsible to continually monitor all common areas resolving unsafe conditions or unsafe practices within their control.

3. Items that require additional resources should be reported to the appropriate Manager or appropriate President’s Staff member.


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4. Audit findings must be entered into the database. Managers must be responsible for completion of their corrective actions and bringing all submitted work orders to closure.

V. Safety Committee

A. Safety Steering Committee Role

The mission of the Safety Steering Committee is to provide a safe working environment at Jacobs Vehicle Systems through OSHA’s VPP program. This will be accomplished by meeting at a minimum of once a month and establishing quantifiable safety goals and objectives while assisting Managers with monitoring and maintaining safe work areas. The Safety Steering Committee will provide recommendations, assistance, direction, safety information and resources to the organization and identify areas for change and improvement.

Members of the Steering Committee JVS President A minimum of one Presidents’ Staff member A minimum of two bargaining unit members Safety Engineer Responsibilities of the Steering Committee

Monitor the Safety Program for effectiveness. Develop plant wide safety goals and objectives.

Promote safety awareness.

B. Voluntary Protection Program (VPP) Star Points

VPP Star Points make up a team of hourly and salaried employees who serve as safety representatives for their respective areas. When employees in a work area have safety concerns, they bring those issues to the attention of their Star Point. The Star Point in turn goes through the necessary channels to get the issue resolved. Star Points meet once a month as a team to report hazards and unsafe conditions, and discuss shop wide safety concerns and solutions with the team.

Members of the VPP Star Points One Bargaining Unit Representative from each business team on each shift One Salaried Representative from each office area in the facility

Responsibilities of the VPP Star Points • Perform on the job training with new associates to teach them about job specific safety

hazards, using the Job Safety Analysis (JSA).


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• Exemplify, encourage, and enforce safe behavior throughout the facility. • Perform monthly safety compliance inspections with their managers. • Listen to the safety concerns of their teammates and report them to the Safety

Department as soon as possible and review them at the monthly Star Point meeting. • Assist in investigation of Near Misses and Incidents, and review Job Safety Analyses

when necessary. • Participate in OSHA recordable incident investigations. • Coordinate with manufacturing managers to prepare and deliver weekly safety

presentations.

C. Contractor/Supplier/Visitor Safety Committee

The Contractor Safety Committee has been established first and foremost to develop and implement a process of Contractor approval for work on site at Jacobs Vehicle Systems. The committee must also review and audit contractor activity while on-site performing work to ensure the safety of the Contractors and JVS Employees. The committee meets at a minimum of once a month.

Members of the Contractor Safety Committee Safety Engineer Facilities Leader MRO Lead Buyer 3 Bargaining Unit Employees from various areas of the plant

Responsibilities of the Contractor Safety Committee

• Meet once per month. • Approve or deny potential contractors for work within the facility, based on the

quality of their Safety Program. • Perform periodic reviews (at least annually) of the Approved Contractor Master

List, and revise it as necessitated by changes to Contractors’ programs and/or safety records.

• Audit all contractors while they work onsite. • Report Contractor Safety Policy infractions to Contractor Management and follow

up on all recommended corrective measures. • Oversee risk assessment of tasks to be performed prior to performing work onsite.

D. Incident Review Team

The incident review team is a cross functional team comprised of bargaining unit and salaried employees formed to make sure that incidents are investigated thoroughly and in a timely manner. The team reviews action plans for appropriate corrective action and makes sure managers follow through to correct hazards as soon as possible.


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Members of the Incident Review Team • A minimum of one bargaining unit representative. • The Safety Engineer, Compliance Officer, Occupational Health Nurse and other

salaried employees who bring varied skills to the team. • Manufacturing Managers present their open and near miss incidents on a weekly or as

needed basis. • Star Points that have open corrective action items for OSHA recordable incidents in

their areas.

Responsibilities of the Incident Review Team • Oversee incident reviews by providing assistance with investigations and ensure timely

and thorough completion of supervisor incident reports and near misses. • The committee has established a daily investigation schedule. On a rotational basis,

team members are responsible for leading the incident investigation with the manager. Team members meet weekly to review reports and recommendations for corrective action.

