Attachment 4.pdf

LEAD REGULATION 385-1

LEAD Safety and Occupational Health Program

DEPARTMENT OF THE ARMY

LETTERKENNY ARMY DEPOT

CHAMBERSBURG, PA 17201-4150

1 JULY 2020

LEAD Regulation 385-1, CONTENTS

Chapter 1 Safety and Occupational Health Program

1-1. Purpose

1-2. References

1-3. Policies

1-4. Safety Awards

1-5. Protection of Employee Rights

1-6. Department of Defense Safety and Occupational Health Program

1-7. Responsibilities

1-

1-9. Job Safety Analysis (JSA) Procedures

1-10. System Safety

1-11. LEAD Safety Bulletins

1-12. OSHA Representative Visits

1-13. Industrial Hygiene (IH) Reports

1-14. Notification of Change

Chapter 2 Risk Management Program

2-1. Purpose

2-2. References

2-3. Definitions

2-4. Responsibilities

2-5. Policy

Table 2-1. Risk Acceptance Matrix

2-6. Deliberate Risk Assessment Worksheet

2-7. Risk Assessment Code Matrix

Table 2-2. Risk Assessment Matrix

2-8. Hierarchy of Controls

Table 2-3. Hierarchy of Controls

Chapter 3 Reporting and Investigating Army Accidents

3-1. Purpose

3-2. Definition of Roles

3-3. Definition of Key Terms

3-4. Post Incident Phase 1

3-5. Post Incident Phase 2

3-6. Post Incident Phase 3

3-7. Additional Requirements

Table 3-1. Accident Classes

3-8. Administrative and Record Keeping Requirements

3-9. Accident Review Board Meetings

3-10. Corrective Action

Chapter 4 Inspections and Reporting of Hazardous Conditions

4-1. Purpose

4-2. Policies

4-3. Responsibilities

4-4. Worksite Inspections

4-5. Imminent Danger Conditions

4-6. Safety Hazard Reporting Process (HRP)

Chapter 5 Training

5-1. Promotion and Education

5-2. Training

5-3. Retraining

Table 5-1. Training Requirements

Chapter 6 Safety and Occupational Health Committees

6-1. Purpose

6-2. Definitions

6-3. Policies and Procedures

6-4. Safety and Occupational Health Committees

6-5. Responsibilities

6-6. Training

Chapter 7 Personal Protective Equipment

7-1. Purpose

7-2. Special Definitions

7-3. Policies

7-4. Responsibilities

7-5. Training

7-6. Prescription Eyewear

Chapter 8 Respiratory Protection

8-1. Purpose

8-2. Definition of Terms

8-3. Policy

Table 8 1. Airline Text Colors

Table 8 2. Airline Text Specifications

8-4. Responsibilities

8-5. Training Outline

LEAD Regulation 385-1, 2020

Form 8 1. Sample Memorandum Format

Figure 8 1. Facial Hair Example

Chart 8 1. Pre-Employment/Job Change Exam Process

Chart 8 2. Employee Annual Exam Process

Chapter 9 Eye Wash/Shower Stations

9-1. Purpose

9-2. Definitions

9-3. Responsibilities

9-4. Procedures

Chapter 10 Hazard Communication Program

10-1. Purpose

10-2. Scope

10-3. References

10-4. Definitions/Acronyms:

10-5. Responsibilities

10-6. Disposal of Empty Pressurized and Non-Pressurized Metal Chemical Containers

Chapter 11 Heavy Metal and Respirable Dust

11-1. Purpose

11-2. References

11-3. Definitions

11-4. Responsibilities

11-5. Policy

Chart 11-1. Regulated Area Employee Personal Hygiene and Personal Protective Equipment (PPE) Management Flow Chart

Chapter 12 Lockout/Tagout Program

12-1. Purpose

12-2. Definitions

12-3. General

12-4. Responsibilities

12-5. Waivers/Exemptions

12-6. Controls

12-7. General Procedures

12-8. Training

12-9. Safety Tags

12-10. Administrative Lockout

Chapter 13 Motor Vehicle Operators Safety Code

13-1. Purpose

13-2. General

13-3. Operator Roles and Responsibilities

13-4. Procedural Requirements

13-5. Protective Equipment

13-6. Mobile Equipment Operations

Figure 13-1. Wheel Chock Example

Table 13-1. Stopping Distances

Chapter 14 Safety Requirements for Fork Truck and Material Handling Equipment

14-1. Purpose

14-2. General Information

14-3. Definitions:

14-4. Responsibilities

14-5. Training

14-6. Policy

Chapter 15 Crane Safety

15-1. Purpose

15-2. General

15-3. Responsibilities

15-4. Rules

15-5. Procedural Requirements for Operators:

Figure 15-1. Crane Hook Inspection Points

15-6. Rules, Procedures, and Standard Hand Signals for Ground Persons:

Figure 15-2. Arm Signals, Part One

Figure 15-3. Arm Signals, Part Two

Figure 15-4. Arm Signals, Part Three

Figure 15-5. Arm Signals, Part Four

Figure 15-6. Crane Identification

Chapter 16 Inspection, Testing, Fabrication, and Maintenance of Lifting Devices

16-1. Purpose

16-2. Scope

16-3. Definitions

16-4. Responsibilities

16-5. Policy

Chart 16-1. Equipment Marking and Inspection Specifications

Chart 16-2. Process for Bringing Shop or Customer Fabricated Lifting Devices, Stands, and Carts to Record Rev X4, Part One

