macadamia processing co. limited · risk – the possibility that harm (death, injury or illness)...

Revision Date: 3/02/2016 Date Printed: 8/02/2016 8:37:00 AM

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2016

MACADAMIA PROCESSING CO. LIMITED

Induction Training Manual

TOPIC 3 – WORK HEALTH AND SAFETY

PART 1 – Work Health and Safety General PART 2 – Hazardous Manual Tasks PART 3 – Lock Out / Tag Out PART 4 – Personal Protective Equipment (PPE) PART 5 – Injury Management.


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PART 1 – WORK HEALTH AND SAFETY – GENERAL

What is this training module about?

This module provides information on MPC safety systems including Risk Assessment and emergency procedures.

Goal of Work Health and Safety

That you leave your employment here in the same physical/mental condition that you arrive in (considering fair wear and tear).

Legislation

Current Health and Safety laws commenced 1st January 2012 with introduction of the Work Health and Safety Act 2011 and the Work Health and Safety Regulation 2011.

Terminologies

PCBU – Previous legislation referred to “Employers”. This has now been expanded to cover any “person conducting a business or undertaking” (PCBU) and includes a retailer, wholesaler, manufacturer, importer, owner driver……..

Officer – An officer is someone who makes or participates in making decisions that affect the whole or a substantial part of a business or undertaking. Eg Director, CEO, Chief Financial Officer.

Reasonably Practicable – What can be done? What is reasonably able to be done considering likelihood, degree of harm, what is known or ought to be known, availability of solutions and after accessing the above you might consider costs.

Worker – Previous legislation referred to “Employees” This has now been expanded to cover all workers and includes employees, labour hire staff, volunteers, work experience students, contractors, sub-contractors, apprentices, trainees and out-workers.

Others – Clients, customers and visitors in a workplace are collectively known as “Others” and their duties are similar to those of a “Worker”.

HSR - While the previous legislation placed emphasis on OHS Committees in the consultation process the new legislation allows a Health and Safety Representative (HSR) with increases powers to play an important role in the consultation process between workers and PCBUs.

HSC – The previous OHS Committee will now be called the Health and Safety Committee (HSC) and can consider the management of health and safety across the whole workforce complementing the activities of the HSR.


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This may include:-

Facilitating co-operation between the PCBU and Workers to instigate, develop and carry out measures to secure the work health and safety of workers.

Assisting in developing health and safety standards, rules and procedures that will be followed and complied with at the workplace.

Other functions agreed by the PCBU and members of the HSC.

Legal Responsibilities

Both PCBUs and Workers have responsibilities to ensure that their duty of care must be fulfilled so far is reasonably practical to make the workplace safe for all person(s) at the place of work. There are Acts and Regulations with which all workplaces MUST comply. In other words, lack of compliance by any workplace with any of those Acts and Regulations places the offending workplace in a position where it would attract various levels of legal penalties depending on the severity of the non-compliance.

However there also exists code of practice, and industry standard with guiding notes. PCBUs are expected to comply with the codes of practice and their industry standards. But that is only an expectation – compliance is voluntary.

Health and Safety Committees

WHS Consultation Sixth Law of Human Communication

‘people are more likely to listen to us if we listen to them’

The WHS Act 2011 places a duty to consult on each PCBU. Under the duty, PCBUs must consult with their workers to enable the workers to contribute to the making of decisions affecting their health, safety at work. The role of the Work Health and Safety Committee includes monitoring and reviewing all WHS aspects of MPC’s Work Health and Safety Human Resources (WHSHR) Management System. The committee consists of two appointed PCBU Representatives and four elected WH&S Employee Representatives who play an integral role in the consultation process between employees, supervisors, managers, engineering and maintenance personnel, contractors and others concerning WHS issues.

MPC Health and Safety Committee

Graeme Lynch – Worker representative (Chairperson) Kerry Whitney – Worker Representative (Morning Shift) – Worker Representative (Afternoon Shift)


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– Worker Representative (Night Shift) Phil Close – PCBU Representative Allen Holmes – PCBU Representative and HSR

MPC WHS Policy

Organisation Commitment

Macadamia Processing Co. Limited (MPC) considers the work health and safety of all persons working for the company, and those visiting the company, to be of the utmost importance. MPC is committed to the development, implementation and periodic review of the Work Health and Safety Human Resource Management System (WHSHRMS) which aims to prevent work-related injuries and illness from occurring. This system is integrated within the overall management system and reflects the company’s vision and values. In order to establish and achieve measurable and meaningful WHS targets and objectives, MPC recognises that effective consultation, consistent co-operation and ongoing involvement with WHS are required at all levels within the company structure. MPC subscribes to the principle of continuous improvement in all areas, including WHS, and is committed to the provision of appropriate resources in order to achieve compliance with all relevant Acts and Regulations and to ensure health and safety in the workplace.

Work Health and Safety Management System

In order to implement the general provisions of this policy, a management system incorporating policies, procedures and programs is developed, implemented and regularly reviewed. The system addresses all aspects of work health and safety including:

a. Development of WHS policies and procedures. b. Training and provision of information to employees and others. c. Consultation arrangements. d. Risk management strategies. e. Work design, workplace design and safe operating procedures. f. Changes to work methods and practice, including those associated with

technological change. g. Emergency response. h. Reporting, recording and investigation of incidents/accidents. i. Injury management and return-to-work programs. j. Provision of appropriate equipment, services and facilities to ensure health

and safety.

Responsibilities

Senior Management

The General Manager and Board of Directors referred to as “officers” under the Work Health and Safety Act 2011, accept overall responsibility and accountability for the effective management of work health and safety.

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Managers

Each Manager is required to ensure that this policy and the WHSHR Management System are effectively implemented in their area of control, and to support supervisors and hold them accountable for their specific responsibilities.

Supervisors

Each Supervisor, Foreman and Leading-Hand is responsible, and will be held accountable, for taking all practical measures to ensure:

a. the workplace under their control is safe and without risks to health. b. the behaviour of all persons in the workplace is safe and without risk to health. More specifically:

The Supervisor, Foreman or Leading-Hand, will be held accountable for detecting any unsafe or unhealthy conditions or behaviour.

If the Supervisor, Foreman, or Leading-Hand, does not have the necessary authority to rectify a problem, they shall be held accountable for reporting the matter promptly, together with any recommendations for remedial action, to a Supervisor or Manager who does have the necessary authority.

Managers and Supervisors

The Manager or Supervisor who has the necessary authority shall be held accountable for taking prompt remedial action to eliminate any unsafe or unhealthy conditions or behaviour.

Managers, Supervisors and Employees

All workers at MPC are required to comply with the WHS policy and programs to ensure their own health and safety and the health and safety of others in the workplace. Breaches of this policy or other health and safety directives may result in disciplinary action, up to and including dismissal.

Contractors/Visitors

All contractors engaged to perform work on/at MPC’s premises are required to comply with MPC’s work health and safety policies, procedures and systems and to observe directions on health and safety matters from designated officers of the organisation. Failure to comply or observe a direction will be considered a breach of contract and sufficient grounds for termination of the contract and/or vacating MPC property.

General Risk and Workplace Management

The WHS Act and Regulations require persons who have a duty to ensure Health and Safety to ‘manage risks’ by eliminating risks so as far is reasonably practicable and if it is not reasonably practicable to do so, to minimise those risks so far as is reasonably practicable.

What is the Risk Management Process

Risk Management process is the systematic application of management policies, procedures and practices to the activities of communicating, establishing the context and identifying, analyzing, evaluating, treating, monitoring and reviewing risk.