• Ensure that managers attend meetings when they have open incident reports and action items.

• Provide the necessary support in bringing the open corrective actions to closure in a timely manner.

• The safety investigation team is responsible for investigating every incident and recording their findings on the supervisor incident report.

E. Safety Committee Authority

Safety Committee members have the authority to conduct unannounced departmental inspections, investigate safety concerns and to take any necessary immediate action to ensure safe working conditions.

All JVS employees have the authority to stop work in an area where a safety hazard represents imminent danger. (This means the existence of any condition or practice that could reasonably be expected to cause immediate death or serious physical bodily harm as defined by Risk Assessment form in Lotus Notes database entitled safety compliance.)

VI. Medical and First Aid A. General Treatment

1. The Occupational Nurse or first aid responders will provide employees, and visitors who become ill or are injured in the facility prompt and adequate first aid.


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2. The Manager is responsible for ensuring that employees in his/her area of responsibility receive proper medical attention in the event of an on-the-job injury or illness.

3. All employees will comply with a Manager’s or his/her designee’s request that the Occupational Health Nurse evaluates his/her work-related injury or condition.

4. The Medical Department will establish policies regarding treatment of injured personnel, contacting Emergency Medical Services, transportation of injured personnel to a health care facility, and allowing the injured worker to receive adequate follow up care.

5. The Medical Department and its designees will be directly responsible for the maintenance of all first aid cabinets.

6. The Medical Department will be responsible for continuous follow-up on injured employees. The objective of following up will be to assure that the employee is receiving adequate medical attention and to facilitate the transition back to work in a timely manner.

7. Any employee out of work for five days or more due to illness is required to call the Occupational Health Nurse before returning to work. If the physician is not available on site the nurse will contact the physician and a decision will be made at that time whether the employee is able to return.

8. Any employee injured in a motorcycle/auto accident, any type of surgery, or home accident involving any lost time is required to contact the medical department before return to work. The Occupational Health Nurse will decide whether the employee must be seen by the Company Physician.

9. Any employee injured on the job is required to be examined and seek follow up care from the Company Physician at the Occupational Nurse’s discretion, regardless of whether they are being treated by an outside MD.

B. Serious Injury/Illness

1. If an injury/illness is severe enough to warrant the services of an EMT, Paramedic

or ambulance, dial the emergency number (EXT. 7510) or dial 9-911 directly from any plant phone that has access to an outside line, or dial 9-1-1 from any pay phone.

2. An injury that is serious enough to require the services of a medical doctor must be reported immediately to the Medical Department. If the nurse is not in attendance, notification must be communicated by voice mail so she may act upon the incident as soon as she returns.

3. Should an injury occur, the Occupational Nurse, security or the Manager is responsible for seeing that the injured individual gets immediate medical attention. If the Occupational Nurse is not available, it becomes the immediate responsibility of the Manager/designee to send the employee to the doctor or hospital.

4. After the individual has been given proper medical attention, it shall be the responsibility of the trained Manager/designee and the area Star Point to conduct a thorough investigation of the incident and to complete the Incident Report within


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one business day (refer to Section VII, Incident Reporting/Investigation). A corrective action report must be completed and submitted to the Incident Review Team. Members of the Incident Review Team may aid the manager in the investigation. Members of the Incident Review Team will be dispatched based on the established rotation schedule.

5. An up-to-date list of qualified First Aid Responders will be distributed to each Manager and posted on each of the four first aid boxes in the plant, on the medical office door and at the reception desk.

C. Lost Time Incidents and Illnesses

1. A workplace incident or occupational illness that causes the employee to be absent

from work, starting with the next regularly scheduled shift, shall be recorded as a DAFW (Days Away From Work) Case.

2. If an individual loses any time from work as a result of an accident in the plant, it should be reported to Medical Department immediately.

3. It is the responsibility of the Manager to investigate all injuries and accidents that have occurred to their direct reports, whether they result in lost time or not.