Chart 16-2. Process for Bringing Shop or Customer Fabricated Lifting Devices, Stands, and Carts to Record Rev X4, Part One

Chapter 17 Machine Guarding

17-1. Purpose

17-2. Definitions/Explanation of Terms

17-3. Policies

17-4. Responsibilities

Chapter 18 Electrical Safety Program

18-1. Purpose

18-2. Responsibilities

18-3. Training:

18-4. Safe Electrical Working Principles, Controls, Procedures, and Requirements

18-5. Energized Electrical Work Permit

18-6. Electrical Safety Board

18-7. Extension Cords

18-8. Surge Protectors

18-9. Operators of Portable Personal Heaters

18-10. Static Electricity

Chapter 19 Walking Working Surfaces and Fall Protection

19-1. Purpose

19-2. Policies

19-3. Definitions:

19-4. Responsibilities

19-5. Training

19-6. Walking Working Surfaces

19-7. Fall Protection Systems

Figure 19-1. Guardrail Example

19-8. Fall Arrest System Rescue Procedures

19-9. Inspection and Maintenance

Chapter 20 Confined Space Program

20-1. Purpose

20-2. Definitions

20-3. Responsibilities

20-4. Posting of Signs

20-5. Procedures

20-6. Administrative and Record Keeping Requirements

20-7. Evaluation of Confined Space Hazards

20-8. Training

Chapter 21 Radiation Safety

21-1. Purpose

21-2. References

21-3. Explanation of Abbreviations and Terms

21-4. Policy

21-5. Responsibilities

21-6. General

21-7. Ionizing Radiation (Including Radioactive Waste) Procedures

21-8. Emergency Procedures

21-9. Laser Radiation Protection Procedures

21-10. Microwave and Radio Frequency Electromagnetic Radiation Safety

Chapter 22 Explosives Safety Management Program

22-1. Purpose

22-2. Policy

22-3. Applicability

22-4. Roles and Responsibilities

22-5. Contracting

22-6. Master Planning

22-7. Site Planning

22-8. Explosives Site License

22-9. Facilities Conformance

22-10. Facilities Maintenance

22-11. Ranges

22-12. Demilitarization/Destruction

22-13. Unexploded Ordnance (UXO)

22-14. Ammunition Amnesty Program

22-15. Risk Management

Table 22-1. DARAD Submittal Process Chart

Table 22-2. Risk Acceptance Authority

22-16. Accident Prevention Program

22-17. Emergency Response

22-18. Inspections/Evaluations/Audits

22-19. Explosives Safety Issuances

22-20. Records Management

22-21. Non-standard Ammunition and Commercial Explosives

22-22. Training

Table 22-3. Training Requirements per Position

22-23. Explosives Storage

22-24. References

22-25. Glossary

Chapter 23 Ergonomics Program

23-1. Purpose

23-2. References

23-3. Definitions/Explanation of Terms

23-4. Policy

23-5. Responsibilities

23-6. Procedures

Chapter 24 Hearing Conservation Program

24-1. Purpose

24-2. Definitions

24-3. Policies

24-4. Responsibilities

Chapter 25 Bloodborne Pathogens

25-1. Purpose

25-2. Definitions

25-3. Responsibilities

25-4. Exposure Determination

25-5. Training

25-6. Engineering and Work Practice Controls

25-7. Personal Protective Equipment (PPE)

Table 25-1. Recommended Personal Protective Equipment

25-8. Cleaning and Housekeeping Practices in the Workplace

25-9. Equipment in the Health Care Environment

25-10. Employee Exposure

25-11. Medical Evaluation after an Exposure

Table 25-2. Bloodborne Pathogens Treatment Protocol

Chapter 26 Miscellaneous Requirements

26-1. Purpose

26-2. Responsibilities

26-3. Equipment Safety Devices

26-4. Requirements for Miscellaneous Operations

Figure 26-1. Air Nozzle Tip Examples

26-5. Safety Communication Binder

26-6. Special Requirements

26-7. Racking Systems

26-8. Pallet Stacking

Chapter 27 Contractor Safety

27-1. Purpose

27-2. Policy

Appendix A References

Chapter 1 13

Chapter 1

Safety and Occupational Health Program

1-1. Purpose. To provide an outstanding Safety and Occupational Health (SOH) Program that protects our Soldiers, employees, contractors, and visitors through an effective and comprehensive Safety and Occupational Health Management System (SOHMS) at Letterkenny Army Depot (LEAD). This regulation prescribes policies, responsibilities, and minimum procedures to protect and preserve LEAD and tenant personnel from injury and property losses.

1-2. References. Required and related publications are listed in Appendix A.

1-3. Policies. The Safety Office will be considered when planning and operating LEAD activities in order to protect employees against occupational injuries and illnesses and to protect LEAD and tenant activities against unnecessary property damage, liability, and reduced efficiency. Everyone is a safety officer. It is lity to identify hazards, stop unsafe acts, and set the example by following safe practices.

a. Provide safe and healthful working conditions at LEAD for all employees, contractors, and visitors.

b. Acquire, maintain, and require the use of protective clothing, equipment, and devices reasonably necessary to protect employees against injury and illness.

c. Ensure employees participate in the SOH Program through the following actions:

(1). Familiarization with and compliance with the standards, rules, regulations, and orders issued by the installation.

(2). Report unsafe and unhealthful working conditions and all injuries immediately to their supervisor.

(3). During duty hours, participate in the activities included SOH Program.

(4). Complete required SOH training.

d. LEAD shall comply with the most stringent regulatory requirement set forth by federal, DoD, Army, or applicable consensus standards.

