Safety Training Manual

Berry Global (Washington, GA)
SAFETY TRAINING
MANUAL
1
TABLE OF CONTENTS
Berry Safety Absolutes 3
Hand Safety 5
Personal Protective Equipment 7
Hygiene Practices 10
Incident/Accident Reporting 12
Back Safety 13
Bloodborne Pathogens 14
Confined Space 18
Crane Hoist & Slings 22
Emergency Evacuation 24
Severe Weather 25
Ladders & Stairs 27
Fire Extinguisher 30
Hazard Communication 32
Hot Work 34
Daily Forklift Inspection 35
Pedestrian Safety Around Forklifts 37
Non-Routine Task Hazard Analysis Program 38
Work Area Housekeeping 39
Lockout/Tagout 40
Heat Stress 45
Job Safety Analysis (JSA) 47
Appendices 54
2
1. Berry Safety Absolutes
1.1 Employee Accountability

There are specific tasks that requires employee mandatory compliance to follow
the safety rules and training due to the potential injury risk.
Any violation of these safety absolutes could/will result in disciplinary action up to

and including termination of employment.
1.2 Failure to LOTO Equipment

1.2.1 LOTO must be applied when working on equipment with the potential for
unexpected release of hazardous energy.
(LOTO) procedures must be followed when working on equipment with the

potential for unexpected release of hazardous energy. Testing and positioning
activities and task that fall under the minor servicing exception with a completed
risk analysis are the only exceptions.
1.3 Reaching into Moving Equipment

1.3.1 NEVER reach into moving equipment.
Body parts shall not be placed in moving equipment unless following standard
operating procedures based upon a current documented risk assessment.
1.4 Failure to Secure Trailers Before Entry

1.4.1 Verify trailers are secured before entry.
All semi-trailers must physically be restrained with a mechanical barrier restraint

and/or wheel chock, during loading/unloading operations. Employee stepping in
or on a trailer verify this condition.
1.5 Operating a Forklift Before Being Training and Certified

1.5.1 Powered Industrial trucks operated by certified operators ONLY.
Only Berry trained and authorized individuals can operate powered industrial
trucks or any other motorized vehicles.
1.6 Failure to Wear Required Fall Protection

1.6.1 NEVER take fall risk. Wear fall protection.
When exposed to an unprotected elevated surface greater than 4 feet (1.219

meters), company authorized fall protection measures must be taken.
3
1.7 Unauthorized Entry of a Confined Space

1.7.1 Authorized personnel only.
Permit required confined spaces can only be entered by authorized

employees/contractors.
1.8 Other Berry Safety Rules

1.8.1 Employee’s must review and follow all safety rules and safe work practices.
1.8.2 All plant injuries must be reported immediately. (No matter how minor)
1.8.3 Dress code policies must be followed at all times. No jewelry including
rings and watches. Clothing must be professional and worn in a manner that
prevents them form being caught in rotating moving equipment.
1.8.4 Good hair management containment must be maintained. Hairnets are
required to be worn in all production work areas. Clean cap over a hairnet is ok
but not mandatory.
1.8.5 Emergency equipment and egress must be plainly marked and assessable
at all times.
1.8.6 Employees must be alert and look in their direction of travel.
1.8.7 Two employee’s working together on a task requires one person to take
the lead. (Communication is the key)
1.8.8 All sharp objects or blades must always be placed in approved containers.
1.8.9 Pedestrians must be aware of forklift traffic. Look and listen before
stepping out into the forklift travel path.
1.8.10 Only authorized personnel are allowed construction zone. Hard hats will
apply in an area when overhead is being done in construction work zones.
1.8.11 Employees must be alert to changes in their work area when walking from
one location to another. Do not create hazards by placing things in the walking
path.
1.8.12 Flammable/Corrosive liquids must be stored and transported in approved
containers.
1.8.13 Visitors must comply with plant safety rules when visiting the facility.
1.8.14 Contractors must comply to all plant safety rules while on premises.
1.8.15 Employee’s must report unsafe conditions to their supervisor immediately.
1.8.16 Employee’s must comply to the company policy of not working impaired.
1.8.17 The following are prohibited on company property: Horseplay or fighting,
fraud or stealing, possession or use of drugs, alcohol, or controlled substances,
firearms or other weapons, tampering with, defacing or destroying company
property, or mental, physical or sexual harassment.
4
2. Hand Safety
2.1 Danger Zones and Injury Types

Danger Zones:
- Handling or struck by sharp objects
- Caught in rotating equipment
- Energized systems
- Struck by or against objects
- Caught in pinch points
- Miss-use of portable power tools; working on energized tools
- Contact with hot objects or materials
- Contact with caustic or corrosive materials
- Poor hygiene practices
- Repetitive motion/poor equipment design
- Improperly dressed wounds
- Poor hand or body position
Injury Types:
- Burns
- Dermatitis
- Sprains and Strains
- Fractures
- Lacerations
2.2 Keep Out of the Danger Zone

Primary Level of Defense: (Danger Zone)
- Awareness
- Safe Work Practices:
o Tool Holders
o Tag Lines
o Correct Tools
o Push Tools
o Good Hygiene
- Body and Hand Position
- Training/Competence
- Distance
- Equipment Guarding
- Physical Barrier
Secondary Level of Defense: (Hand Placement)
PPE:
- Gloves Required
- Correct Gloves
5
2.3 Impact Resistant Glove Policy

Purpose: Prevent Berry employees from suffering hand injuries while using hand
tools for assembling or dissembling operations.
Scope: The policy applies to all Berry Global- SFD employees who use hand
tools.
Policy: All Berry Global – SFD employees must wear impact resistant gloves
when there is a potential for hand strikes due to high torque operations using hex
tools, pliers, ratchets, sockets, wrenches, pry bars, hammers, chisels, or
screwdrivers. One of the most common high torque operations is tightening or
loosening nuts and bolts.
Never wear gloves when working with, in, or around moving equipment.
2.4 Recommended Impact Resistant Gloves

Hyflex 11-511 Cut-Resistant Gloves (Appendix A)
- Hand protection for minimal impact task and handling or working around
sharp equipment and blades of all types.
- Example: Handling wooden pallets, moving shafts, metal carts, working with
or around any blades.
Mechanix Wear – M-Pact Glove (Appendix B)
- Hand protection for HIGH impact task such maintenance related task.
- Example: Loosening/tightening bolts, working with tools, and moving heavy
equipment or parts.
2.5 Why Focus on Hand Safety?