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Risk – The possibility that harm (death, injury or illness) might occur when exposed to the hazard. Hazard – Means a situation or thing that has the potential to harm a person. (Hazards at work may include noisy machinery, a moving forklift, chemicals, electricity, work at heights, a repetitive job, bullying and violence at the workplace.) Risk Control – Taking action to eliminate health and safety risks so far as is reasonably practicable, and if that is not possible, minimizing the risks so far as is reasonably practicable. Eliminating the hazard will also eliminate any risks associated with the hazard. Incident – Something that has happened that could have caused an injury but didn’t, ie “near misses”.

Identify Hazards

Definition

The process of identifying tasks and activities which could result in injuries or harm.


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Purpose

To collect information and look for trends on hazardous tasks. In general, three identification techniques are used. These may be employed either in isolation or in combination. The three identified techniques are:

1. Inspect the workplace, eg formal inspection, observation; 2. Consult with workers, eg ask, surveys, reports, committees; 3. Review information, eg publications, statistics.

Common Hazards

Manual tasks, gravity, electricity, machinery and equipment, hazardous chemicals, extreme temperatures, noise, biological and Psychosocial hazards.

Assess the Risk

A risk assessment involves considering what could happen if someone is exposed to a hazard and the likelihood of it happening, a risk assessment can help you determine:

How severe a risk is

Whether any existing control measures are effective

What action you take to control the risk

How urgently the action needs to be taken. A risk assessment can be as simple as a discussion with your workers or involve specific risk analysis tools and techniques recommended by safety professionals. A risk assessment should be done when:

There is uncertainty about how a hazard may result in injury or illness

The activity involves a number of different hazards and there is a lack of understanding about how hazards may interact with each other to produce new or greater risks.

Changes in the workplace that may impact on the effectiveness of control measures.

A risk assessment is not necessary in the following circumstances:

Legislation requires some hazards and risks to be controlled in specific ways

A code of practice or other guidance sets out ways of controlling a hazard or risk

There are well known and effective controls that suit the circumstances.

If one wishes to know whether a risk exists and, if it can be predicted, what precautions are to be taken in advance to avoid its reoccurrence – a risk assessment must be conducted. To assist in the assessment and subsequently the ranking of the level of risk the use of a two-dimensional matrix is one approach and the approach that MPC currently utilises.


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Work out the Severity considering:

What type of harm could occur?

What factors could influence the severity of harm that occurs?

How many people are exposed both inside and outside the workplace?

Could failure lead to other failures?

Could a small event escalate? Work out the Likelihood considering:

How often people are exposed to the hazard?

How long might people be exposed to the hazard?

The effectiveness of current controls?

Could work organisation increase the likelihood?

The work environment including infrequent and abnormal situation?

Could the way people act or behaviour affect the likelihood?

Do differences between individuals make it more likely for harm to occur? The assessment should also take the following into account:

How work is actually done, eg posture, actions and movements required

The layout and design of the work station or workplace

The location of loads and the distances they have to be moved

Weights and forces involved

Characteristics of the load and equipment

Skills, experience and personal factors.


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Controlling the Risks

Definition

The process of eliminating or minimising the risks so far as reasonably practicable.

Purpose

To make the job or task safer for employees.

Controlling risks are ranked from highest level of protection and reliability to lowest. Level 1 – Eliminate Level 2 – Substitute, isolate or engineer Level 3 – Administrative actions, Personal Protective Equipment (PPE).

To fix the problem a combination of the above methods may be required.

All risks can be controlled by such measures as stopping the activity or providing instruction. There are normally options between these two extremes. Cost may be taken into account, but cannot be used as a reason for doing nothing.

Implementing Controls

Control measures usually requires changes and it is usually necessary to support control measures with:

Revised work procedures

Training

Supervision.

Ensure control measures remain effective

Action that may help:

Accountability for health and safety

Maintenance of plant and equipment

Up to date training and competency

Up to date hazard information

Regular review and consultation.

Review Controls

Control measure should be reviewed when:

Control is not effective

Before a change is likely

A new hazard is identified

Consultation indicates a review

If a HSR requests a review.


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Keeping Records

Demonstrates possible compliance

Demonstrates how decisions were made

Assists targeting training

Provides a basis for safe work procedures

Allow easier review of risk assessments

Demonstrates to others that health and safety risks are being managed.

Consultation

A team approach is the most effective way of controlling hazards and risks. Workers should:

Report unsafe conditions immediately

Advise your Foreman/Leading Hand and or complete an Employee Hazard

Report form available in the lunchroom.

Report incidents or accidents including near misses

Advise your Foreman/Leading Hand and complete an Incident/Accident Report Form available in the lunchroom.

PCBUs (Employers) should

Take action to identify and minimise hazards.

REMEMBER TO DO NOTHING IS NOT AN OPTION.


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MPC General Safety Rules:

Reduce the risk of being injured or injuring others by adhering to MPC General Safety

Rules:

Always wear PPE that is in good condition when required

Running or skylarking in any part of the factory is hazardous and forbidden (e.g.

rushing, chasing, fighting, wrestling, throwing any item, hosing others).

Do not operate machinery unless training has been provided, authorisation has

been granted and safety guards are in place.

Do not use hot water or compressed air to wash boots, clothing or PPE

equipment while still wearing them.

Do not use hazardous substances or chemicals without training, PPE and

authorisation.

Use designated walkways when moving between work sections/areas.

Ensure effective communication when working with or near mobile plant.

Don’t arrive at work over-tired or under the influence of alcohol or drugs

(prescribed or illegal).

Bullying and violence will not be tolerated.

Work within your physical capability (lifting, reaching, repetitive movements).

Don’t perform any action/task unless you are trained and confident you are

following MPC procedures (ask your supervisor if in doubt).

Drive to conditions in car park (not exceeding 10kph) considering other vehicles

and pedestrians.

Pedestrians should avoid walking behind vehicles when traversing the car park

(you may be unsighted by the driver).

Never leave factory grounds without permission after starting your shift or during

evacuation situations.

Understand and obey signage throughout the factory.

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Signage:

Prohibition Signs

Warning Signs

Danger Signs

Mandatory Signs

Emergency Information Signs


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Personal Protective Equipment (PPE)

All PPE provided must be worn by employees. Employees are responsible for the maintenance and cleaning of PPE. Compulsory areas for PPE are signposted.

Examples include: Hearing protection Eye protection Hard hats Footwear

Mobile Plant

MPC uses mobile plant throughout the factory.

Look out for all mobile plant and listen for horns. Do not be a passenger on mobile plant. Use walkways provided to ensure safety. Communicate with operators when working near mobile plant.


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Confined Spaces

What is a Confined Space?

An enclosed or partially enclosed space.

What hazards can be associated with a confined space?

1. Oxygen Deficiency 2. Oxygen Excess 3. Fire and explosion 4. Wet slippery surfaces 5. Hot Work 6. Falls

NOTE: ONLY TRAINED AND APPROVED (COMPETENT) PERSONS CAN ENTER

AND WORK IN A CONFINED SPACE.

Hazardous Substances

Legal Requirements:

All substances (i.e. containers) must be clearly marked

PCBUs must have a current Material Safety Data Sheet for all substances

PCBUs must have a register of all hazardous substances.

Employee Requirements:

Only use chemicals at the approved dilution for the task being performed Don’t use any substance unless you understand the hazards and safe working

instructions of the substance, and are authorised to do so Never empty substances into an unlabelled container Never empty substances into drains or on the ground – always adhere to safe

disposal rules Follow all safety instructions and Company rules.