1-4. Safety Awards.

a. The safety awards program is designed to create and maintain the active interest of employees in accident prevention. It further provides an opportunity for directors, managers, and supervisors to give public recognition to deserving employees. Recognition of individual efforts through incentive awards reinforces accident prevention and mission goals. Also individual behavior can be favorably affected through the sense of personal recognition nurtured by the awards program.

(1). The Safety Incentive Award Program.

(a). A safety award ticket will be provided to a government civilian or military employee who is observed performing their duties in a safe manner and going above and beyond the call of duty in regards to safety and occupational health. This includes promoting safety, preventing an accident, or submitting a suggestion, AMLD Form 4294, and entering it into the electronic Hazard Reporting Process (HRP) system. The Safety Office will review, approve, or disapprove all suggestions based on merit. The safety award will entitle government personnel to a gift that has been purchased by the Safety Office when funds are available.

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(b). Safety award tickets will be provided on request from supervisors. In addition, the Commander, deputy to the commander, chief of staff, and the Safety Office may present tickets to deserving employees.

(2). Safety Impact Awards procedure:

(a). Supervisors, managers, and directors may at any time submit a DA Form 1119-1 to the Commander for review. The awards will be presented during town hall meetings to highlight the accomplishment of the employee to their peers to inspire esprit de corp.

(b). The DA Form 1119-1 will include the name of the employee and what action was taken or contribution made to support the issuance.

(c).

awarded for those contributions.

(d). Awards can be for participation in safety slogan development, participation in safety related activities beyond the normal scope of work, a suggestion that improves safety or has the potential to reduce the injury and illness rate.

1-5. Protection of Employee Rights. No employee will be subject to restraint, interference, coercion, discrimination, or reprisal because o SOH Program or for reporting unsafe or unhealthful working conditions.

a. Provisions to ensure protection against reprisal:

(1). Individual Anonymity, when requested.

(2). Prompt, impartial investigation of allegations of reprisal.

(3). Administrative actions when such allegation are substantiated.

b. The use of the inspector general channels to investigate allegations of reprisal is appropriate for military and civilian complaints in accordance with DoDD 5106.01

c. Civilian personnel have the right to file a grievance through an administrative grievance procedure in accordance with Volumes 771 and 2014 of DoDI 1400.25 and Labor Management Agreements.

d. In accordance with 29 CFR 1960 employees have the right to decline to perform an assigned task because of a reasonable belief that, under the circumstances the task poses an imminent risk of death or serious bodily harm and there is insufficient time to seek effective redress through normal hazard-reporting and abatement procedures. In this situation, both the affected personnel and local management are entitled to the considered opinion of a qualified industrial hygiene, safety engineer, health physicist, safety, fire prevention, or health professional, as applicable, on the extent of the hazard.

e. Employees of LEAD that are engaged in SOH program related activities to include but not limited to, safety council or committee meetings, JSA development, area inspections, or involvement in an OSHA inspection are authorized official duty time.

f. Any employee or designated representative may request and shall be furnished with copies of the OSH occupational safety and health program, and applicable safety and health standards.

g.

made available to each supervisor, each occupational safety and health committee member, and to employee representatives.

h. All employees have the right and are encouraged to self-identify underlying medical conditions that may pose a risk to their safety. If an employee chooses to self-identify, the employee will be referred to the clinic

Chapter 1 15 for an assessment to determine if the underlying conditions require job restrictions or limitations. If an employee seeks a reasonable accommodation for his/her medical condition, all such requests will be processed in accordance with LEAD's reasonable accommodation program and/or AR 690-12 and 5 CFR 339.

i. Employees who believe they are pregnant or breast feeding have the right to self-declare. In accordance with 10 CFR part 20 the declaration must be in writing, and will be kept on file until the declaration is withdrawn or declaration expires (1 year from the date of declaration). The self-declaration shall include the name of the employee and the estimated date of conception. Once a declaration is received the supervisor

1-6. Department of Defense Safety and Occupational Health Program. Each work area will have DD Form 2272, Safety and Occupational Health Program, visibly posted on the a The DA Form 4755, Employee Report of Alleged Unsafe or Unhealthful Working Conditions, will be available in work areas and only posted on area safety information boards when required. The DD Form 2272 outlines employer and employee responsibilities and rights concerning the Safety and Occupational Health Program.

1-7. Responsibilities.

a. The Commander is responsible for ensuring the establishment and maintenance of an effective SOH program. The Commander will ensure budgeting for Personal Protective Equipment, SOH training, ensure adequate staffing of SOH professionals. Publish annual SOH program goals based on trends. Ensure SOH staff schedule and conduct annual inspections of all LEAD facilities and work areas.

b. LEAD Safety Manager serves as the principal staff advisor and technical consultant coordinating with the Commander on all safety issues. The Safety Manager shall ensure all baseline hazard assessments have been conducted and update as new processes are added or conditions change. Maintain the hazard abatement log and ensure all identified hazards have an associated Risk Assessment Code (RAC) in accordance with MIL-STD-882.

c. Contractors will comply with the Occupational Safety and Health Administration (OSHA) standards and LEAD safety rules and regulations.

hazard analysis for the job to be performed before starting work at LEAD.

d. Directors, division chiefs, chiefs of tenant activities, and all supervisors will comply with OSHA and LEAD safety policies and regulations. Additionally, they are responsible for safety within their areas of operation to the same extent that they are responsible for production or services. They will ensure that employees are aware of their rights and responsibilities under current Safety and Occupational Health guidelines.

e. Supervisors will:

(1). Be responsible for identifying and dealing with potential hazards through the development and maintaining of Deliberate Risk Assessment Worksheet (DRAW), DD Form 2977. Reference Chapter 2 of this document for instructions. Safety Office personnel are available for technical assistance.