VII. Incident Reporting/Investigation A. Reporting of Incident

1. Each incident, no matter how minor, is to be reported to the employee's immediate Manager or his/her designee during the current shift. If an employee goes home without reporting an accident/incident, the company may assume the incident is not serious. When an incident is not promptly reported the company may have no way of verifying if the incident happened on the job, and workers’ compensation may be denied in such cases. Incidents that may come to light that were not reported immediately will subject the employee to progressive discipline up to and including discharge.

2. Managers are responsible for encouraging near miss and incident reporting among employees. Managers need to promptly collect all relevant data regarding incidents.

3. Proper reporting of incidents will be emphasized to all employees by the Medical Department, the safety engineer and reemphasized by the Manager periodically.

B. Forms Used for Reporting Injuries

1. First Aid Log

The First Aid log is located in the Medical Department. All incidents are to be logged at the time of treatment by the Occupational Nurse, First Aid Responder or Manager /designee.


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2. Manager Incident Report

The Manufacturing Manager or his/her designee is responsible for the investigation

and completion of the Lotus Notes incident report within 24 hours of an incident. He/she must investigate or report his/her findings to their Operations Manager so

that the Operations Manager may report the incident and corrective action to the Company President.

3. OSHA 300 Log

a. All recordable injuries will be recorded on OSHA’s 300 Log Form. The

OSHA’s 300 Log Form summary will be posted annually on February 1 and will remain posted for three months.

b. All OSHA recordable injuries shall be recorded in the OSHA - 300 log within seven calendar days of receiving information that a recordable injury or illness has occurred.

c. The Occupational Nurse will be responsible for maintaining these reports. C. Major Incident Procedure

1. Definition: A major incident is any situation that may result in significant loss of property

or person (i.e. death, dismemberment, significant property loss and threats of environmental harm.)

2. Do not allow any part of the incident scene to be disturbed unless it poses a threat to others (i.e., turning off power, etc.). Any machine posing risk of injury shall be shut down and Locked Out immediately.

3. Record the names of all involved, including witnesses, all persons in the area, and anyone else who was involved with the incident.

4. Fully document the scene of the incident with photographs before anything is displaced. 5. If the scene is contaminated with any bodily fluids, it should be treated as though the

bodily fluids are infectious. The area should be secured (until decontaminated). Only trained personnel (i.e. first aid responders/nurse) are to decontaminate and clean the accident scene.

6. Refer to the Emergency Call List to notify the appropriate management personnel. The Security Guard and Manufacturing Managers maintain this list.

VIII. Safety Rules

A. Safety is the responsibility of every employee. These instructions are not intended to be

the limit of safety guidelines and cannot possibly address all situations. Special situations or conditions may require additional guidelines as specified by management at the time the condition or situation is encountered.


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1. All suppliers, customers, vendors, visitors, contractors and Jacobs employees will wear

safety glasses with clear lenses and side shields, that meet OSHA specifications 1910.133 anywhere within the Production Facility and engineering lab. Office areas, conference rooms, restrooms, picnic tables during breaks, manufacturing cubicle offices, Dyno control room, hallway to blue building and the cafeteria are the ONLY excluded areas.

2. All employees assigned or working in the production facility in designated hearing

protection areas will wear hearing protection at all times.

3. Steel toed fully enclosed, oil /slip resistant safety shoes will be worn at all times by anyone entering the production facility. Office areas, restrooms, cafeteria, and main green walkways are excluded from this requirement. Special shoes may be required of certain employees (i.e. electrical hazard shoes for electricians).

4. Customers, suppliers, visitors, contractors and Jacobs employees may wear flat-soled,

fully closed, (rubber soled) non-skid footwear when walking within the main walkways of the facility and during tours of the engine laboratory.

5. The style of dress and personal grooming (i.e. hair length, beard, etc.) shall not present

a safety hazard while operating machinery. Therefore, in all areas of the production facility, hair that can extend lower than shoulder length must be contained in such a way that it does not present a hazard while working with machinery.

6. Wearing jewelry when working with machinery or handling material is a recognized

hazard with the potential for serious injury. Jacobs has established and will enforce the following Industry Best Practice. When anyone is working with machinery or handling material in the production facility, blue building or engine lab, the wearing of the following jewelry is forbidden:

Rings Watches Bracelets Necklaces Any type of hoop (nose, ear, eye) Any earring that extends below the earlobe.