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Emergency & Evacuation Procedure

Macadamia Processing Co. Limited (MPC) is committed to ensuring the health and safety of all persons working at or visiting the workplace. These procedures have been developed to provide management staff, contractors and visitors with guidance as to the appropriate action to take in case of an emergency event at the workplace. Macadamia Processing Co. Limited (MPC) requires all persons to comply with the following organisational arrangements for the orderly movement of persons out of danger areas to an area of safety during emergency situations. In the case of a fire, sensors that detect heat and smoke will automatically activate an alarm and notify the local Fire Brigade. Messages may be broadcast on the loudspeaker system and flashing lights will activate. During an emergency no-one is to operate the alarm panel. At other times the alarm panel may be operated by the Manager – WHS & Training, Production Manager, the Plant Engineer, the General Manager, the Maintenance and Installation Manager or contractors authorised by one of the above people.

When the alarm is activated:

Those persons who have been appointed as fire wardens are to take up their positions and assume their responsibilities. If safe to do so, the Leading Hands are to halt the flow of macadamia nut-in-shell and kernel by pressing the appropriate emergency stop buttons. Those persons who have not been appointed as fire wardens are to proceed in a calm, safe and orderly manner to the nearest emergency exit, or if the nearest emergency exit is unsafe to use, the next available exit. These persons are to vacate the building using the emergency exit and are to clear the exit as soon as possible. No person is permitted to retrieve any item or items before evacuating the building. When persons have exited the building they are to proceed to the assembly point area in the car-park adjacent to the main entry to the property. They are to assemble in this location and await further instructions. They are to ensure that they do not assemble in a manner that might hinder the access of emergency service vehicles or personnel. Visitors and contractors to the site are to evacuate the building and proceed to the assembly area with their MPC contact person. Persons are not permitted to re-enter the building until the “all clear” has been announced by the Chief Warden or Deputy Chief Warden.

During the alarm period:

The Chief Warden, or one of the deputy Chief Wardens, is to take control of the

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situation and remain in control until one of the emergency services personnel relieve him or her of his or her duties and responsibilities. Liaison between the Chief Warden and Area Wardens must be maintained. The Chief Warden (or the deputy), shall, if it is safe to do so, coordinate the investigation through regular contact with the Area Warden/s and the Emergency Response Team (ERT) and shall determine the extent/scope of the emergency. The Area Wardens are to ensure that all personnel in their area of control evacuate the building. When all persons have been accounted for, the Area Warden shall report to the Chief Warden. The Chief Warden may verbally instruct the Area Warden and other wardens to evacuate the building if their assistance is no longer required.

After the alarm has been silenced:

With the exception of emergency response personnel, no-one is permitted to re-enter the building until the Chief Warden (or deputy) has been authorized by the emergency services senior officer that it is safe to do so. The Chief Warden (or deputy) shall announce the “all clear” to the persons assembled in the car-park. If the “all clear” is not forthcoming, further instructions shall be announced by the Chief Warden (or deputy).

Emergency Assembly Point:


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PART 2 – HAZARD MANUAL TASKS

Hazardous Manual Risk Control

Aim

To provide participants with the knowledge and skills to effectively identify hazards, assess and control risks arising from manual handling tasks.

Learning Outcomes

At the completion of this session, the participants should be able to recognise Hazardous Manual handling risks in tasks, and in consultation, decide the best way to eliminate or minimise them. Participants should be able to recognise the basic principles of anatomy and biomechanics which are relevant to Manual Handling.

What is a musculoskeletal disorder (MSD)?

A musculoskeletal disorder, as defined in the WHS Regulations, means an injury to, or a disease of, the musculoskeletal system, whether occurring suddenly or over time. It does not include an injury caused by crushing, entrapment (such as fractures and dislocations) or cutting resulting from the mechanical operation of plant. MSDs may include conditions such as:-

sprains and strains of muscles, ligaments and tendons;

back injuries, including damage to the muscles, tendons, ligaments, spinal discs, nerves, joints and bones;

joint and bone injuries or degeneration, including injuries to the shoulder, elbow, wrist, hip, knee, ankle, hands and feet;

nerve injuries or compression (e.g. carpal tunnel syndrome);

muscular and vascular disorders as a result of hand-arm vibration;

soft tissue hernias;

chronic pain.


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MSDs occur in two ways:

1. gradual wear and tear to joints, ligaments, muscles and inter-vertebral discs caused by repeated or continuous use of the same body parts, including static body positions;

2. sudden damage caused by strenuous activity, or unexpected movements such as when loads being handled move or change position suddenly.

Injuries can also occur due to a combination of these mechanisms, for example, body tissue that has been weakened by cumulative damage may be vulnerable to sudden injury by lower forces.

What is a hazardous manual task?

A hazardous manual task, as defined in the WHS Regulations, means a task that requires a person to lift, lower, push, pull, carry or otherwise move, hold or restrain any person, animal or thing involving one or more of the following:-

repetitive or sustained force;

high or sudden force;

repetitive movement;

sustained or awkward posture;

exposure to vibration.


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Other negative consequences of suffering an injury could be;

Pain and discomfort relating to the injury Inability to participate in sporting events May interfere with social events and/or family life May interfere with hobbies and other leisure activities Reduce quality if life Injuries are often associated with feelings of depression and frustration Perceived negativity from other people (i.e. that you are “bludging” on workers comp).

Legal Responsibilities

Both PCBUs (eg employers) and workers have responsibilities to ensure that every care is taken to make the workplace safe for all person(s) at the place of work. This is governed by national and state rules and regulations. This diagram shows that, there are acts and regulations with which all workplaces MUST comply. In other words, lack of compliance by any workplace with any of those acts and regulations places the offending workplace in a position where it would attract various levels of legal penalties depending on the severity of the non-compliance.

There also exists codes of practice and industry standards with guiding notes. PCBUs in a given industry are expected to comply with the codes of practice and their industry standards. But that is only expectation – compliance is voluntary.

What is required to manage the risk of musculoskeletal disorders?

Regulation 60: A person conducting a business or undertaking must manage risks to health and safety relating to a musculoskeletal disorder associated with a hazardous manual task. Regulation 34-38: In order to manage risk under the WHS Regulations, a duty holder must:

identify reasonably foreseeable hazards that could give rise to the risk;

eliminate the risk so far as is reasonably practicable or if it is not reasonably practicable to eliminate the risk;

minimise the risk so far as is reasonably practicable by implementing control measures in accordance with the hierarchy of control;


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maintain the implemented control measure so that it remains effective;

review and if necessary revise, risk control measures so as to maintain, so far as is reasonably practicable, a work environment that is without risks to health and safety.

The Muscles

The main muscles to consider for manual handling are the large thigh muscles, the abdominal muscles and the arm muscles. The back muscles are quite small and are designed to assist posture - not to do heavy work. Muscles work most effectively in their middle range rather than fully flexed or fully extended. So the knees and hips work most efficiently in a slightly bent rather than fully bent position. For example, a semi squat with the knees at about right angles is easier than a full squat position. Muscles work by contacting and relaxing and work best in a controlled or rhythmic manner. There are two main types of muscle work, known as static or holding, and dynamic or moving. In static muscle work, such as holding a tool overhead, the muscles remain contracted and so have a reduced blood flow from in the muscle's blood vessels. After long periods of static muscle work there is a build up of waste products and a lack of oxygen, and this can result in a heavy or painful feeling in the muscle.

In dynamic muscle work - the muscle is alternatively contracting and relaxing, and so bringing in new oxygenated blood and removing the waste products. Dynamic muscle work can usually be sustained for long periods, but static work is more tiring.

Watch out for static movements that cause strain to your muscles and minimise these movements as much as possible.

Principles of Biomechanics.