- Hand injuries account for over 1 million emergency room visits per year.
- Of these injuries, 30% were wearing the wrong glove for the task. We provide
and require you to wear many different types of hand protection to keep you
safe.
o The majority of injuries at Berry includes lacerations.

o When a hand injury occurs, exposure to blood or bodily fluids could
result in Blood Borne Pathogen health risk.
6
3. Personal Protective Equipment (PPE)
3.1 Training
- Each required employee shall be training to know at least the following:
o When PPE is necessary
o What PPE is necessary
o How to properly put on, take off, adjust, and wear PPE.
o Limitations of the PPE
o Proper car and maintenance, useful life and disposal of PPE.
3.2 Employee Responsibility

- Wear PPE at all times as required by the plant safety policies.
- Ensure that the PPE is maintained and in good working condition.
- Request replacement if detective to a level that it doesn’t provide adequate
protection.
3.3 Hazard Assessment

- Hazard assessment will be conducted to determine PPE needs.
- PPE will be provided and made available for employees.
- Employee’s will be held accountable for proper use and maintaining their
PPE.
Assessment:
1. The employer shall: assess the workplace to determine if hazards are
present.
2. Select, and have each affected use, the types of PPE that will protect them
from the hazards identified in the hazard assessment.
3. Communicate the selection decision to each affected employee.
4. Select PPE that properly fits each affected employee.
3.4 PPE (Extrusion Operations)

- PPE is required for extrusion operations where molten plastic is or can be
present.
Mandatory PPE:
- Safety glasses
- Face shield with chin protection
- Torso protection
- Arm protection
- Heat resistant gloves
- Leg protection
Optional PPE:
- Neck protection
7
3.5 Eye Protection

- Safety glasses: Must be work everywhere on the job. (Inside and outside)
- Neve substitute regular prescription glasses for safety glasses.
- Glasses must be ANSI approved safety lenses and safety frames including
side shields.
- Face shields or goggles must be worn in conjunction with regular safety
glasses when working with grinders, air hoses, and where full-face protection
is needed.
3.6 Hand & Arm Protection

- Gloves protect hands from workplace hazards.
- Gloves DO NOT offer 100% protection. Heat gloves resist heat. Cut gloves
resist cuts.
- Cut gloves shall be worn when working with blades and stringing up
machines in areas where blades are present. Not around nip points or
moving spindles.
- Cut sleeves and gloves must be worn on both hands and arms when cutting
down cardboard, plastic or using excessive force.
- Cotton heat gloves and sleeves must be worn when working around any hot
objects. (Dies connecting pipes, etc.)
- Use gloves whenever possible to protect your hands. (Cut gloved with coated
palms must be worn to help protect hands in impact situations and high
impact maintenance tasks.)
- Rubber gloves: help protect hands from chemicals, paint, etc.
- Use the right glove for the job and replace gloves when they become worn.
3.7 Foot Protection

- Steel-toe safety shoes are designed to protect your toes from falling objects
and are a requirement of this facility and must be worn by all plant
employees, working visitors, and contractor personnel.
- Make sure your safety footwear fits properly and that it is replaced when it
starts to show signs of wear or if the soles become slick.
- Escorted visitors are NOT required to wear foot protection while touring the
facility if they stay with the escort.
- Each Berry employee receives a monetary shoe allotment per year.
3.8 Dress Code

- All employees are expected to dress appropriately and professionally for the
job they perform.
- To meet GMP (Good Manufacturing Practices) standards while at the plant,
all employees must wear a hairnet to prevent hair from making contact with
moving equipment.
8
- If your hair falls below the collar line, it must be tucked or contained within a
hairnet. (Totally bald is the only exemption from the hairnet requirement) A
cap can be worn with a hairnet but not in place of the hairnet.
- Clothes that do not meet the professional standards of the job, are defined
as, but not limited to the following:
o Clothes with holes or ragged edges.
o Clothes of off-color or of sexual nature.
o No tank tops, or shirts that expose midriff.
o Clothes made of spandex.
o Excessively loose clothing.
o Shorts must be knee-length, shirts must have sleeves, shirttails
tucked.
o Button up shirts must be button up to the last two buttons.
o No sagging or hanging clothing that could become caught in
equipment.
o No metallic jewelry such as watches, bracelets, loose chains, rings, or
dangling/loop earrings are allowed.
9
4. Hygiene Practices
4.1 Purpose
Purpose: The purpose of this procedure is to ensure that the product is
protected from possible contamination through the use of good hygiene
practices.
Scope: The scope of this procedure includes all employees and contractors
working at the Washington, GA facility.
Responsibility: It is the responsibility of the department managers,

facilitators, team leaders, and machine operators to ensure that this policy is
followed.
4.2 Rules
4.2.1 Eating/Drinking
- Eating shall only be allowed in the designated areas:
o Offices (excluding team offices)
o Break rooms
o Conference rooms
o Outside the facility
- No candy, gum, lifesavers, etc. are permitted around the production lines.
- Hands must be washed prior to returning to work areas.
- Water is the only beverage allowed in the production areas and must be kept
in a closed container.
- Acceptable containers are bottles with caps and spill resistant plastic mugs or
cups.
4.2.2 Tobacco Use

- The use of tobacco products is prohibited on all company owned property
and at all company sponsored indoor activities.
4.2.3 Restroom Facilities

- Restrooms are to be well maintained, routinely cleaned, and positioned within
walking distance of the work areas.
- Hands must be washed prior to returning to work areas.
4.2.4 Housekeeping
- All employees are responsible for the cleanliness and housekeeping of their
work area and the areas that they encounter during the course of a work day.
10
- It is the responsibility of each employee to ensure that all cleanliness

violations that they see are corrected immediately.
4.2.5 Maintenance in WIP/FG Areas

