Safety is an important concern for our facility, both for something and something. RayDesks will follow safety guidelines from OSHA, ADA, EPA, and Risk Mitigation Strategies. Safety impacts Human Resources, Layout, and Financial.
Occupational Health and Safety Administration (OSHA)
Much of our manufacturing facility will be qualified as a walking-working surface, which means we will keep the facility in a clean, sanitary, and orderly manner to help prevent injuries or disasters from occurring. Emergency exits will be well-lit, permanent, separated by fire resistant materials, and always be unlocked from the inside. Emergency exits will also be clearly marked. RayDesks will also have a fire prevention plan that will be reviewed yearly and will be reviewed by all new employees. Fire Extinguishers will also be included.
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General construction areas will have lights placed at 5 foot-candle intervals and that warehouses, walkways, corridors, exits and other indoor spaces will have lights placed at 3 foot-candle intervals. Immediately outside the manufacturing facility, lighting will be placed at 3 foot-candle intervals, while in the parking lot, lights will be at 4 foot-candle intervals.
RayDesks will protective guards on all machines and during machine maintenance, machines will have lockout devices. Specifically, several machines will require emergency buttons to stop production, including the injection molding machine, the metal cutting and punching machine, and the automatic screwdriver. For the injection molding machine, an operator’s gate will also be required, in order to let the operator gain access to the mold. For the metal cutting and punching machine and the automatic screwdriver, an operator will need to use a button to ensure limbs are safe before proceeding.
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Personal Protection Equipment (PPE) and a dress code will be required for all employees, at differing levels depending on employees’ tasks. RayDesks recommends that heat resistant gloves, dusk masks, face shields, and paint suit be purchased for various tasks. For the welding machine, a specific welding helmet will be required, which is included with the welding machine chosen by the manufacturing analyst. The welding machine will also need welding approved gloves, which can be supplied by the heat resistant gloves. Injection molding machines and the paint oven will also require heat resistant gloves. Dusk masks and paint suits will be required for the powder paint spray guns and a spray booth to prevent potential inhalation and skin irritation. Face shields will be used by the injection molding machines, the metal cutting and punching machines, and the metal bending machines to prevent possible injury or inhalation. A dress code of long pants and long shirt sleeves will be required for the automatic screwdriver, manual interior thread machine, and metal bending machine to protect against cuts and burns.
Storage of materials will be limited in height and secured to prevent possible falling. Forklifts will be needed for some material handling in our facility, and forklift operators will receive training and have recertification every three years. For the storage of excess powder paint, RayDesks recommends the use of powder coating disposal bags for the safety of employees. The spray booth will be situated away from the rest of the machines and will keep the paint within the booth.
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American Disabilities Act (ADA)
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RayDesks aims to follow all requirements set out by the ADA. Aisle length will be at least 32 inches to accommodate people with wheelchairs. Counters will be between 24 and 34 inches high. The facility does not need any elevators, as it is a one-story facility. Any ramps will have a minimum width of 36 inches and will not be longer than 30 feet without a landing. Additionally, 18 inches of free space is required for doors to swing out at ramps and be 1/2 inches off the ground.
RayDesks recommends a separate accessible stall be added that includes clear space of 32 inches to the wall, a toilet that is 17-19 inches high and centered exactly 18 inches from the wall, and a toilet paper dispenser that is no more than 19 inches off the ground. At least one sink in every bathroom will have a clear space of 30 by 48 inches and the counter height will not be taller than 34 inches. RayDesks also recommends adding a soap dispenser to the side of the sink, to make it easier to reach.
For parking, several parking spaces will be accessible, and they will be located the shortest possible distance to entrances to the facility. The parking spaces will require at least 60 inches with 5-foot-wide access aisles and clear marking to indicate handicap accessible. For every 1 in 8 accessible parking spots, ADA requires that one be van accessible, which requires 11 feet of space in addition to aisles on the passenger side. Van accessible parking spots also should have clear signage.
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Environmental Protection Agency (EPA)
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One hazard from furniture manufacturing is coating of metal surfaces, which is regulated by the EPA. There are standards that need to be met to prevent hazardous air pollutants, which RayDesks will meet using the spray booth and the choice of powder paint versus other traditional spray paint. RayDesks will not be emitting enough greenhouse gases to be required to make a report to the EPA. The waste products within our facility can be recycled and are classified as non-hazardous by the EPA which include powder paint, metal, and a variety of plastics.
Risk Mitigation
There are several areas of risk mitigation we hope to emphasize within our manufacturing facility. Avoiding repetitive motion trauma is one key area. Repetitive motion trauma can lead to repetitive motion injuries (RMI) and commonly affect hands and the upper extremities. RayDesks recommends taking several steps to avoid RMIs, including training employees on best practices, rotating schedules, and microbreaks. RayDesks also proposes that the greatest at-risk jobs have an ergonomic job analysis. Lifting injuries is another concern in a manufacturing facility and will be offset using forklifts. Training on proper technique for picking up large objects will also be recommended. Training will be done through an Environmental Health and Safety Consultant. RayDesks recommends having a consultant and an assessment to ensure safety and prioritize employee’s health.
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The location of the facility is in Memphis, Tennessee, which has a high crime rate in comparison to the rest of the United States. So, RayDesks also recommends investing in a security system that includes an alarm system, cameras, and monitoring, as well as hiring security guards. RayDesks will need 5 security guards, working 8-hour shifts.
Ergonomic Design
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To ensure the safety and longevity of the operators in the facility, an ergonomic assessment was conducted on the most physically demanding job. Employees in assembly station five are tasked with stacking sixteen boxes onto a pallet. This repetitive lifting puts the operator at high risk for ergonomic injuries. Utilizing the National Institute for Occupational Safety and Health (NIOSH) Lifting Equation, calculations are made for both the initial job and the redesigned job. The redesigned job makes improvements to multiple multipliers by means of purchased solutions and modifying the lifting style. A Spring-Actuated Automatic Elevating Pallet Carousel Table provides a constant vertical distance, so no bending is required.
Total Costs
RayDesks recommends spending $753,717.50 per year on safety and ergonomic measures, including PPE, Safety/Ergonomic Assessments, Security System and Guards, Fire Extinguishers, and Powder Paint Disposal Bags.