For our bodies to move, the muscles have to pull on the bones or our arms, legs and back. The bones are therefore like levers.

To understand the mechanism we need to look at some basic principles of levers.

A weight at a short distance from the fulcrum requires less effort to move than the same weight at a longer distance from the fulcrum (pivot point).

When lifting a load, the closer it is to a person's body, the less stress there is on the body, and therefore lower the risk.

If the load is further away, there is greater stress on the person handling the load. The distance between the person and the load is caused by a variety of factors, such as the layout of the work area, a cluttered floor making access difficult, or the large dimensions of the item held.


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The spine can sometimes be used as a lever, although it was not designed to be a crane. The crane becomes a very long lever arm, with a load being handled at the end. The muscles of the back have to support not only the weight of the load being handled, but also the weight of the trunk as it is bent over. The force exerted by the spinal muscles can be up to 10 times greater than the weight of the load handled.

Actions and Movements

Taking into consideration how parts of the body work together, the body works best, and most efficiently, if movements are; Performed in a symmetrical, forward facing position Smooth and controlled, and not jarring Within the mid-range of the joints movement Dynamic and moving muscles rather than static and holding muscles or joints in a fixed

position. Performed in an upright rather than bent over posture.

The Best Posture for Lifting

The principles of good lifting are to:

Avoid twisting the back

Hold the load close to the body

Utilise the leg muscles

Maintaining the normal spinal curves, so not bending the back

Be in a stable position

Always bend the knees if objects must be lifted from low levels. A full squat to the ground is not necessary, but a semi squat will transfer some of the load from the back to the leg muscles.

Working Posture and Position

Using a good posture when sitting, standing, walking and performing any manual handling is necessary.

What is good posture?

Posture is more than just sitting or standing up straight. While posture includes when the body is still, it also refers to moving positions, such as reaching to grasp something or bending or picking up something. Since backs are not straight, but have three curves, it is better to think of alignment of the back and the maintenance of these curves.

A good posture involves working with the spine with the following curves:

A slight inward curve at the neck

An outward curve (or kyphosis) between the shoulder blades

An inward curve (or lordosis) in the lower back.


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Consequences of poor postures and positions The reason that posture is so important is that bad postures could cause gradual damage to the muscles, ligaments and discs. Poor posture does not need a load to make it damaging. People working in a sustained bent posture can experience back pain. This sort of back pain develops slowly, and the old expression about "the straw that broke the camel's back" is a very accurate description of the problem.

Best postures and positions To reduce the risk of postural problems, workers should be able to: Maintain a good posture for the duration of the task Vary their posture, avoiding long periods of any one posture Avoid bending or twisting the spine Work with their joints in mid range without having to over

reach Take rest breaks and stretch Rotate to another task if a poor posture cannot be avoided Work between shoulder and waist level Lift loads close to their bodies.

Basic Lifting Rules

Plan the lift Clear the path Move in close to the load Place feet shoulder width apart Secure your grip Maintain normal curves of the spine Hold your head upright Power the lift with legs and body weight Don't twist Use smooth, controlled movements


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PART 3 – LOCK OUT / TAG OUT


This module provides the participants with a basic knowledge of the company’s procedures in relation to equipment lock-out and tag-out. At the end of the module, the participants will be able to follow the lock-out /tag-out procedure correctly and identify situations in which it is used.

Overview

Each year, many workers are injured or killed by the uncontrolled release of hazardous energy. Many of these types of accidents could have been prevented by proper lock-out/tag-out procedures which ensure that equipment is kept from being set in motion and endangering workers during maintenance or cleaning. To assist staff to understand the use of lock-out/tag-out, a set of guidelines have been prepared.

Definitions

Lock only

Locks are used to restrict access to areas or parts of equipment, eg secure guards.

Lock with Out of Service Tag

An Out of Service tag is a yellow and black tag that is used to indicate out of service machinery. The tag may be removed by appropriate maintenance staff or a Supervisor/Foreman once the machinery/equipment is deemed safe. The out-of-service tag and lock is not a substitute for a personal danger tag and lock.

Lock with Danger Tag

A danger tag is a red and white tag that is used to protect individual personnel and machinery and may only be removed by the personnel who placed and signed the tag. This tag may only be removed when the machinery/equipment is deemed safe or the individual has completed their task. Multiple tags must be used when more than one person or group is working on an isolated energy source. In this instance one tag or isolation device is to be used on each energy source being worked on by each individual.


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Emergency

An emergency is an adverse situation where there is the potential for injury, threat to life or severe damage to property.

Energy Sources

An energy source is any form of energy that has the potential to damage property, injure or kill personnel. Energy sources may be in the following form: electrical, mechanical, hydraulic, pneumatic, chemical, thermal, gravitational, radiation, and other forms of stored or kinetic energy. Isolation is preferred both locally and at the source of the energy where practicable.

What Is Lock-out/Tag-out? Lock-out is the use of a special lock and system to prevent power from being accidentally turned on during equipment maintenance, cleaning or repair. This may be electrical or other power such as hydraulic power, compressed air or coiled springs. In lockouts:

a disconnect switch, circuit breaker or other energy-isolating mechanism is put in the safe 'off' position;

a device is often placed over the energy-isolating mechanism to hold it in the safe 'off' position; and

a lock is attached so that the equipment can't be energized, i.e., turned on.

Tag-out is the use of a special tag to warn workers of the danger of starting the equipment when it can't be locked out.

When Should You Lock out/Tag out or Tag Out? Lock-out/tag-out is necessary whenever you are performing service, cleaning or maintenance around any machine where you or your colleagues could be injured by unexpected start up of the equipment or a release of stored energy.

Some jobs for which lock-out/tag-out should be used are:

when you must remove or bypass a guard or other safety device;

when you must place any part of your body where you could be caught by moving machinery;

repairing electrical circuits; and cleaning (certain equipment).


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Lock-Out/Tag-Out Procedure

Procedure for EQUIPMENT LOCK-OUT

The equipment shall be switched off at the stop/start button by a person authorised to do so. The employee shall then turn the electrical isolator to the OFF position.

After ensuring that the equipment has come to a stop, that person is to use a padlock and danger tag to lock and identify the isolator so as to ensure that the isolator cannot be returned to the ON position without the removal of the lock.

The padlock used for the lock-out of an isolator is to be identified with a danger-tag. The danger-tag is issued at the time of padlock issue and shall remain locked onto the padlock at all times. The danger-tag is to clearly state the name of the person using the padlock, the date and the reason for the lock-out. The danger tag must be signed by the employee using the danger tag.


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The isolator that prevents the equipment from being operated must be locked out and identified prior to an employee gaining access to that equipment.

Note that an isolator is only permitted to be utilized if the isolator is identified with the name of the equipment that it isolates. The equipment being isolated must also be identified by a sign attached to the equipment. These identifications are only to be put in place by the Maintenance & Installation Manager or by someone instructed to do so by the Maintenance & Installation Manager.

There are isolators located on some control cabinets that will isolate multiple items of equipment. The equipment that these isolators isolate are identified by labels attached to the control cabinet and the equipment is identified by labels attached to the equipment. Using these isolators will reduce the quantity of padlocks and danger tags required.

The situation will arise where an employee is required to lock out an isolator but finds that the isolator is already locked out. In this case it is imperative that each employee who has reason to work on that equipment locks out the isolator with their own padlock. They are not to rely on someone else's padlock to lock out the isolator. In this situation a "multi-lock hasp" is to be utilized. These can accommodate up to six padlocks and danger tags, and can be sourced from the shift foreman or sorting area leading-hand.