- Anytime maintenance work is to be performed in a WIP or Finished Goods
area, and WIP/FG material is to be moved 25 feet away from the work area.
- The work area and affected material will be inspected to prevent the
possibility of contamination.
4.2.6 Personal Hygiene

- All personnel are encouraged to maintain good personal hygiene at all time
during their work day.
- Any personnel with small scrapes, cuts, sores, etc. must have the proper
protective bandage. Bandage must be changed as needed to ensure no
contamination of product.
- Hand sanitizer is available on all production lines and at all building
entrances.
4.2.7 Glass
- If an accidental glass breakage occurs, a functional leader will inspect to
make sure that all glass, etc. is cleaned up properly and has not
contaminated any product.
- All fluorescent lights in the facility use shatter-shield bulbs.
- Employee use of any glass (porcelain coffee cups, glass drink bottles, etc.) is
prohibited throughout the plant.
11
5. Incident/Accident Reporting
5.1 Short- and Long-Term Corrective Actions

- Warning placards mounted at each machine unwind and rewind in the plant
showing and communicating specific pinch point dangers.
- A notice of this incident was posted on the communication monitors for visual
review by all employees.
- Signage will be posted on the equipment showing the pinch point hazards.
5.2 Incident and Injury Reporting Requirements

5.2.1 Injured Employee
- Report all workplace incident to supervisor immediately (within 15 minutes).
- Evaluate injury & administration of first-aid treatment with supervisor/first
responder.
- Participate in investigation and corrective action measures.
- If no injuries but problems occur later (report immediately to management)
5.2.2 Supervisor
- Assist employee with assessment of injuries and first-aid treatment
- Contact emergency response 911 in event of life-threatening injuries.
- Call and inform EHS & Management personnel of the incident.
- Ensure security of the incident/accident scene.
- Ensure personnel are available to assist with investigation.
5.2.3 Incident Scene

- Based on the situation the operation/production line will be
stopped/suspended.
- If the operation or production line was involved in the incident, then the line
will be stopped/idled until the investigation is complete. (DO NOT CLEAN,
STRAIGHTEN, OR SCRAP THE SCNE UNTIL INVESTIGATION IS
COMPLETE)
- The managers will form an investigation team to review the incident.
12
6. Back Safety
6.1 Basic Rules of Proper Lifting

** Most back injuries are preventable through the use of proper lifting techniques.
- Size up the load before you lift. Test load by lifting a corner.
- If heavy, get help or mechanical aid. When in doubt, don’t lift alone.
- Bend the knees. This is the single, most important aspect of lifting.
- Place your feet close to the object and a comfortable distance apart.
- Get a good hand hold grip on the object.
- Lift with your leg muscles, not your back.
- Do not twist or turn your body. Step in direction of travel if you turn.
- Reverse procedure to set the load down properly.
- Always push, not pull, an object when it’s on a cart or dolly.
6.2 Job Duties where Lifting Hazards Exist

- Lifting rolls of film.
- Pushing, pulling or moving heavy objects.
- Maintenance related task of handling equipment, rolls, etc.
- Manual loading of scrap racks or recycle racks.
- Manual lifting of spindles. Get help or use a mechanical means: a hoist, roll
cart, dolly, or crown lift.
6.3 Weight Limits

- The Washington< GA self-imposed safe lifting limit is 55 lbs. per person.
- Any load greater than 55 lbs. Per person requires additional personnel or
mechanical assistance.
- Use roll handling equipment to move and package all rolls. (Rolls lighter than
55 lbs. shall only be lifted manually when roll handling isn’t available.)
- Never carry a load that is so large it obstructs your vision.
13
7. Blood Borne Pathogens
7.1 Training Objectives

- Understand what a blood borne pathogen is.
- Understand exposure risk.
- Review Exposure Control Plan goals.
- Review first aid support and first responders.
- Understand universal precaution.
- Review methods to reduce exposure.
- Review Hepatitis B vaccine offer.
- Review reporting and treating exposure.
7.2 What are Blood Borne Pathogens?

- Blood Borne Pathogens are a virus or bacteria that is carried in the blood
through body fluids (i.e., saliva, mucous) and can cause disease in people.
- Examples:
o Hepatitis
o Human Immunodeficiency Virus (HIV)
7.2.1 What is the risk of exposure?
- Unbroken skin forms a barrier against blood borne pathogens. However,
infected blood can enter your system through:
o Open sores or cuts
o Abrasions
o Any sort of damaged or broken skin such as sunburn, acne, or blister
7.3 Other Modes of Transmission

- Accidental puncture or cut from contaminated sharp objects can result in
transmission of blood borne pathogens. Blood borne pathogens may also be
transmitted through the mucous membranes of the mouth, nose, and eyes.
7.4 Exposure Control Plan

- Control plans vary but may have common elements.
o Employee training
o Work practice control procedures
o PPE use requirements
o Procedures to prevent exposure
o Housekeeping procedures
7.5 Recognize Exposure
14
- Before entering a scene...STOP.

- Take time to protect yourself.
- Look for:
o Blood and infectious materials at injury or accident scenes.
o Bodily fluids
o Potential suspicious fluids
- Do not touch or clean any blood from your fellow worker. For first aid
situations have a first responder assist you. -They have been trained to follow
universal precautions.
- “Universal Precautions” is the name used to describe a prevention strategy in
which all blood and potentially infectious materials are treated as if they are,
in fact, infectious, regardless of the perceived status of the individual source.
7.6 PPE Use and Protection Procedures

1. When complete- carefully remove all PPE. Remove gloves last, turning
them inside out.
2. Place all infected materials and PPE into the red Bio-bag. (Turn in bag to
EHS for proper disposal.)
3. Wash hands with antibacterial soap.
7.7 Reduce Exposure

- Handwashing is one of the most important (and easiest) practices used to
prevent transmission of blood borne pathogens.
- Hands or other exposed skin should be thoroughly washed as soon as
possible following an exposure incident.
7.8 Exposure Procedures