(2). Be cognizant of the inter-relationships between different operations under their supervision to be sure that hazards are not transferred from one work station to another. This requires continual review of all operating procedures and methods and can be accomplished by performing Job Safety Analysis (JSA) on job processes.

(3). Ensure work processes, work cell procedures, and/or SOPs are reviewed annually by each employee and new employees before engaging in operation. JSA will be updated when a significant change takes place in existing operations. Reference paragraph 1-9. Processes must be approved before a new operation begins.

(4). Investigate, report, and document (if appropriate), employee complaints of known or suspected safety hazards. Promptly advise employees of planned corrective action(s) to eliminate the hazards. If an

Chapter 1 16 employee is dissatisfied with the corrective action(s) taken, advise the employee of their right to request that the condition be further investigated.

(5). Ensure quarterly safety inspections are completed by using Hazard Report Form and AMLD Form 4294. After inspection, enter any findings in the electronic Hazard Reporting Process (HRP) system.

Employees who complete this or any other required safety inspection on behalf of the supervisor will receive OSHA general industry training prior to completing the inspection. A Safety and Occupational Health specialist will review corrective actions and close reports once an adequate corrective action has been input into the HRP system. Overdue corrective actions will be forwarded to directors for review and action. AMLD Form 4614 (Office Area Safety Inspection Checklist), AMLD Form 4614-1 (Industrial Area Safety Inspection Checklist), and AMLD Form 4614-2 (Outdoor Inspection Checklist) may be used to assist in the inspection.

(6). Ensure that all employees follow and uphold all safety rules, regulations, laws, and procedures;

initiate appropriate disciplinary action against all violators.

(7). Conduct and document weekly safety meetings with all employees. Documentation will be on a training attendance sheet or similar record. Maintain a record of these briefings for a period of at least one year. Ensure all weekly safety meetings are conducted within the first two days of every work week or the morning of the third day. Meetings held after this time frame will be limited and fully justified in writing on the sign-in sheet. Weekly safety meeting leader will also record meeting on the

The Safety Meeting Central (SMC) on the Safety Office portal page will be the primary source for weekly meeting topics. Meetings will consist of a review of all recent LEAD accidents, regardless of applicability, and a review of all applicable industrial, office, and hot safety topics.

(8). Ensure all required employees attend the OSHA General Industry Training in accordance with Chapter 5.

(9). Ensure new and reassigned employees receive a worksite safety orientation that includes a review of the fire evacuation plan, eyewash stations, break area, safety communication binder, applicable

, and medical surveillance if needed.

f. Employees will:

(1). Actively participate in the development of local safety and health regulations, JSAs through suggestions and discussions at the weekly staff/stand-up safety meetings, direct work on JSA/work procedures, and at organizational monthly safety committee meetings.

(2). If serving as a safety team member, coordinate and lead in addressing LEAD safety issues.

(3). Follow safety rules, acknowledge and assist in the efforts to correct hazards, and observe the following:

(a). Report hazards and unsafe conditions to their supervisors.

(b). Report all accidents, near misses, and injuries, no matter how slight, immediately to the supervisor.

(c). Keep work and break areas clean and orderly.

(d). Dress according to the conditions in which they work, to include wearing safety shoes, safety glasses or goggles, gloves, hearing protection, or other required personal protective equipment

(PPE).

(e). Refrain from participating in horseplay.

(f). Smoke only in designated smoking areas.

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(g). Attend scheduled SOH training.

(h). Be familiar with work procedures, DRAW, and/or JSAs at the immediate work station and be familiar with the hazard control measures associated with all job tasks.

1-8.

a. Meetings will be conducted in a structured format with minutes documenting old and new issues and held quarterly.

b. A charter covering the council code of conduct, membership, frequency, responsibilities, and other pertinent information shall be developed and signed by the Commander.

c. The Commander will serve as chairperson. The LEAD safety manager will serve in a dual capacity as advisor and facilitator and will disseminate the meeting minutes. The council will include the following members: All directors, installation medical officer, industrial hygienist, Fire and Emergency Services Division Chief, environmental officer, Federal Employee Compensation Act administrator, safety specialists, union representatives, and others as determined by the Commander.

d. Council Members will:

(1). Aid in review of the SOHMS objectives in determining its adequacy, effectiveness, and methods for improvement.

(2). Become familiar with the personal injury experience and the potential hazards that might cause injury.

(3). Devise ways and means to eliminate unsafe acts, unhealthy conditions, and to correct unsafe mechanical and physical conditions.

(4). Plan to strengthen the safety program through training or promotional efforts designed to create interest in accident prevention.

(5). Review the management review requirements outlined in the LEAD Safety and Occupational Health Management System (SOHMS) Manual.