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For example, if four employees are required to work on the same piece of equipment, then each employee shall ensure that their own padlock and danger tag is used to lock out the isolator. They must ensure their own safety by using their own padlock. They can do this by using a "multi-lock hasp"

When the employee has ensured that the isolator cannot be returned to the ON position without the removal of their lock, the equipment may be accessed.

When the employee has completed his/her task, he/she shall remove their lock and danger tag. If theirs is the last lock to be removed they must ensure that all equipment is correctly reassembled and that all guards or fences are returned to their normal positions and secured in place before removing the lock and danger tag.


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The employee shall return the isolator to the ON position. The equipment or machinery may now be operated

Note that an employee may only remove the padlock and danger tag that bears their own name and signature.

An employee may only fit a lock and danger tag that bears their own name and signature.

Employees found removing other people's locks and tags, or putting locks and tags on for other people, are in breach of the lock-out procedure and could be subject to dismissal.

If an employee leaves his/her padlock and danger tag locked on an isolator and vacates the premises, that employee shall be contacted and asked to return to the factory in order to remove the padlock.

Padlocks and danger tags are issued by the shift foreman or area leading-hand. Employees must sign for all padlocks, tags and keys when issued and on return.

The shift foreman or area leading-hand shall maintain a list of padlocks and danger-tags issued. This list shall record who was issued a padlock. .

Employee safety is of paramount importance.


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The lock-out procedure must be adhered to. Failure to comply with the lock-out procedure could lead to dismissal. Employees who have not been trained in the lock-out procedure are not to dismantle or access equipment that requires lock-out.

Procedure for the use of Out-of-Service Tags

These tags are to be attached to the equipment (at the appropriate isolation point or at a point that is immediately obvious to all employees) by any trained and authorised employee when:

The equipment is unsafe. In this situation the out-of-service tag and lock shall be applied to the appropriate isolation point.

Damage may occur if left operational. If this is the case the out-of-service tag and lock shall be applied to the appropriate isolation point.

The equipment is shut down for production or maintenance purposes. In this situation the out-of-service tag shall be attached to the equipment in a location that is immediately obvious to the operator.

The "out-of-service" tag and lock is not a substitute for a personal danger tag and lock.

If you are required to clean or work on equipment fitted with an out-of-service tag you must also fit a personal lockout padlock/lockout tag. Use a hasp if only 1 lock can be fitted. The out-of-service tag must clearly state the reason/s why the equipment is out of service, the name of the person placing the tag, the date and time that the tag was placed. Out-of-service tags shall be locked in place using only the padlock supplied with the tag.

Examples of when to use Out-Of-Service tags and locks:

After the crackers have been cleaned, the maintenance personnel may require access to the cracker blades. It would be dangerous to leave the crackers in a dismantled state without the crackers being isolated and locked out. The person responsible for conducting the clean is required to remove the danger tag and lock that he/she placed on the isolator, but because the equipment is to be left in a dismantled state that same person must replace their lock and tag with an out-of-service tag and lock. An out-of-service tag and lock shall be used to notify all persons that a kernel silo is not to be filled if it requires cleaning before further use.


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If the vacuum sealing machine is causing repeated creases in the heat seal of the pouch, an out-of-service tag shall be utilized to notify all persons that the equipment is not to be used until maintenance work has been carried out to rectify the problem.

Maintenance staff and Production Foremen only, are permitted to remove out-of-service tags and locks.

Exemption of Equipment from Lock-out Procedures

Some equipment does not pose a danger in normal operating situations and is therefore not guarded or fenced off. When equipment is to be dismantled for cleaning or maintenance purposes the risk of injury is greatly increased and the lock-out procedure must be adhered to. It is possible to safely clean certain equipment without any form of dismantling. Equipment that is not guarded or fenced off and does not require any form of dismantling for the purpose of cleaning may be exempt from the lock-out procedure. The following equipment, for the purpose of cleaning, is exempt from the lock-out procedure:

Flat Bed Conveyors eg Mainline & Secondary Sorting Tables


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PART 4 – PERSONAL PROTECTIVE EQUIPMENT

What is this Training Module About?

This module provides general advice about using personal protective equipment (PPE) to minimise exposure to risks associated with workplace hazards. It provides guidance on selecting, using, storing and maintaining such equipment.

What is Personal Protective Equipment (PPE)?

Personal protective equipment is any clothing, equipment or substance designed to be worn by a person and to protect that person from risks of injury or illness.

Examples of personal protective equipment include: Hearing protective devices, such as ear muffs and ear plugs; Respirators; Protective eyewear, such as goggles; Safety helmets (hard hats).

PCBUs (Persons Conducting a Business or Undertaking) must: Ensure the required resources are available in the area under his or her control Explain the reasons for PPE Demonstrate correct use and care Workers must: Wear approved PPE when and where required Ensure that PPE is free of any defects and that it is kept in a hygienic state. Keep PPE in a clean and hygienic state Advise MPC when replacement is required.

Occupational Noise

Noise is a common problem found in many workplaces. Research has found that high levels of noise can damage your hearing. Losing your hearing is a gradual process, and is less noticeable than other types of workplace injuries. It is, however, a permanent handicap for those who are affected.

Why Hearing Protection is Important

Hearing protection is important because your ears are composed of very delicate structures. Whenever a sound is produced, air is set into motion as sound waves.

- Sound is collected in the outer ear and funnelled to the eardrum.

- When sound waves hit the eardrum, it vibrates and sends sound to the middle ear.


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- The middle ear amplifies the vibrations and sends them to the inner ear. The vibrations stimulate hair cells in the inner ear and create an electrical impulse.

- This impulse travels to the brain along the auditory nerve, causing the sensation of sound.

Damage to the delicate structures of your ears can result in the loss of your ability to hear. There are two types of hearing loss:

1. Conductive

2. Sensory

Conductive hearing loss is caused by damage to or a malfunction of the outer and middle ear. It results in a decrease in your hearing, but you can still understand speech.

Causes of Conductive Hearing Loss

Several medical disorders cause conductive hearing loss. These disorders can be treated medically or surgically. These disorders are:

- Middle ear infections - Fixation of the ossicular chain

- Perforation of the eardrum - Otosclerosis

Sensory hearing loss is a hearing loss caused by damage to or a malfunction of the inner ear, auditory nerve, or the brain. It makes it more difficult to understand speech, but it does not result in a decrease in loudness.

Causes of Sensory Hearing Loss

Causes of sensory hearing loss are:

- Hereditary - Disease

- Damage to foetus

- Injury

- Aging - Drugs

- Noise

Sensory hearing loss CANNOT be corrected medically or surgically. It is permanent.

As you can see from the above list, hearing loss in the workplace would most likely be a sensory hearing loss.

http://www.free-training.com/osha/ppe/hear/def504.htm

http://www.free-training.com/osha/ppe/hear/def506.htm


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The noise produced in the factory is at a level that can cause serious permanent hearing damage. Be aware that hearing damage can be caused in a very short space of time – hours or minutes only. Therefore it is essential that you wear the MPC supplied hearing protection at all times in the factory.

Types of Personal Protective Equipment Used at MPC

Hearing Protection

Types of Hearing Protection

Many types of hearing protection devices are available. Popular types of hearing protection devices are: 1. Foam and PVC Earplugs 2. Earmuffs Each of the types of hearing protection devices has its advantages and disadvantages.

The advantages of Foam and PVC earplugs are:

1. Small & lightweight; 2. Comfortable in hot environments; and 3. Easily used with other safety equipment. The disadvantages of earplugs are:

1. May work loose and require occasional refitting;

2. Require specific fitting instructions; and

3. Are frequently soiled.

Earmuffs are another type of hearing protection device. H10B H7


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The advantages of earmuffs are:

1. Easy for your employer to supervise the wearing of this device; 2. One size fits all; and 3. Fits better for longer periods of time.