- If you are exposed to any type of bodily fluids, you should:
1. Wash the exposed area thoroughly with soap and running water.
Use non-abrasive, anti-bacterial soap if possible. If blood is
splashed in the eye or mucous membranes, flush the affected area
with running water for at least 15 minutes.
2. Report the exposure to your supervisor as soon as possible.
3. Fill out an exposure report form. (Appendix C)
7.9 Medical Records

- Must be made available to employee and include:
o Employee name and social security number
o Hepatitis B vaccination status
o Results of all exams, testing, follow-ups
o Copy of physician’s professional opinion
o Copy of information provided to healthcare professional
15
- All medical records are confidential to the employee only.
7.10 Hepatitis B Vaccine

- A Hepatitis B vaccine is available to employees that are at high risk of
exposure.
o First responders, supervisors, and primary care givers.
- Treatment is also available after an employee has experiences exposure to
blood or other potentially infectious materials.
- Employees complete a Hepatitis Response form declining a vaccine or
requesting a vaccine. (Appendix D)
7.11 Response to Potential Exposed Worker

- Review worst case scenario
- First responders or worker that may be involved and as one who has been
exposed or as a witness or participant with potential exposure, arrange for
immediate and confidential medical evaluation.
- Document how the exposure occurred
- Identify and test the source individual, if possible.
- Test the exposed employee’s blood, if consent is obtained
- Provide counseling
- Evaluate any reported illness
7.12 Summary
7.12.1 Feedback
- Your reported near miss and safety concern just might save someone else.
7.12.2 Clean Hands

- Take advantage of the hand sanitizer stations posted throughout the plant.
- Get in the habit of using it each time you walk by in order to keep your hands
clean.
7.12.3 Training
- Ask questions if you feel you do not have all the training you need to safely
operate equipment.
- Always follow the correct procedure for the equipment you have been
authorized to use.
7.12.4 Be Aware
- Know where all the possible hazards are on the machines you are
using/working (pinch points, hot areas, moving parts).
16
- Never use a machine with missing or damaged guards and never by-pass a
machine by reaching over, around, or through it.
7.12.5 Inspect
- Before you start, make sure that equipment and machinery is in good
operating condition.
17
8. Confined Space
- A confined space is a large enough area to enter and perform work.

- Limited in the way of entry or exit
- Not designed for continuous occupancy
8.1 Permit Required

- Regular confined space with the following higher risk:
o Actual or potential hazardous atmosphere
o Materials could engulf entrant
o Internal shape could trap entrant
o Contains other serious hazards
- Conduct hazard evaluations
- Post danger signs
- Develop a permit space program
- Entry into a permit-required confined space is not a one-person job. It

requires a team of individuals who work together and have the knowledge
and skills necessary to complete the job safely.
8.2 Entry Permit

- An entry permit is provided by the employer and authorizes entry into a
permit space.
8.2.1 Entry permit components:

o Space to be entered
o Purpose of entry
o Date and authorized duration of permit
o Authorized entrants
o Names of attendants
o Name of entry supervisor
o Hazards of the permit space
o Measures used to isolate the permit space
o Acceptable entry conditions
o Results of initial and periodic testing
o Rescue and emergency service numbers
o Communication procedures
18
o Equipment required
o Other pertinent safety information
o Any additional permits
8.2.2 Alternate Entry Requirements

- Hazardous atmosphere is controlled by continuous forced air ventilation.
- Monitor and inspection data are developed and documented.
- Written certification must contain:
o Date
o Location of the space
o Signature of person certifying space
8.2.3 Entrant Responsibilities

Entrants must:
- Alert attendants to warning signs/symptoms
- Alert attendants to prohibited conditions
8.3 Confined Space Hazards

- Physical Hazards: mechanical equipment, moving parts, gases, liquids, or
fluids, heat, excessive noise.
- Oxygen Deficiency: minimum safe level is 19.5%, maximum safe level is
23.5%, gases displace oxygen and chemical reactions consume oxygen.
- Combustibility: flammable and combustible gases or vapors are present,
hazardous atmospheres contain more than 10% of lower flammable limit.
- Toxic Air Contaminants: occur from previously store material, result from
coatings, cleaning solvents, or preservatives, detection is difficult.
- Engulfment Hazards: water or other liquids, grain, sand, sawdust, or
powders.
8.4 Behavioral Effects

Asphyxiation:
- Mild changes
- Collapse
Too Much Oxygen:

- Coughing
- Fainting
- Rapid breathing
Fatigue:
19
- Tiredness
- Weakness
- Irritability
- Indecisive
- Uncommunicative
- Unable to recall details
8.5 Attendant Responsibilities
Attendants must:
- Maintain accurate count of entrants
- Accurately identify entrants
- Communicate with entrants
- Use roster or other tracking system
- Monitor activities inside and outside space
- Remain outside space during entry
- Be trained and quipped for rescues and relieved by another attendant before
entering space
- Alert entrant of evacuation
- Know the hazards that could be faced
- Understand behavioral effects of exposure
- Protect the permit space
Conditions for immediate evacuation:

- Prohibited condition emerges
- Behavioral effects are detected
- Situation arises outside space
- Duties cannot be performed safely
- Evacuation alarm is activated
8.6 Contractor Safety

- When contractor employees participate in entry operations, the contractor
supervisor/employer must have procedures to coordinate entry operations
that meet or exceed Berry Global policy and procedures.
Minimum Requirements:
- Contractor employee’s must review the visitor safety rules prior to their first
time entering the plant.
- All incidents and accidents shall be reported immediately to a member of
management.
- PPE required:
o Safety glasses with side shields
o Ear plugs
o Steel-toe shoes
o Cut resistant gloves (when using sharp instrument)
20
o Face shield (when grinding/cutting)