1-9. Job Safety Analysis (JSA) Procedures.

a. Job Safety Breakdowns (JSB) are no longer an authorized or recognized document. Hazards of processes, machines, or work practices will be documented using Job Safety Analysis (JSA) AMLD Form 4040. Note that AMLD Form 4040 is only available through the JSA SharePoint workflow.

b. The LEAD Safety Office will develop and manage LEAD wide standardized JSAs. The purpose of standardized JSAs is to eliminate redundancies in common tasks, ensure consistency in safe working practices LEAD wide, and improve communication of JSA changes. LEAD wide JSAs will be identified with a cost center number of 00000. Each work area supervisor will be responsible for ensuring the development and maintenance of all work area specific JSAs as outlined paragraph 1-7 d.

c. Approved and signed JSAs and the JSA Annual Review Record (AMLD form 4161) will be posted in a binder or similar document holder on the cost center production board. Cost centers that do not maintain a production board will post their JSAs in their respective safety communication binder.

d. A JSA must be created or updated when hazards have been identified or eliminated within a process. The JSA will outline the corrective action and preventative action of the new or changed hazards or the need for new or changed controls. The cost center will conduct a risk assessment and corrective action plan and document findings in a JSA prior to starting work. Situations that require a JSA to be created or updated include:

(1). Establishment of a new process.

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(2). A process changes in a way that adds or removes hazardous conditions.

(3). An accident or injury occurred as a result of inadequately identifying hazards in the JSA.

(4). An outdated JSA is being used.

NOTE

-rewritten when the supervisor changes. The JSA only needs updated if one of the above conditions exists.

(5). JSA will be revised and resigned at least every 5 (five) years.

e. Work areas that employ alternative job hazard identification methods and corrective actions such as Standing Operating Procedures (SOP) or detailed work instruction (WI) are not required to duplicate information that would otherwise be covered in a JSA. In order to appropriately replace a JSA, the SOP or WI must address the same elements as a JSA and there must be a documented review process.

f. JSA completion process:

(1). The JSA process is an electronic system that has been designed to automate the review and approval process of JSAs. All new or changed JSAs will be processed electronically through this system which is located on the Safety Office portal page.

(2). Employees will:

(a). Work together with other employees familiar with the process to write the JSA.

(b). Complete electronic AMLD Form 4040 or work directly with another employee to complete the electronic form to be sent to the supervisor for approval. Instructions for completing the form are located on the form itself.

(c).

(3). Supervisors will:

(a). Thoroughly review the JSA to ensure that all hazards have been identified. The supervisor has seven calendar days to review and approve/disapprove the JSA. After seven days, the supervisor will be contacted by the Safety Office.

(b). Ensure that all identified hazards have been adequately abated and documented in the JSA.

(c). Electronically sign and approve the JSA before submitting the form to Industrial Hygiene (IH).

(d). Provide employees the necessary tools, materials, equipment, time, and/or guidance to adequately protect them from identified hazards.

(e). AMLD Form 4161.

(f). Not permit employees to begin work on a process without first establishing a JSA and allowing documented on AMLD form 4161 prior to employees starting work.

(g).

employees familiar with the process.

(4). The Industrial Hygiene (IH) office will:

Chapter 1 19

(a). Review all JSAs to verify that health hazards have been adequately identified and abated through a clearly written JSA document.

(b). Approve/disapprove JSAs within seven calendar days.

(c). Work with cost centers and the Safety Office to ensure that employees are adequately protected from identified health hazards through engineering, administrative, and/or personal protective equipment controls.

(5). The Safety Office will:

(a). Review all JSAs and verify that the JSAs have adequately identified and abated known hazards through a clearly written JSA document.

(b). Approve/disapprove within seven calendar days.

(c). Work with cost centers and the IH office to ensure that employees are adequately protected from identified safety and health hazards through engineering, administrative, and/or personal protective equipment controls.

(d). Log the completed and approved JSA in the JSA library on the safety portal.

g. While the purpose of JSAs are to identify hazards within a process, they are not intended to be a detailed work instruction. As a result, certain elements of a job task are optional and not required as part of the JSA process. However, if these optional items are input into the JSA, they must be appropriately updated to reflect changes. Examples of optional items are as follows:

(1). Tasks or operations that do not contain hazards, or contain hazards that are minor in nature.

Examples include handling of paperwork that could cause paper cuts, or walking between work areas where an employee could trip over their own feet.

(2). Chemical specific PPE such as rubber aprons or goggles will be optional for LEAD JSAs. In an effort to continuously improve LEAD process, chemicals may change regularly thereby changing PPE requirements. The source for chemical specific PPE is covered within the specific chemical Safety Data Sheet (SDS) or Hazardous Material Approval Group (HMAG) form and will be the primary reference for chemical PPE requirements. Documenting chemical specific PPE requirements in a JSA is redundant and may result in inappropriate donning of PPE for a specific chemical.

1-10. System Safety. System safety is the use of engineering and management principles to develop new criteria and techniques that will optimize safety within the constraints of operational effectiveness, time, and cost throughout all phases of a system or facility life cycle.

a. The developing agency of equipment or facilities has the prime responsibility for the determination of its safety. Safety aspects will be incorporated into the LEAN six sigma processes.

b. LEAD elements have responsibilities as follows:

(1). Safety staff will:

(a). Review all engineering drawings and specifications for new construction, major modifications and layout of operating facilities, machinery, and equipment in order to certify compliance with the general industry safety and health regulations, codes, and standards.

(b). Ensure that warnings, cautions, limitations, and procedures necessary to avoid hazards are included in maintenance technical manuals and other related documents.

(c). Review all work orders, SOPs, and JSAs.

(d). Review specifications for operating machinery equipment, PPE, and machine guards.

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(e). Investigate accidents to determine cause factors and proper corrective action to uncover equipment failure, material deficiencies, or need for improvements.

(f). Establish safety requirements for equipment, items, and/or services to be procured using military standards.

(g). Identify potential hazards involving new processes or common processes in areas such as: toxic materials, cleaning fluids, flammable materials, corrosives, explosives, extreme temperatures, welding, hoisting, handling, and assembly.