7. Bare midriffs are prohibited

8. Shorts are not allowed in the production facility or engine lab. Skirts, dresses and capri

pants are not to be worn in the production cell areas.

9. Loose hanging clothing is prohibited while working on machinery.


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10. Any other form of clothing that presents an obvious risk to safety is prohibited.

11. Running is not permitted in the facility.

12. Walking or stepping onto conveyors, skids, or boxes of any type is prohibited.

13. Good housekeeping rules, striving for 5S, are to be followed at all times.

14. Anyone operating equipment in the facility must be trained and are to follow safe

operating rules.

15. Employees are expected to be thoughtful and orderly in their conduct. "Horseplay" and fooling around will not be tolerated.

16. Before using any chemicals, employees shall be trained in hazard communications and

understand their Material Safety Data Sheets (MSDS).

17. Keep all equipment controls free from obstructions.

18. All safety guards and devices must be in place while equipment is operating. Removing a safety device for other than maintenance purposes is a willful safety violation that can be subject to disciplinary action.

19. Correct hazards of imminent risk before starting equipment.

20. Allow only authorized personnel to lockout/tagout and service the equipment.

21. If the equipment design allows loading or inspection of the product by the operator, the

operator must stay in the specified area and strictly adhere to standard operating procedures.

22. Employees must participate in all training identified by the Safety Committee.

{Examples may include: fork lift operations, crane operations, fire safety and evacuation, hazard communication, lockout / tagout, emergency response plans, electrical safety, machine guarding, use of personal protective equipment, etc.}

23. All employees will be responsible to continually monitor all common areas resolving

unsafe conditions or unsafe practices within their control. (i.e. if you see a spill, mop it up).

24. Any conditions or practices, which appear unsafe, must be reported to the Manager,

Safety Star Point or Safety Engineer.


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25. Employees must exercise care for their personal safety and do everything possible to avoid personal injury and avoid injuring other employees. Employees must take responsibility for their own actions.

26. Employees shall be safety conscious and give their Manufacturing Managers, Safety

Star Points or Safety Engineer any suggestions they have for improving safety measures or devices.

27. No one should ever put their hands into moving chip conveyors or other rotating parts.

B. Application

It is the responsibility of every individual in the facility to ensure that safety instructions are followed.

1. This safety policy must be reviewed with all new hires and temporary employees

prior to employment. Job specific safety guidelines must be reviewed with all employees and the star point in their area before job assignment.

2. If safety instructions or procedures are ignored or safety equipment is not used properly, disciplinary action up to and including termination will be enforced.

3. The Central Steering Committee shall review this safety policy annually. IX. Bloomfield Facility Visitor/ Supplier/ Contractor Safety and Security Policy All Visitors are required to sign in with the Guard or Receptionist on duty, receive a numbered Visitor’s Badge, and record the time of arrival and party or area they are calling on. All Visitors not recognized as Approved Contractors or Approved Visitor/Vendor/Suppliers must be accompanied by a Jacobs Vehicle Systems Representative/escort at all times. All visitors must wear safety glasses with side shields at all times while in the manufacturing facility or engine laboratory. Safety glasses will be provided by or approved by Jacobs Vehicle Systems Security or Reception. Visitors entering the manufacturing facility are required to wear rubber soled shoes and may not wear spike heels or heels more than ½” high. Regular and steel/ composite toed shoes may be available at the front desk. Visitors may not enter a manufacturing cell or Test Cells within the Engineering Lab unless wearing steel toed shoes and hearing protection if working on the manufacturing floor. Regular and steel/composite toed shoes may be available from the Security Personnel. Hearing protection is available from the Cell/Lab Manager.


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Visitors must comply with all safety policies and procedures for the specific area they are working in. This includes wearing any personal protective equipment as advised by management and following any other procedures as advised by management. Visitors must immediately report to their Jacobs Vehicle Systems escort, security and their supervisor from their company management any accident or injuries, regardless of how minor. This includes, cuts, bruises, strains, falls, splinters or any other issue. If a visitor is involved in an incident and does not report such incident, they accept full personal responsibility for such incident and agree to hold the company (Jacobs Vehicle Systems) harmless for any and all possible claims or actions that could potentially occur as a result of such accident. X. Safeguarding against Hazards

A. New Hire Selection and Placement

1. All new hires are to be placed in jobs only after careful consideration of the employee's qualifications relative to the physical and safety requirements of the job.