o Heat resistant gloves/sleeves (when working around hot objects)
o Full body harness when elevated over 6 feet off the ground (unless
working within the confines of a scissor-lift with guard rails and the
employee remains within the confines of the guard rails.)
- Personnel shall follow safe lifting practices and not exceed 55 lbs. per
person.
- Tools shall be transported in toolboxes or pouches. No tools in pockets.
- A Hot Work Permit shall be acquired, completed and signed off before cutting
or grinding can be performed. A Team Leader, Plant Engineer, or
Maintenance Personnel can sign off hot work permits the permit will require a
clean, burn free area, a fire extinguisher, a fire watch and other precautions
specific to an area.
- All contractor EE’s must be aware of the emergency evacuation procedures
and evacuation routes exits.
- Material Safety Data Sheet (MSDS) books for all materials in our facility are
stationed in all three-production areas and will be pointed out before work
begins.
- Lockout/Tagout (LOTO) procedures shall be strictly followed. Violation of
LOTO procedures may result in immediate termination or dismissal.
- Only electric or propane powered vehicles are allowed in the facility unless
prior approval is given.
- Contractor must show proof of insurance coverage before beginning job.
*Contractors must ensure that their employees meet or exceed our plant safety rules at
all times. Failure to do so can result in immediate removal from the facility.
21
9. Crane Hoist & Slings
- Safety of the employee is the first priority.

- Only trained and authorized personnel shall operate crane/hoist.
- Never, under any condition, shall the load be lifted or moved directly over a
person, or never allow a person to be under a load that is suspended by the
crane/hoist.
- Never allow a person to ride the load or be lifted by the crane/hoist under any
circumstances.
- The operator is responsible for the safe operation of the crane/hoist.
- While a load is suspended, the pendant shall be under operator control at
ALL times.
9.1 Hoist Pre-Operation Check

- The pre-operation check shall be made every day the crane/hoist is used.
The inspection shall be noted on the Operator Daily Hoist/Crane Inspection
Log.
- Make a safety pre-check of crane/hoist and area, prior to use each day.
- Check pendant operation.
- Check for exposed wires.
- Check for visible leaks.
- Check for wear on chain or frayed cables.
- Check to ensure the hook/clasp for proper operation. Check to be sure that
the hook isn’t cracked, worn, or bent. Hooks without safety latch should not
be used.
- Check trolley movement for loose hardware or poor movement.
- Initial Operator Daily Hoist/Crane Inspection Log after pre-check.
- Ensure that they inspection log is complete and in place at the production
line.
- Use lockout/tagout procedures to lock and tag crane/hoist “out of service” if
the equipment becomes defective during inspection or operation.
9.2 Safe Sling Operating & Inspection Practices

- Whenever any sling is used, the following practices shall be observed:
o Slings that are damaged or defective shall not be used.
o Slings shall not be shortened with knots or bolts or other makeshift
devices.
o Sling legs shall not be kinked.
22
o Slings shall not be loaded in excess of their rated capacities.

o Slings used in a basket hitch shall have the loads balanced to prevent
slippage.
o Slings shall be securely attached to their loads.
o Slings shall be padded or protected from the sharp edges of their
loads.
o Hands or fingers shall not be placed between the sling and its load
while the sling is being tightened around the load.
o Shock loading is prohibited.
o Always use the correct size sling for the job task.
o Always be sure that the weight transfer on the sling is downward on
the sling.
o Slings should never be used at any angle greater than the safe
example below.
9.3 Sling Inspections

Inspections:
- Inspect each sling-before use on each shift.
- Any questionable slings, fasteners, and attachments shall be brought to the
attention oof competent person designated by the employer (Supervisor) for
secondary review.
- Additional inspections shall be performed during use, where service
conditions warrant.
- Damaged or defective slings shall be reported to your supervisor and
immediately removed from the service.
9.4 Summary
- Inspect equipment before each use each shift.
- Follow all safe operating instructions
- Report and replace damaged equipment immediately.
- Never: Lift more than equipment rating.
- Never: Use damaged slings
- Never: Operate a crane or hoist over a person.
- Never: Allow anyone to ride a load.
23
10. Emergency Evacuation
10.1 Instructions
- In the event of an emergency in or near the plant, an evacuation alarm will
sound.
- The alarm can be activated at one of the manual pull stations located at each
exit.
- Upon hearing the evacuation alarm, or visually detecting one of the strobes,
the Plant 1 supervisor or designate will check the alarm control panel to see
where the alarm was activated from and silence the alarm.
- The supervisor will then visually inspect or contact personnel in the area of
the alarm to identify if there is an actual emergency or false alarm.
- In the event of an actual emergency, the supervisor will sound the alarm a
second time.
- All employees are to assemble in the designated assembly areas as
indicated on the evacuation route maps posted throughout the plant.
- Evacuation leaders will confirm attendance of all personnel, so that he/she
can inform rescue workers of any missing personnel.
- Search and rescue operations will be conducted by the Fire
Department/Rescue workers ONLY. No one other than the fire department
search and rescue personnel is to reenter the evacuated building until the
Emergency Coordinator has communicated approval.
- Planned evacuation drills will be held once per year. Evacuation drills will be
performed at shift change. Shift personnel will evacuate the facility at the
sound of the alarm per their scheduled drill time and proceed to designated
assembly areas. Out going or incoming shift personnel will assume normal
duties are complete.
- Notice: the first alarm alerts all employees that there is potential for
Emergency Evacuation situation.
- The second alarm is indication to immediately evacuate the facility. All
employees will then proceed to the nearest exit in an orderly manner to their
designated area.
- If time permits, line teams should idle or shutdown their equipment without
risking their personal safety.
10.2 Muster Areas

- Evacuation: Out of the building
24
- Communicated by audible Alarm

- All employees are to assemble in the designated assembly areas as
indicated on the evacuation route maps posted throughout the plant.
- Evacuation leaders will confirm attendance of all personnel, so that he/she
can inform rescue workers of any missing personnel.
11.Severe Weather
11.1 Communication Terminology