(h). Perform system safety analyses on hazardous operations using those analytical techniques that are judged most suitable to each operation.

(2). Directors, office chiefs and chiefs of tenant activities, coordinators, project officers, and engineering program managers will:

(a). Furnish the Safety Office with copies of test plans and results, solicitation documents and other procurement type data, construction project data, and procedures for maintenance modifications, rebuild, and disposal of materials, etc.

(b). Coordinate with the Safety Office to ensure that each program/project incorporates the maximum degree of safety consistent with operational requirements.

1-11. LEAD Safety Bulletins.

a. LEAD safety bulletins are a tool for the Safety Office to quickly distribute essential safety program information to LEAD without requiring immediate or frequent changes to local LEAD regulations.

b. Safety bulletins will be incorporated and published into LEAD regulations based on applicable timelines set by the Safety Office. This procedure will allow the LEAD Safety Office to keep the workforce informed of all safety program changes in an effective and timely manner.

c. LEAD safety professionals will write and review draft safety bulletins which outline changes or additions to the LEAD safety practices or other critical safety information for distribution to LEAD. The numbering of the bulletins will contain the fiscal year published and bulletin number (i.e. 19 01). The safety manager will approve the bulletin for distribution to the workforce.

(1). If the bulletin contains only revisions and changes, the safety specialist, when possible, will cross reference the updates to the appropriate regulation in the bulletin to ensure the changes are clearly cross-referenced from the bulletin to the applicable LEAD regulation.

(2). If the bulletin contains only new policies and procedures to be incorporated into LEAD regulations, no references will be required.

d. Once approved by the safety manager, the safety bulletin will be distributed to the workforce through the SMC and email distribution as needed.

e. Once a bulletin is incorporated into the applicable local regulations an updated copy of the regulation will be distributed to LEAD. At this point, the safety bulletin will no longer be used as a reference and will be removed from circulation.

1-12. OSHA Representative Visits.

a. The purpose of this section is to help employees and supervisors understand the steps necessary for maintaining a healthy and cooperative relationship between LEAD and OSHA.

b. OSHA compliance officers are required to enter installations and facilities to conduct investigations and assess alleged workplace hazards. These inspections are necessary and required by federal law in accordance with OSHA regulations.

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c. All OSHA representatives will be directed to the LEAD Safety Office. The LEAD Safety Office may be reached at 717-267-5253.

d. During meetings with OSHA personnel, the LEAD Safety Office will serve as the liaison between OSHA and LEAD management.

e. OSHA may request to interview employees during the course of an inspection, these interviews are exempt from management or Army counsel presence. However, In the event that OSHA requests to speak with a supervisor or manager, LEAD SOH personnel and legal counsel may be present.

f. The Safety office OSHA activities.

1-13. Industrial Hygiene (IH) Reports.

a. All IH testing and sampling will be completed by the LEAD IH Office and forwarded to the LEAD Safety Office and to applicable directors, division chiefs, and branch chiefs.

b. The affected cost center will review all IH reports with affected employees within the area. Employees will sign an employee roster indicating their review or briefing of all applicable IH reports. The training roster will be attached to the IH report and placed within Tab 13 of the safety communication binder.

1-14. Notification of Change.

a. Definitions:

(1). Change Agent: The person responsible for facilitating the purchase or relocation of equipment or implementing the major process change/reorganization. This may be a supervisor, engineer, or LEAN facilitator.

(2). Change: The addition, modification, alteration, or relocation of equipment or processes which presents new or different hazards to employees.

(a). Equipment Change: Equipment that is different in design and/or function than any other pieces of equipment within a work area. May include new or used equipment additions where employees have little to no experience with the equipment.

(b). Process Change: A change in a shop or office environment including but not limited to shop moves, new equipment, and reorganizations. These work process changes could pose new or different hazards than current work area operations and processes. Processes that include the major change of product flow, movement of processes to another building or reduced foot print of current processes, or major changes in work instructions. Additional examples include the movement of welding or gas cutting operations, reductions in workspace, and changes in processes that adversely affect ergonomics, noise level changes, or air quality changes.

NOTE

If a process is being accomplished in one area at LEAD, it does not mean that all areas at LEAD may participate in the same or similar process. One example would be a lathe outside of the machine shop.

(3). Notification of change: The procedure by which changes will be reviewed in order to ensure due diligence has been given to the change in order to reduce the risk of employee exposure to hazards.

b. Notification of change process.

(1). Any time a work area undergoes a change, as defined above, AMLD Form 4461, Notification of Change, will be completed. All forms will be completed electronically on the Safety Office portal page.

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(2). The change agent will create the change title, the process owner, location effected by the change, and a description of the change in as much detail as possible. There is also the ability to include attachments, if needed, to facilitate the change appropriately.

(3). The offices identified below will automatically be selected and notified. Each office will receive an automated message to review the proposed change. The reviewing offices include:

(a). Process Owner

(b). Safety Office

(c). IH Office

(d). Fire Department

(e). Production Engineering

(f). Industrial Equipment Maintenance

(g). Test Equipment Maintenance

(h). DPW Engineering

(i). DPW Environmental

(j). DOIM

(k). DES

c. Responsibilities.

(1). The change agent and the following stakeholders identified above in paragraph 1-13 b (3) will:

(a). Review and understand the change and provide the change agent with direction to meet the requirements of their stakeholder entity.

d. Exemptions: The following changes are exempt from the notification of change process as review mechanisms are already in place for these changes.