2. New hire physical exams will be conducted by the Company and will include drug testing.

3. The physical requirements of the job will be explained to the prospective employee during the interview process.

B. Orientation

1. The safety engineer provides safety orientation including but not limited to

emergency evacuation procedures, incident reporting procedures, back safety, Bloodborne Pathogen procedures, pedestrian safety, machine guarding, PPE and VPP.

2. Before starting their work, the manager shall ensure that all new employees have

completed their work specific Safety Orientation. Orientation will include: a. Plant safety instructions along with any special rules or personal protective

equipment required, reviewed with instructions on proper fit. b. The role of the employee regarding safety, reporting safety concerns, and

reporting accidents/incidents. c. Emergency Evacuation Procedures. d. Hazard Communications.

3. If the newly hired employee passes the physical, the Medial Department will

review the following safety policies with the employee: a. Hearing protection


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b. Eyeglass policy c. Safety shoe policy d. Injury reporting e. Absenteeism f. Return to work after illness/injury g. Ring/jewelry/proper attire and hair policies i. Fire exits

C. Training

1. Training will contain the safety factors as set forth by standard work. 2. It will be the responsibility of the Manager to see that safety factors are emphasized

to all employees during their training periods. 3. The Manager, in conjunction with manufacturing/facility engineers and the Safety

Committee will be responsible for determining other supplemental safety training needed for employees (i.e. hearing conservation, forklift training, personal protection equipment etc., as applicable). Selection of personal protection equipment will be in accordance with the safety department.

4. The planning of special training sessions will be the responsibility of the safety department.

5. All First Aid attendants are to be trained and certified bi-annually in CPR and every three years in First Aid procedures including bloodborne pathogens.

D. Job Safety Analysis

1. The Manufacturing Managers and Engine Lab group leaders are responsible for

ensuring and promoting safe work practices, equipment, tools, and materials for the employees in his/her area. To accomplish this, the Manager must know the jobs under his/her supervision and be aware of potential safety hazards associated with these job processes.

2. Job Safety Analyses is performed in each manufacturing area within the context of standard work on each job process and all pieces of equipment in the production facility. A Job Safety Analysis shall be reviewed and revised accordingly. A job safety hazard analysis must also be completed for all line changes or new equipment installed in the cells prior to being released for production (excluding prototype). The results will be entered into a Lotus Notes database. It is the responsibility of each Operations Manager to implement appropriate engineering or administrative controls to abate hazards.

3. Once the Safety Analysis is complete and the necessary control measures are established the analysis will become a part of each job-training package. The analysis will also be maintained on file in Lotus Notes. The analysis will be used in the placement and training of employees, accident investigations, and in the day-to-day supervision of the employees.


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4. The Job Safety Analysis will specify the need for any special tools, and/or personal protective equipment.

5. The Job Safety Analysis serves to verify the safety of standard work requirements. 6. Line operators should be involved in the Job Safety Analysis review process.

7. Managers should ensure the safety of all process and equipment changes made in their area.

E. Machinery Safeguarding

1. Each machine or piece of equipment within the facility will be safeguarded for

maximum feasible protection against accidents. Safeguarding will be consistent with Federal OSHA and EPA laws and regulations.

2. The appropriate energy isolating lockout, tagout procedure established in the company’s lockout, tagout program, must be in effect on all machines when required (i.e. maintenance, servicing, adjustment, jammed equipment, removing guards, cleaning, etc.) The procedures are on file in the Maintenance department. The Facilities Leader and the Compliance Engineer maintain the master list. A computerized version of the document exists on the Jacobs Share Drive at, H://Share/Public/HR/Safety/Safety Policies/LOTO Program.doc.