The disadvantages of earmuffs are: 1. May fit tight on your head; 2. Uncomfortable in a warm environment; and 3. Problems occur when used with other equipment.

You should wear a hearing protection device whenever you are exposed to noise that is 85 decibels or greater for an 8-hour period of time.

Fitting Your Hearing Protection

Foam Earplugs Foam earplugs provide the most protection.

To insert foam earplugs properly:

Reach around the back of your head, and gently pull your ear back and up.

Roll the plug into a small diameter.

Insert the plug well into the ear canal

Hold the plug in place for a few seconds while it expands and forms a good seal.

Earmuffs

Earmuffs fit over the outside of the ears. Because their effectiveness is limited to the quality of the seal around your ear, they are often not as effective as earplugs. For this reason, a combination of earplugs and earmuffs are used in some work environments.

When using earmuffs:

Make sure that the earmuffs fit snugly around your ears

Consider using earplugs if you wear glasses or have facial hair that would prevent the earmuffs from forming a good seal around your ears.


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Storage and Maintenance of Hearing Protection

Foam Earplugs - When not using your foam earplugs, store them in a clean, cool, dry place. (Your pocket may not be the cleanest storage area.)

- If your foam earplugs become soiled, torn or stiff, discard them and obtain a new sealed set of earplugs from the supply in the factory foyer or ask your Supervisor.

Earmuffs

When not using your earmuffs, store them in a clean, cool, dry place. Do not stretch the band on the earmuffs as it will affect the clamping force of the

earmuff. If the earmuff becomes soiled, you can clean them with a mild solution of soap and

water (this includes the foam insert). Rinse and then dry them with a soft towel. Always inspect your earmuffs for cracks around the foam cups. If the cups are

damaged have them replaced immediately by asking your Supervisor or the Manager – WHS & Training for a new hygiene kit.


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General Information on Noise

Exposure to noise

permanently damages

hearing

Deafness is a serious disability that has a major impact on the

quality of life of the deaf person.

Even with partial hearing problems people suffer because

they either withdraw from conversation (especially in groups)

or are excluded from conversation by the group.

The maximum noise

level employees may be

exposed to for a normal

working day is 85 dBA

NSW WH&S legislation specifies that an employer must

ensure that appropriate control measures are taken if a

person is exposed to a noise level that:

a. Exceed an 8-hour noise level equivalent of 85dB (A), or

peaks at more than 140dB (C).

Noise levels double

every 3 dBA. So 88

dBA is 2x as noisy as 85

dBA

The dBA scale is a logarithmic scale

91 dBA is not a little noisier than 85dBA it is in fact 4 times

noisier.

On the other hand, 82dBA is only half as noisy as 85dBA.

Hearing protection

reduces the amount of

noise to the ear, and

therefore must be worn

when noise levels cannot

be reduced to safe levels

Typical ear plugs may be rated at 12 dBA. This means they

reduce the noise that reaches the ear by 12dbA, but only

when properly fitted.

When the noise level is 93 dBA ear plugs therefore reduce the

noise level to the ear to about 81 dBA, which is safe.

When the noise level is 99 dBA ear plugs therefore reduce the

noise level to the ear to about 87 dBA, which is still too high

and therefore better hearing protection is required. (Ear

muffs for example may be rated from 10 to 25 dBA).

The law requires PCBUs

to identify all areas

where noise levels may

be excessive and ensure

hearing protection is

worn when noise levels

cannot be reduced to a

level below the limit

In our WHSHR Management System we have a procedure

that deals with Hearing Protection. The procedure requires:

Management to measure noise in all areas

Management to identify areas where noise levels exceed

the legal limit

Management to provide suitable hearing protection to all

employees

Workers to comply with the requirement to wear hearing

protection in all areas that have been declared as hearing

protection zones

If a manager, or supervisor, or employee, breaches a provision

of the Hearing Protection Procedure then that person has

effectively breached the requirements of the WH&S Act.


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Eye & Face Protection

What Types of Accidents Cause Eye Injuries?

The major types of accidents that cause blindness include:

Objects striking the eye;

Contact with chemicals and other hazardous materials;

Being struck by swinging objects such as chains and ropes; and

Viewing radiant energy sources such as welding operations or lasers.

Potential Hazards:

Dusts, Powders, Fumes, and Mists

Small particles of matter can enter your eyes and damage them. Operations such as grinding, chiselling, sanding, hammering, cleaning with compressed air and using high pressure cleaners create small airborne particles; particles that can injure your eyes.

Toxic Gases, Vapours, and Liquids

Toxic chemicals in the form of gases, vapours, and liquids can damage your eyes. Always read the appropriate MSDS before working with any hazardous material.

Flying Objects or Particles

Operations such as grinding, chiselling, sanding, and hammering often create flying objects or particles that can damage your eyes.

Large Objects Large objects such as:

swinging chains, cables and ropes;

tools that are thrown or fall;

any sharp objects such as knives, scissors, pencils, etc.; and

walking or falling into obstructions can damage your eyes or face.

Electrical Hazards

Any time you work around electricity, there is the potential for arcs and sparks to occur. Take time to talk with your Supervisor or the Manager – WHS & Training concerning the type of eye protection you should wear if you will be working around electrical hazards.

Thermal and Radiation Hazards

Operations such as welding, metal cutting, and working around


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furnaces can expose your eyes to heat, glare, ultraviolet, and infrared radiation. Check with your Supervisor or the Manager – WHS & Training to learn the specific type of eye protection you will need to use during these types of operations.

Protective Measures - Lighting

Good lighting is important in work areas. Good lighting reduces eye strain and glare. It also promotes both safety and improved productivity.

Signs and Warnings

Obstructions and protruding objects should be identified and marked. Use caution when working around obstructions and protruding objects.

Eye injuries

If you accidentally get something in your eyes, flush your eyes with water for 15 minutes. Be sure to hold your eyes open with your fingers and "look" directly into the water streams. DO NOT RUB YOUR EYES! Rubbing your eyes may scratch or embed particles into your eyes. Once you have flushed your eyes with water, seek medical attention immediately.

CAUTION: Some chemicals are water reactive and become toxic when mixed with water. Be familiar with the location and content of MSDS’s for all chemicals used in your job.

Safe Work Practices

As you work:

Read and follow all warnings and precautions that may be found on equipment and hazardous materials;

Do not throw tools or participate in horseplay;

Keep sharp or pointed objects away from your eyes; and

Follow your Supervisor's or the Manager – WHS & Training's suggestions and recommendations for working safely.

Machine Guards

Many types of machines such as lathes, grinders, and sanders are equipped with guards, shields and screens. Guards you may see at MPC are used to cover moving machinery such as conveyors or machines using electricity and gas. Always make sure that guards, shields, and screens are in place and in good working order before using or working on these types of machines. Don't forget lockout procedures and to wear eye protection if appropriate.


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Work Area Barriers (Exclusion zones)

At MPC exclusion zones are used when persons may be working above an area or maintenance is being performed.

Ventilation

Ventilation systems are in place at MPC to reduce heat and moisture in the Roasting room and dust in the Cracking room and in the Dehusking area.

Goggles

Goggles give you more protection than safety glasses because they fit closer to your face. Because goggles surround the eye area, they give you more protection in situations where you might encounter splashing liquids, fumes, vapours, powders, dusts, and mists. You must wear goggles at MPC when cleaning using compressed air.

Contact Lenses

If you wear contacts, keep the following safety tips in mind.