(1). Movement of Hazardous Material (HAZMAT) cabinets

(2). New chemical purchases (HMAG Approval)

(3). DPW Work and Service Orders; FEMS requests

(4). New Business Development (Owned by the Business Development Office)

Chapter 2 23

Chapter 2

Risk Management Program

2-1. Purpose.

specifies the establishment of initial and residual risk levels, as well as appropriate risk acceptance authority through the use of DD Form 2977.

2-2. References.

a. DA PAM 385-30 Risk Management

b. AR 385-10 The Army Safety Program

c. DA PAM 385-10 Army Safety Program

2-3. Definitions.

a. Formal Risk Assessment: A documented risk assessment using DD Form 2977 that has been reviewed by the chain of command, signed by the risk acceptance authority, and posted within Tab 22 of the cost center safety communication binder.

b. Hazard: A condition that has the potential for causing a loss, such as injuries to personnel or damage to government property.

c. Loss: Any reduced value to the government including injuries sustained by personnel and/or damage to government owned property.

d. Risk: The probability and severity of loss linked to hazardous working conditions or operations. It is the measure of the expected loss from a given hazard, group of hazards, or operation usually estimated as the combination of the likelihood (probability) and consequences (severity) of the loss.

e. Risk Acceptance Authority: The grade or rank of Army leadership that has the authority to accept a level of risk.

f. Risk Assessment:

an operation or series of operations.

g. Undocumented Risk Assessment: A Risk Assessment that has been completed mentally, hand written on paper, or electronically that results in an estimated initial and residual risk. The purpose of this type of assessment is to assist the person conducting the assessment in determining the level of emphasis and priority that will need to be placed on completing a formal risk assessment with an appropriate risk acceptance authority accepting the residual risk level.

2-4. Responsibilities.

a. Directors will:

(1). Oversee subordinate operations to validate that formal risk assessments have been completed by all applicable operations, accept risk in accordance with Table 2-1, and elevate all risk assessments that exceed their risk acceptance level.

(2). Take immediate action to address operations that have not been appropriately assessed for risk in accordance with this program.

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b. Supervisors will:

(1). Ensure that formal risk assessments are completed for all non-administrative operations under their responsibility.

(2). Not permit operations and equipment to be operated that have not been appropriately assessed for risk in accordance with this program.

(3). Ensure all subordinate operations adhere to the requirements of this program.

c. The Safety Office will support all activities in the assessment of risk by providing technical consultation in the area of Safety and Occupational Health. The Safety Office possesses no risk acceptance authority.

2-5. Policy.

a.

LEAD personnel to manage the risk posed by the mission requirements of LEAD.

b. All LEAD supervisors will complete Army Risk Management Basic training (Army Learning Management System) within 60 days of being assigned as a supervisor.

c. All LEAD supervisors will have performance standards that incorporate Risk Management that are Specific, Measurable, Achievable, Realistic, and Timely (SMART).

d. Leaders at all levels will analyze and assess the risk of all subordinate operations, with the exception of those that are administrative in nature. All formal risk assessments will be conducted utilizing DA Pam 385- 30 and DD Form 2977 or approved equivalent. Risk assessments will consider all operations and associated hazards that could result in a loss to the government. Risk assessments may consider a single operation within an organization or multiple operations that are similar or logically connected.

e. A formal risk assessment using DD Form 2977 will be completed in the following situations:

(1). Each LEAD cost center that possesses operations, other than administrative operations, will establish a baseline formal risk assessment. At least one DA Form 2977 will be completed and signed by the risk acceptance authority for each applicable cost center. One risk assessment can cover multiple operations. Additional risk assessments may be completed to logically assess distinctly different operations in order to properly assess risk. The actual number of risk assessments will be determined by the chain of command with support from the LEAD Safety Office.

(2). Administrative employees that work primarily in administrative operations, but visit non-administrative operations to perform their assigned duties will conduct a formal risk assessment. Examples include engineers, shop coordinators, and contracting officer representatives. Employees who conduct infrequent trips to non-administrative work areas will conduct an undocumented risk assessment prior to each trip. Frequent is defined as more than 3 visits per week lasting more than 3 hours. Note that the definition of frequent is a general guide and not a hard rule. Formal risk assessments are recommended for every work area despite the number and frequency of visits to non-administrative operations.

(3). When new processes or pieces of equipment are being considered within a work area, the baseline risk assessment will either be revised, or a supplemental risk assessment will be completed. This risk existing DD Form 2977. Once the new process or equipment has been implemented and proven, a revised baseline risk assessment will be completed, if applicable.

Chapter 2 25

NOTE

New processes and equipment are inherently more dangerous than mature processes and equipment; therefore, it is preferred that new processes and equipment have their own risk assessment until the new process and equipment has been proven over an appropriate amount of time. Risk assessments cannot be utilized to accept risks that violate regulatory or statutory laws.

f. All risk assessments will consider the following elements:

(1). Employee training required to complete the job.

(2). Formal documents such as Job Safety Analyses (JSAs), National Maintenance Work Requirements (NMWRs), Depot Maintenance Work Requirements (DMWRs), Technical Manuals (TMs), Standing Operating Procedures (SOPs), and Work Instructions (WIs).

(3). Employee and leadership considerations such as lone workers, employee competency (knowledge, skills, and abilities), leadership competency (knowledge, skills, and abilities), hazards of new employees, and employee complacency.

(4). Facilities, vehicles, and equipment considerations.

(5). Supporting programs such as Confined Space Entry, Lockout/Tagout, and Lead, Cadmium, and Chromium.

g. In accordance with Table 4-1 Note 1 of DA PAM 385-30, the Commander of LEAD delegates risk acceptance authority to LEAD directors for all low risk operations with durations greater than 1 year.