3. The Facilities Leader and Electricians will ensure that all machinery interlocks are in proper working order.

4. No unauthorized employee shall perform Lock Out Tag Out or Maintenance on any piece of equipment. Any employee performing maintenance work on a piece of machinery or equipment without isolating all forms of energy and power sources shall be subject to disciplinary action. Where troubleshooting is required, it is acceptable to troubleshoot the equipment while power is being supplied, as long as the employee performs lock out tag out procedures once the problem is identified, and prior to beginning repairs on the machinery.

XI. Evacuation Plan

Any fire or emergency that may require evacuation of the building is to be reported to the Security Desk (Guard Station) by dialing 7510. All plant phones should have a Red Emergency Sticker attached to them with the emergency # 7510 (It should be noted that Jacobs Personnel are not required to perform any fire fighting duties).

The guard will sound the evacuation signal (a series of loud High-pitched beeps and flashing strobe lights) by pulling the Fire Pull alarm located in the Main Lobby in front of the Security Desk. The alarm will be sounded for several minutes and an announcement will be made over the public address system. AS SOON AS YOU HEAR THE ALARM, YOU MUST IMMEDIATELY EXIT THE BUILDING. Do not stop to get personal belongings or anything else. Announcements will be made as appropriate to indicate a test, a fire drill or an actual emergency in the building.


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Fire/Emergency Evacuation announcements are made by the Security Guard using the public address system microphone at the Security Desk. Do not wait for the announcement but begin exiting the facility immediately when the alarm signal is heard.

Upon hearing the evacuation signal, the Fire Monitors (acting Cell Mangers or designees) or their alternates will see to it that all employees, visitors, and contractors in their area of responsibility leave the building by the nearest exit to their workplace. Employees driving fork trucks should park, leaving aisles clear, leaving any keys with the truck, and proceed on foot out the nearest exit. These evacuation routes are posted throughout the plant.

Once outside the building, employees are to report to their assigned "Rally Point" and "Fire Monitors" so that the fire monitors and alternates can take a head count to determine if anyone is missing and possibly left in the building. Fire Monitors shall report all missing persons to one of the Emergency Response Coordinators who will report to the Security Desk via Walkie-talkies. The Security Officer will compile a list of missing persons for use by the fire and rescue services. "Rally Points" are indicated on the Evacuation Plan posted throughout the building. Note: On Weekends and off-shifts (2nd & 3rd shifts) everyone will exit at the nearest exit and report to Rally Point # 1 (Main Parking Lot).

Employees are to remain outside of the building at their designated Rally Points until a Senior Management Official or an Emergency Response Coordinator notifies them that it is safe to re-enter the building. In the event of an actual fire or chemical release the decision to re-enter the building will be made under the direction of the Fire Department or other Emergency Response Agency.


Revision: 10/6/2004

APPENDIX 1: Risk Assessment Severity Matrix

Consequence/Severity Risk Assessment

0 - Minimal 1 - Slight 2 - Moderate 3 Severe/Serious

Likelihood 5 - Almost Certain 0 5 10 15 4 - Likely 0 4 8 12 3 - Possible 0 3 6 9 2 - Unlikely 0 2 4 6 1 - Rare 0 1 2 3

Required Action

Red = High Risk Immediate Operational Shutdown & Risk-Assessment Attention and Fix

Orange = Medium Risk Immediate Risk Assessment, Implement Immediate Short-Term Hazard Control and define Long-Term Corrective Action if Necessary

Yellow = Low Risk Risk Assessment within 24 Hrs., Implement Corrective Action as Required .

Green = Very Low Risk Risk Assessment within 24 Hrs., Implement Corrective Action as Required .

White = No Risk No Action Required


Revision: 10/6/2004

Severity Rating Level Description

3 - Severe/Serious Could likely result in a Permanent Injury or Death

2 - Moderate Likely to result in an OSHA Recordable Incident

1 - Slight/Minor Likely to result in a 1st Aid Incident

0 - Minimal No injury or adverse outcome likely. Recognized as harmless.

Frequency of Occurrence Rating

Level Descriptor Description

5 Certain Likely to occur or Re-occur on many occasions

4 Likely Will probably Occur or Re-occur but not an everyday event 3 Possible May Re-occur occasionally

2 Unlikely Do not expect it to happen or happen again but possible 1 Rare Can't believe this will happen or happen again

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