- Severe Weather: Thunderstorms, Ice/Snow, Severe Winds, Tornado, etc.
- Watch: Indicates that conditions are favorable for that type severe weather
(Be Alert).
- Warning: Indicates that severe weather has been detected in the area (Take
Cover Immediately).
11.2 Instructions
11.2.1 Watch
- Lab personnel shall monitor a weather radio for emergency weather watches
and warnings.
- When a severe weather WATCH is issue for the area, the lab personnel will
verbally notify appropriate shift/department personnel (EHS Coordinator, Shift
Supervisors, etc.) to be alert and on standby.
- Lab personnel will continue to monitor the weather broadcast for updates or
changes.
- Employees are not notified of the WATCH so as to minimize the number of
employees off task.
11.2.2 Warning
- When a WATCH is upgraded to a WARNING, the lab personnel will notify
appropriate shift/department personnel (EHS Coordinator, Shift Supervisors,
etc.) of the upgrade who will then monitor the broadcast and make the
decision when and if to have employees evacuate to the storm shelters
based on the weather conditions and reports.
- Once the decision has been made to evacuate employees to the storm
shelters, shift/department personnel (EHS Coordinator, Shift Supervisors,
etc.) will instruct ALL employees via the plant public address system, two
radios, and by verbal communication to follow instructions for each type
warning as stated above.
- When instructed all employees will proceed safely to the nearest designated
storm shelter. (List below)
- The lab personnel will transfer the weather radio into the storm shelter to
continue monitoring weather conditions.
11.2.3 Seeking Shelter
25
- Never exit the building when severe weather is approaching for any reason.
- In the event that an employee is caught off guard by the storm and can’t
reach a storm shelter. Take cover in an area that allows cover and protection
from the storm such as a closet, under a desk, or in a ditch if outside.
- If time permits, line teams should idle or shutdown their equipment without
risking their personnel safety.
- The weather conditions will continue to be monitored by weather radio from
the storm shelters and by computer internet connections in the electrical shop
for weather broadcast updates or changes.
- Once the warning is lifted or after an adequate amount of time has passed,
the EHS Coordinator or Shift Supervisor shall proceed to a safe area to
observe outside conditions.
- When all conditions are determined to be safe the EHS Coordinator or Shift
Supervisor will instruct all employees to resume normal duties.
- In the event that the building was damaged due to the storm, employees will
be instructed to follow standard Emergency Evacuation procedures and
assemble in the designated areas.
11.3 Storm Shelters

Converting – Rest/Locker Rooms
Plant 1 -- Electrical Shop
Plant 1 – Rest/Locker Rooms
Plant 2 – Rest/Locker Rooms
Persimmon – Rest/Locker Rooms
26
12.Ladders & Stairs
12.1 Hazards
12.1.1 Stairs/Steps
- Clutter slippery surfaces
- Damage
- Poor lighting
- Unsafe work practices
12.1.2 Ladders
- Falls
- Slips
- Reaching too far
- Weather
- Oil or grease on a ladder
- Not secure
- Contact with electricity
- Objects that fall from ladders
12.2 Staying Safe

- Eliminate slippery conditions
- Clean up spills
- Keep free of ice and snow
- Ensure proper lighting in stair areas
12.3 Precautions
- Inspect the ladder for defects frequently and before use.
- Select the correct ladder for the job and load.
- Do not use metal ladders near electrical lines.
- Use ladders for their intended purpose only.
- Set up the ladder on a firm, solid surface.
- Keep ladders secured/barricaded.
- Keep areas around the top and bottom of the ladder clear.
- Open stepladders fully, and lock the spreaders.
- Set up straight ladders when ascending/descending.
- Use both hands to grip the side rails whenever possible.
- Only one person on a ladder at a time.
- Don’t stand on the top 2 steps of a stepladder.
- Never move a potable ladder with someone on it.
27
- Hoist material up to you when you’ve reached the top of the ladder.
- Work within the side rails of man lifts and platforms.
- Store ladders back in their designated storage areas when not in use.
12.4 What happens during a fall?

- A person loses his/her balance.
- Body unintentionally moves from an upright position to a prone, or semi-
prone position.
- Free-fall velocity at impact when falling 12 feet is nearly 20 mph.
- The person hits the ground in less than one second from this distance.
12.5 Why falls are dangerous?

- The free-fall distance the worker falls.
- The shock absorption at impact.
- The potential for head, severe neck or back injury.
- The body weight of the worker falling because falls can have more severe
impact on heavier workers.
- Heavy workers may also have issues that prevent fall arrest equipment from
fitting properly.
12.6 Shock absorption at impact

- Varies according to the types of fall protection equipment used.
- Shock-absorbing lanyards reduce the probability of injury.
- Personal fall arrest systems.
12.7 Fall Hazards

12.7.1 Reporting Fall Hazards
- Employees will not experience repercussions from reporting hazards.
- Employees should report unsafe equipment, conditions, procedures.
- Equipment repair receives top priority.
- Under no circumstances shall defective equipment be used.
- When fall conditions exist, you should:
o Take short steps (maintain balance)
o Keep toes pointed out
o Walk on the whole foot when crossing rough or slippery surfaces
o Avoid making sharp turns
o If you fall, protect your head and neck
12.7.2 Housekeeping and Falls

- Effective housekeeping helps to prevents falls
- Keep high work areas free from:
o Tools
o Materials
28
o Debris
o Liquids
o Housekeeping and Safety go hand in hand.
12.8 Maintenance
- Remove ladders with structural defects, corrosion, or defective parts from
service immediately.
- Tag damaged ladders: “Do Not Use”
- Repair ladders to the original design
- Have qualified personnel make repairs
29
13. Fire Extinguisher
- Fires are classified as:

o Class A: fires of ordinary combustibles or fibrous materials, such as
wood, paper, cloth, rubber, and some plastics.
o Class B: fires of flammable or combustible liquids such as gasoline,
kerosene, paint, paint thinners, and propane.
o Class C: fires of energized electrical equipment, such as appliances,
switches, panel boxes and power tools.
Fire extinguisher classification information:

- Fire extinguishers are classified by the size and class of the fire that they are
designed to extinguish, and by their extinguishing agent. The higher the
rating or classification, the greater the extinguishing capacity.
o Example: a unit classified 4A can be expected to extinguish twice as
much class A fire as one classified 2A.
- Some extinguishers are able to put out more than one class of fire and are
marked wit multiple rating such as AB, BC, and ABC.
13.1 Types of Fire Extinguishers