Reference Table 2-1 of this document.

h. Leaders at all levels will take immediate appropriate action to address inadequately developed risk assessments or the absence of a risk assessment if required by above paragraph 2-5 e. If an inadequate or absent risk assessment is identified in an operation that is occurring, the supervisor shall conduct an undocumented risk assessment immediately to determine a Risk Assessment Code (RAC). If the operation has a residual risk greater than low, the operation will be halted immediately until the appropriate risk acceptance authority has taken responsibility for the operation in accordance with Table 2-1. In this scenario, operations with a residual risk of low will be assessed and approved by the risk acceptance authority within 15 calendar days.

i.

accepted by the appropriate risk acceptance authority in accordance with Table 2-1. All completed and signed risk assessments for a work area will be maintained within Tab 22 of safety communication binder. All risk assessments will be reviewed with all affected employees at least annually.

Employee review of risk assessments will be documented on AMLD Form 2585 or similar training record and posted along with the risk assessment in Tab 22.

j. All DD Form 2977s will be updated and resigned by the appropriate risk acceptance authority at least every two years or when any person within the chain of command changes. Updates to DD Form 2977 will be completed prior to the expiration of the two year period and within 30 calendar days of the change in leadership below the director/deputy director level and within 90 days of a change to the risk acceptance authority, director or above.

k. Undocumented risk assessments may be used to complete operations that are not covered on a formal risk assessment so long as the operation is considered temporary, less than 1 month, the residual risk is low, and the operation aligns with the current mission of the cost center. For new or different operations that fall outside of the mission scope of the cost center, the supervisor will complete a formal risk assessment and have it signed by the appropriate risk acceptance authority in accordance with Table 2-1 before beginning the new or different operation.

Chapter 2 26

Table 2-1. Risk Acceptance Matrix.

Duration of Risk

Event waiver Waiver Exemption

Category of risk 1 month or less 1 month to 1 year 1 year to 5 years Permanent or greater than 5 years

Extremely high risk

AMCOM CG Army Headquarters Commanding General (CG)

Army Headquarters

CG

Army Headquarters

CG

High risk LEAD Commander AMCOM CG AMCOM CG AMCOM CG

Medium risk Director GS-13 or GS-14

LEAD Commander AMCOM CG AMCOM CG

Low Risk First Line Supervisor

Director GS-13 or GS-14 *May be delegated 1 level

Director GS-13 or GS-14

Director GS-13 or GS-14

2-6. Deliberate Risk Assessment Worksheet. All DD Form 2977 completed by the first line supervisor and approved by the appropriate risk acceptance authority will serve as a risk profile for a given cost center.

2-7. Risk Assessment Code Matrix. Table 2-2

a. Descriptions for Table 2-2

(1). Hazard Severity

(a). CATEGORY: I CATASTROPHIC: Death, unacceptable loss or damage, mission failure, or unit readiness eliminated.

(b). CATEGORY: II CRITICAL: Severe injury, illness, loss, or damage; significantly degraded unit readiness or mission capability.

(c). CATEGORY: III MODERATE: Minor injury, illness, loss, or damage; degraded unit readiness or mission capability.

(d). CATEGORY: IV NEGLIGIBLE: Minimal injury, loss, or damage; little or no impact to unit readiness or mission capability.

(2). Accident Probability

(a). LEVEL A: FREQUENT: Continuous, regular, or inevitable occurrences.

(b). LEVEL B: LIKELY: Several or numerous occurrences.

(c). LEVEL C: OCCASIONAL: Sporadic or intermittent occurrences.

(d). LEVEL D: SELDOM: Infrequent occurrences.

(e). LEVEL E: UNLIKELY: Possible occurrences but improbable.

Chapter 2 27

Table 2-2. Risk Assessment Matrix.

Chapter 2 28

2-8. Hierarchy of Controls. Table 2-3

a. Descriptions for Table 2-3

(1). Elimination: Although not always feasible, physically removing the hazard completely from the facility is the best option for keeping workers safe.

(2). Substitution: The second most effective route for controlling hazards is by replacing the hazard with a less dangerous substitute.

(3). Engineering Controls: Instead of eliminating the hazard, engineering controls work to keep people away from the hazard. Common examples include machine guarding, modifying equipment, ventilation systems, etc.

(4). Administrative Controls: This type of control works to change the way work is done. It includes changing or implementing policies and procedures, employee training, maintenance, and more.

(5). Personal Protective Equipment: Finally, personal protective equipment (PPE) is considered the least effective in the hierarchy. PPE includes any piece of clothing or equipment worn by workers that acts as a barrier between them and the hazard. Because PPE has a chance of failing, it should never be the only hazard control used.

Table 2-3. Hierarchy of Controls.

Chapter 3 29

Chapter 3

Reporting and Investigating Army Accidents

3-1. Purpose. Provides policies and procedures and assigns responsibilities for the notification, investigation, and reporting of LEAD accidents and near misses. It establishes policy for the prompt notification of all accidents and ensures proper investigation for all accidents. The causes of all accidents should be determined and corrective measures developed and implemented to prevent recurrence. The primary purpose of investigating and reporting Department of the Army (DA) accidents is prevention.

3-2. Definition of Roles.

a. LEAD Safety Office: Develops and establishes processes to conserve Army resources, personnel and property, through accident prevention. The results of a Safety Office investigation may be used for accident prevention purposes only. Under no circumstances may a Safety Office report be used to determine negligence for the purpose of liability or disciplinary action.