You may not wear your contacts while using a full face respirator.

Wear your contacts with caution if you work in areas where you might be exposed to fumes, dusts, powders, vapours, chemical splashes, molten metals, or intense heat, light or glare.

If you get anything under your contacts, take time to remove and clean them. Follow your eye doctor's instructions for cleaning and caring for your contacts.

Some chemicals can react with contacts and cause permanent injury.

It is wise to keep an extra pair of contacts or a pair of glasses handy in case you should lose or damage one of your contacts while you are working. If you loose a contact lense you must immediately advise your Supervisor.

Care of Eye Protection Equipment

Clean your eye protection equipment.

You can usually use mild soap and water.

You may also use special wipes that are designed for cleaning protective eye equipment. Never use abrasive soaps, rough paper, or cloth towels. These items will scratch and damage your equipment.

Always keep your eye protection equipment in


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good working condition.

If it is damaged, have it repaired or replaced.

Store your eye protection equipment in a sanitary, cool, dry area away from moisture.

Read the manufacturer's directions and warnings before using any eye protection equipment.

If you have any questions concerning your eye protection equipment, talk with your Supervisor or the Manager – WHS & Training.

Potential Hazards

Impact to the Head

Falling or flying objects are a common cause of head injuries. Also, falling or walking into hard objects can cause head injuries. These injuries include neck sprains, concussions, and skull fractures. Safety helmet are available at MPC whenever performing tasks where head injuries are possible.

Electrical Shocks

Accidents involving electricity result in electrical shocks and burns. Please follow MPC lockout procedures and report any damaged equipment or potential electrical hazards.

Splashes, Spills, and Drips

Toxic liquids such as acids, caustics, and molten metals can irritate and burn the eyes and skin. Notify your Foreman if you become aware of any splash, spill or drip incidents so MPC spill procedures can be implemented.

How Hard Hats Protect You

Safety hats protect you by providing the following features:

A rigid shell that resists and deflects blows to he head;

A suspension system inside the hat that acts as a shock absorber;

Some hats serve as an insulator against electrical shocks;

Shields your scalp, face, neck, and shoulders against splashes,spills, and drips; and

Some hard hats can be modified so you can add face shields, goggles, hoods, or hearing protection to them.

http://www.free-training.com/osha/ppe/head/def406.htm


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Type of Hard Hat Used at MPC

Type 1 Hard Hats

Type 1 hard hats are designed to:

Protect you from falling objects; and

Protect you from some electrical shocks

Wearing Hard Hats

Always wear your hard hat while you are working in areas where there are potential head hazards.

Adjust the suspension inside your hard hat so that the hat sits comfortably, but securely on your head.

Inspect the shell of your hard hat for cracks, gouges, and dents.

Inspect the suspension system for frayed or broken straps.

If your hard hat needs to be repaired, have it repaired immediately or ask your supervisor or Manager – WHS & Training for a new one.

Never paint, scratch or drill "air holes" in your hard hat.

You may apply reflective plastic tape if you must work at night.

Never use metal tape on your helmet because it can conduct electricity.

Never carry personal belongings such as cigarettes, lighters or pens in your hard hat.

Caring for Your Hard Hat

Because your hard hat is an important piece of personal protective equipment, you should:

Clean your hard hat at regularly (or as needed) to remove oil, grease, chemicals and sweat that can collect in and around your hat.

You can clean your hat by soaking it in a solution of mild soap and hot water for 5-10 minutes. Rinse with clear water, wipe, and let air dry. Or follow the manufacturer’s recommendations for cleaning your hat.

Because sunlight and heat can damage the suspension of your hat, always store your hat in clean, dry, and cool location.

Excuses

There are NO excuses for not wearing your PPE!


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PART 5 – INJURY MANAGEMENT:


This module provides participants with information regarding the prompt, safe and durable return-to-work after an injury at the workplace occurs. Participants will also be provided with information pertaining to claims management.

What is Injury Management?

Injury management is about ensuring the prompt, safe and durable return-to work of an injured worker. It includes treatment of the injury, rehabilitation back to work, retraining into a new skill or job, management of the workers compensation claim and the employment practices of the Person Conducting a Business or Undertaking (PCBU), previously referred to as the Employer. Everyone involved is required to cooperate and participate in injury management, including the insurance company, PCBU, injured worker, treating doctor and all treating practitioners.

MPC Injury Management Policy

Macadamia Processing Co. Limited (MPC) is committed to preventing injury and illness through providing a safe and healthy working environment. However, in the event of injury or illness occurring MPC has, through consultation and agreement with worker representatives, developed a Return-to-Work Program for the management of workers who are injured at work. This program forms part of MPC’s Work Health and Safety Human Resource Management System (WHSHRMS), is consistent with the insurance company’s Injury Management Program and will be re-evaluated annually in the course of the OHSHRMS internal audit and review. MPC undertakes to have a current workers compensation insurance policy with an accredited workers compensation insurer, currently Allianz Australia Ltd. The insurer shall, as per the obligations placed on workers compensation insurers by the NSW Workplace Injury Management and Workers Compensation Act, establish and maintain an injury management program. MPC shall comply with the obligations imposed by the insurer’s injury management program. MPC provides a permanent staff member who is trained and appointed as the Return-to-Work Co-ordinator. The Return-to-Work Co-ordinator is Allen Holmes. MPC has return-to-work procedures that set out the steps to be followed when a workplace accident and/or injury occurs. These procedures are brought to the attention of staff members and displayed in the lunchroom, available to all staff.


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Workers will be consulted through the Health and Safety Representative (HSR) and the Health and Safety Committee (HSC) members. MPC shall inform the insurer of workplace injuries, within the legal timeframes required. MPC shall also inform WorkCover of all serious and significant injuries within the required timeframes. MPC undertakes to consult with the injured worker, their nominated treating doctor, an accredited rehabilitation provider and all other relevant parties when planning the return to work of an injured worker who requires a return-to-work plan and suitable duties. MPC will ensure that the return-to-work process is commenced as soon as possible after an injury in a manner consistent with the injured worker’s medical fitness for work. MPC is committed to ensuring that early return-to-work by an injured worker is a normal practice and expectation. MPC shall endeavour to make suitable duties available to all injured workers as appropriate and whenever possible. The person responsible for arranging suitable duties is the Return-to-Work Co-ordinator. MPC is committed to ensuring that participation in a return-to-work plan will not, of itself, disadvantage an injured worker. MPC is committed to making every effort to resolve disagreements about the company’s Return-to-Work Program, or its components, through discussions and in a spirit of co-operation.

MPC Return-to-Work Procedure

This procedure details a co-ordinated program of treatment, claims management, rehabilitation and employment practices to ensure the safe, timely and durable return to work of injured workers in accordance with WorkCover requirements.

Notification of Injury

The worker must notify his or her supervisor of any injury as soon as is practicable and if minor (not bleeding), eg sore muscle prior to end of shift. The supervisor must notify the Return-to-Work Co-ordinator of all potentially claimable injuries and incidents as soon as is practicable and appropriate to do so and within 24 hours of the incident occurring.


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All workplace injuries will be recorded in the Register of Injuries, which is located in the Foreman’s office, as soon as is practicable. MPC will notify the insurer within 48 hours after becoming aware that a worker has received an injury for which a worker’s compensation insurance claim may be lodged.

First aid, medical treatment

The first duty of the supervisor to whom the injury is reported is to ensure that the injured person receives appropriate first aid and/or medical treatment as soon as possible.