- ABC Extinguisher:
o The extinguisher can be used on all classes of fire A, B, and C.
- C-02 Extinguisher:
o This extinguisher should be used to extinguisher Class C electrical
fires.
- Clean Guard Extinguisher:
o This extinguisher should be used to extinguish computer equipment
such as terminals, keyboards, and monitors. It is designed to minimize
damaged to the equipment from the extinguishing agent.
o This type extinguisher is very expensive to refill.
13.2 How to use a Fire Extinguisher

1. Grasp the unit by the carrying handle and the base; remove it from the
mounting bracket and carry it to the fire.
2. Pull the locking pin to break the tamper seal. If the unit has a hose,
remove the hose from its retaining clip.
3. Move the extinguisher as close to the fire as possible without
endangering yourself. Grasp the hose in one hand and press or squeeze
30
the handle or trigger release with the other. (If the unit is a CO 2
extinguisher, do not grasp the plastic discharge horn, since it may freeze
your hand.) if the unit has no hose, direct the stream of extinguishing
agent by maneuvering the extinguisher.
4. Discharge the contents of the unit at the base of the flames with a back
and forth, sweeping motion. Sweep from the near edge to the rear of the
fire and then up the vertical surface. Always leave an escape route for
yourself when you are fighting a fire.
5. If the fire can not be controlled. Follow the escape route out of the
building. (Call 911-Fire department)
6. Return all used/spent fire or damaged extinguishers to the maintenance
department for replacement and refill.
13.3 P.A.S.S.
P... Pull he pin.
A... Aim extinguisher nozzle at the base of the flames.
S... Squeeze trigger while holding the extinguisher upright.
S... Sweep the extinguisher from side to side, covering the area of the fire
with the extinguishing agent.
31
14. Hazard Communication
We must ensure:
- All employees who are exposed to chemical hazards will be made aware of
this program and all of its requirements.
- All employees will be informed of their right to receive information about
hazardous materials which they may encounter in the workplace.
- All employees will receive the information prior to their exposure to these
materials.
- The information provided and reviewed will all employees in both written and
oral form, through training, overhead slides, Safety Data Sheets and labeling.
- All manufacturers and in-house containers must be appropriately labeled.
- Safety Data Sheets made readily available for all hazardous materials in the
workplace.
- HAZCOM program and Chemical SDS sheets are located on an electronic
program on computer at all work stations through Cornerstone Environmental
SDS tracking.
14.1 Globally Harmonized System (GHS)

It’s “Your Right to Know” about workplace hazardous chemicals
- In 1983 OSHA created the Hazard Communication Standard (29 CFR
1910.1200) to help ensure your safety when working with hazardous
chemicals.
14.1.1 GHS Major Changes

- Consistent defined specific Hazard Classifications of chemical information.
- Consistent labeling by manufacturers that includes GHS harmonized signal
words, pictograms, and hazard statement for each hazard class & category.
- All SDS/Safety Data Sheets will have the same standardized pictograms and
16 section formats.
- Labels: Nine symbols (hazard pictograms) with red border. (Appendix E)
14.1.2 Flammability Rating

1 = Extreme (FL. Class IA) “Danger”
2 = Moderate (FL. Class IB) “Danger”
3 = Slight (FL. Class IC / Comb. Class II) “Warning”
4 = Combustible (Comb. Class IIIA) “Warning”
32
- (No rating for Combustible Class IIIB or lower)

- The LOWER the number = the HIGHER the severity
- HMIS and NFPA system where the high numbers = higher severity
14.1.3 GHS Safety Data Sheet

1. Identification of the substance or mixture and of the supplier
2. Hazards identification
3. Composition/information on ingredients. Substance/Mixture
4. First aid measures
5. Accidental release measures
6. Handling and storage
7. Exposure controls/personal protection
8. Physical and chemical properties
9. Stability and reactivity
10. Toxicological
11. Ecological information (non mandatory)
12. Disposal consideration (non mandatory)
13. Transport information (non mandatory)
14. Regulatory information (non mandatory)
15. Other information including information on preparation and revision of the SDS
33
15.Hot Work
- Definition: Work that can cause enough heat to ignite nearby combustibles or
flammable materials (cardboard, dust, paper, clothing, flammable liquids).
- Examples: Welding, burning equipment, heat-treating, open fires, portable

grinders, any other flames, or spark producing equipment, hand grinders,
bench, welder, torch, etc.
- Required Equipment/PPE:
o Fire extinguisher
o Fire blanker (if needed)
o Caution tape/cones to mark the area
o Signed and approved valid Hot Work Permit
o Employees should be wearing all required PPE:
 Welding helmet
 Apron
 Gloves/sleeves
 Face shield
14.1 Hot Work Instructions/Procedures

- Prior to beginning the hot work task, a two-part Hot Work Permit form must
be filled out by a Maintenance Team Member Production Team Leader or
Plant Engineer (Other than the employee performing the hot work).
- The inspector/approver is responsible for accurate completion of the permit
form and inspection of the work area before the work starts ensuring that the
work area meets the conditions of the permit requirement.
o The (White) top copy will be places with the manger that issued the
permit.
o The (Orange) copy will be posted on the equipment or area where the
work is being conducted and turned back in to the issuing manger
once the work is finished and the final inspection of work area is
completed and signed off by the fire watch.
o Both copies must be filled out completely and filed on the Maintenance
Team Hot Work Permit Station in the Plant One Team Office for future
reference
34
16.Daily Forklift Inspection
- 1910.178 (q) (7)

o Industrial trucks shall be examined before being placed in service, and
shall not be placed in service if the examination shows any condition
adversely affecting the safety of the vehicle. Such examination shall
be made at least daily. Where industrial trucks are used on a round-
the-clock basis, they shall be examined after each shift. Defects when
found shall be immediately reported and corrected.
- Check Level
o Hydraulic Fluid
o Engine Oil
o Engine Coolant
o Transmission Fluid
Note: Never remove the radiator cap to check the coolant level when the engine is
running or while the engine is hot.
- Gauges: Are they all properly working?
- Overhear Guard: Are there broken welds, missing bolts, or damaged areas?
- Mast Assembly: Are there broken welds, cracked or bent areas, or worn or
missing spots?
- Lift Chains and Rollers
o Is there wear or damage or kinks, signs of rust, or any sign that
lubrication is required?
o Is there squeaking?
o Are they cracked or bent, worn, or mismatched?
o Is there excessive oil or water on the forks?
- Hydraulic Cylinders: Is there leakage or damage on the lift, tilt, or attachment
functions of the cylinders?
- Tires: what do they look like?
o Are there large cuts that go around the circumference of the tire?
o Are there large pieces of rubber missing or separated from the rim?
o Are there missing lugs?
o Is there bond separation that may cause slippage?
- Battery Check
o Are the cell caps and terminal covers in place?
o Are the cables missing insulation?
35
o Is their any corrosion on the terminals?