Early contact with worker and treating health services

The Return-to-Work Co-ordinator will contact the injured person within 24 hours of receiving notification of the injury in order to confirm the details of the incident, including significance of the injury, and to discuss any initial action to be taken. The injured person must follow the guidelines, which are posted on the meal-room notice-board. Injured workers shall inform the Return-to-Work Co-ordinator of their nominated treating doctor and provide a WorkCover Medical Certificate. Injured workers are required to co-operate in facilitating communication between MPC, the insurer, the rehabilitation provider and all health professionals involved. If required, the Return-to-Work Co-ordinator will contact the treating doctor, after obtaining permission from the worker, to discuss the case and any available options for an early return to work. The insurer will contact the injured worker to initiate action regarding the establishment of their injury management plan within 3 working days of receiving notification of a significant injury.

Provision of suitable duties

When the injured worker is, according to medical judgment, capable of return to work, an individual return-to-work plan will be developed. This will include suitable duties which will be identified through consultation with all relevant parties. The return-to-work plan is to be approved by the nominated treating doctor and is to be specified in writing. Suitable duties will be monitored closely, regularly reviewed and upgraded as required. The suitable duties provided will match the regular pre-injury duties of the injured worker as closely as possible and will be productive and meaningful and not demeaning to the worker. Prior written approval from the treating doctor is required to be given to the Return-to-Work Co-ordinator before permission to complete overtime shall be given to any injured worker who is on a suitable duties medical certificate.


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Appropriate assistance will be given to workers from a non-English speaking background and to those deemed permanently unable to return to pre-injury duties. In the event that an injured person is deemed permanently unable to return to pre-injury duties MPC will refer that person to the rehabilitation provider for re-training.

It is the responsibility of the Return-to-Work Co-ordinator, with assistance from the accredited rehabilitation provider, to identify suitable duties when required.

Arrangements for dispute resolution

Every endeavour will be made to resolve any disagreement about the Return-to-Work Program through discussion and negotiation amongst the key parties, including the injured worker, Return-to-Work Co-ordinator, treating doctor, insurer and the rehabilitation provider.

In the event that a dispute over suitable duties or fitness for work cannot be settled through discussion with the key parties, then referral to an injury management consultant may be organised through the insurer. An independent mediator may also be employed if further disputes arise.

If parties are unable to reach agreement on an issue, advice may be sought from the WorkCover Claims Assistance Service, contactable on 13 10 50. If a worker’s compensation claim is disputed, the worker may seek resolution through the Worker’s Compensation Commission. This includes disputes relating to an injury management plan, return-to-work plan and suitable duties. The Worker’s Compensation Commission is contactable on 1300 368 040.

Administrative arrangements

An injured worker who intends to submit a Worker’s Compensation claim to the insurer is to notify the Return-to-Work Co-ordinator and provide a WorkCover Certificate of Capacity, which is obtained from the treating doctor.

It is the responsibility of the Return-to-Work Co-ordinator to notify the insurer of the injured worker’s claim and to forward the WorkCover Medical Certificate to the insurer. The Return-to-Work Co-ordinator must keep a formal record of notification of injuries/incidents to the insurer, including the method of notification, as well as a record of acknowledgement.

Treatment arrangements

It is the policy of MPC that ongoing treatment arrangements will be organised so that treatment is provided outside of the working hours of the injured worker whenever possible. However, when necessary, treatment times may be negotiated with MPC on an ‘as needs’ basis.

Injured workers must gain prior approval from the insurer before changing their nominated treating doctor.


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OHSHR11-200 INJURY MANAGEMENT FLOWCHART

MACADAMIA PROCESSING CO. LIMITED

RECORD INJURY IN "Register of Injuries and Treatment Book"

PROVIDE TRANSPORT FROM MPC IF

REQUIRED FOR WORKER TO ATTEND

FURTHER MEDICAL TREATMENT

REPORT INCIDENT TO SUPERVISOR

COMPLETE RETURN TO WORK PLAN (OHSHR11-005)

Insurer determines Provisional Liability and

approves/denies liability

RTW CO-ORDINATOR forwards

documentation to Insurer

Ongoing Management by RTW Coordinator, Insurer, Treating Doctor and Injured Worker

Issue of final Medical Workcover Medical Certificate

Insurer closes Workers Compensation Claim

PROVIDE WORKCOVER MEDICAL

CERTIFICATE AND COMPLETE

WORKERS INJURY CLAIM FORM

COMPLETE PCBU INJURY REPORT

FORM

PROVIDE MPC LETTER TO DOCTOR AND

INFORMATION CONSENT FORM

(OHSHR11-203)

SEEK FURTHER MEDICAL ATTENTION IF

REQUIRED

Injured worker OR PCBU representative (eg Foreman) to advise RTW Co-ordinator - Allen Holmes

INSURER NOTIFIED BY RTW

CO-ORDINATOR WITHIN 24 HOURS OF

INJURY

Accident occurs and someone is Injured

INJURED WORKER PCBU

PROVIDE FIRST AID TREATMENT IF

REQUIRED


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Why should a PCBU get involved in Injury Management?

The earlier an injury is treated and managed, the sooner the worker will return to work and recover from the injury.

What Responsibilities does a PCBU have in relation to Injury Management?

If a worker is injured, a PCBU must: - Attend to the injured worker as soon as possible, - Notify the insurance company within 48 hours of an injury occurring, - Cooperate and participate with the insurance company to develop an injury

management plan for the injured worker, and - Implement and monitor a return-to-work plan for the injured worker.

What is a Return-to-Work Plan?

A return-to-work plan consists of the formal policy and procedures that an organisation must have in place to help injured workers and their recovery and return to the workplace. It outlines an organisation’s commitment to assist injured workers with accessing necessary treatment and rehabilitation, and specifies the steps to be taken to achieve a safe, timely and durable return-to-work.

What is a Return-to-Work Coordinator?

A return-to-work coordinator is a worker nominated by the PCBU, whose principal purpose is to assist injured workers with returning to work in a safe and timely manner. The return-to-work coordinator ensures that the policy and procedures in the PCBU’s return-to-work program are followed. Your return-to-work coordinator is ALLEN HOLMES.

What are Suitable Duties?

Suitable duties are short-term work duties, agreed between the PCBU and the injured worker to assist the injured workers rehabilitation. Suitable duties must comply with a current medical certificate, and may include:

- parts of the job the worker was doing before the injury, - the same job, but on reduced hours, - different duties altogether, - training opportunities, - a combination of some or all the above.

Must a PCBU always provide Suitable Duties to an Injured Worker?

Yes. Failure to provide suitable duties when it is reasonably possible to do so may affect a PCBU in two ways:

- The cost of the claim can increase. - A penalty may be imposed for not complying.

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The PCBU does not have to provide suitable duties if:

- The worker voluntarily resigns, or - The PCBU terminates the worker’s employment after the injury for justifiable

reasons, other than the injury or fitness for work.

Must an Injured Worker Accept Suitable Duties?

Yes. The workers compensation benefits of an injured worker who refuses a reasonable offer of suitable duties may be stopped or reduced if they don’t.

What to do if there is an Injury?

Responsibilities of the PCBU

Provide the injured worker with: - First aid and/or transport to medical treatment - Name of the PCBU’s insurance company - Company name and contact details of the PCBU - A workers compensation claim form - Suitable duties and any assistance that will help the worker to recover and return

to work quickly

Responsibilities of the Worker

- Seek medical attention - Notify the PCBU as soon as possible (complete the “Register of Injuries and

Treatment” book - Sign the WorkCover certificate of Capacity (2 places) - Participate and cooperate with development and implementation of an injury

management plan - Make all efforts to return to work as soon as possible.

END OF WORK, HEALTH & SAFETY

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