- Steering
o Is there excessive free play?
o If power steering, is the pump working?
- Horn: does the horn work?
- Brakes
o If pedal goes all the way to the floor when you apply the service brake,
that is the first indicator that the brakes are bad. Brakes should work in
reverse, also.
o Does the parking brake work? The truck should not be capable of
movement when the parking brake is engaged.
- Seat Belts: Do they work?
- Lights: If equipped with lights, are they working properly?
- Load Handling Attachment
o Is there hesitation when hoisting or lowering the forks, when using the
forward backward tilt, or the lateral travel on the side shift?
o Is there excessive oil on the cylinders
- Propane Tank: is the tank guard bracket properly positioned and locked
down?
- Propane hose
o Is it damaged?
o It should not be frayed, pinched, kinked, or bound in any way.
o Is the connector threaded on squarely and tightly?
- Propane odor: If you detect the presence of propane gas odor, turn off the
tank valve and report the problem.
36
17. Pedestrian Safety Around Forklifts
17.1 Objective
- There have been many incidents within the Berry Global Corporation
regarding forklifts and pedestrians.
- Pedestrians need to be aware of their surroundings, including the operation
of forklifts. The following actions can make forklift operations safe for the
pedestrian and the operator.
17.2 Safety
- Familiarize yourself with types of equipment and regular travel routes.
- Walk in designated aisles. (Use when available)
- When not available: Stay to one side of the forklift path.
- Yield the right of way or make sure the vehicle has yielded.
- Look all ways before stepping into the aisle or around the corner.
- When walking in manufacturing and warehouse areas:
o Be cautious, pay attention to moving carts and trucks
o Listen for horns and alarms
o Look for lights and signs
- Whenever a forklift approaches, stop and make eye contact with the
operator.
o Never assume the operator has seen you.
- Always let the operator know that you are around.
o You can easily be caught between a truck and an object.
- Use pedestrian-designated doors in available.
- Only approach a forklift that has come to a complete stop.
o Approach from side, never directly in front or rear.
- Do not walk or work beneath loads on raised forks.
- Do not operate powered equipment unless trained to do so at this location.
o Violation is a terminating offence.
- Never ride on a forklift.
o Do not allow yourself to be lifted on a pallet or fork blades.
- Keep walkways clear of obstructions and clean of debris.
o This includes parking forklifts or golf carts in walkways.
37
17.3 Summary
- Pedestrians are to obey signs, take advantage of barriers, and use fixed
crosswalks and designated walkways.
- Where walkways are not provided, pedestrians must exercise care for their
well-being.
18.Non-Routine Task Hazard Analysis Program (NRTHA)
18.1 Purpose
- To ensure that every non-routine task not defined by a written work
instruction or procedure is properly reviewed and approved prior to work
being performed.
- Berry Global Corporation believed that by managing hazards and potential
risks, we can meet our commitment to eliminate all workplace injuries.
18.2 NRTHA
- Any task that is not part of the normal or habitual operations and does not
include a written procedure and a job safety analysis.
- Some examples of these non-routine tasks are:
o Roof work
o Rigging
o Equipment move
- Non-Routine Task Hazard Analysis Form (Appendix F)
38
19. Work Area Housekeeping
- House keeping and safety go hand-in-hand.

- Second only to strains, sprains, slips, trips, and falls are the most frequent
accidents leading to personal injury at Berry Global.
- Help us eliminate slips, trips, by keeping your work area neat and in good
working order at all times.
- Everything has a place and must be stored properly.
- Good housekeeping is the first and the most important (fundamental) level of
preventing falls due to slips and trips.
- Simple steps to help work in a cleaner, safer environment:
o Clean all spills immediately.
o If the spill cannot be cleaned immediately-mark spills and wet areas
with brightly colored cones or WARNING tape.
o Keep your work area free of debris.
o Put things back in their places. Everything has a place.
o Remove obstacles from walkways and always and always keep
walkways free of clutter.
o Remove power/extension cords from traffic areas.
o Secure (tack, tape, etc.) mats, rugs, and carpets that do not lay flat.
o Always close file cabinets or storage drawers.
o Cover cables that cross walkways.
o Keep work areas and walkways well lit; replace used light bulbs and
faulty switches.
- Benefits of good housekeeping include:
o Less injuries
o An improvement in employee morale, through a clean and orderly
workplace
o Conservation of space, equipment, operating materials, time, and
effort makes work easier for everyone
o Less likelihood of fires
** A cluttered, unkempt workplace lends itself to slips, trips and falls.

** A cluttered workstation = a cluttered mind
39
** Housekeeping is part of everyone’s job.
20. Lockout/Tagout
20.1 Lockout Definition

- Process of preventing the flow of energy
o Consists of installing a lock, clock, or chain.
o Requires an authorized employee to apply a lock prior to servicing
equipment and removal once service is complete.
20.2 Tagout Definition

- Process of placing tag on power source
o Tag acts as a warning
o Tag must clearly state “Do not operate”
o Tag used when machine won’t accept lock
o Tag must be applied/removed by the authorized employee only
20.3 Hazardous Energy Sources

- Electrical
- Mechanical
- Pneumatic
- Hydraulic
- Chemical
- Thermal
- Water under pressure
- Gravity
- Potential energy
20.4 Energy Control Program

- Energy control procedures
- Employee training
- Periodic inspections
- Intended use of the procedure
- Specific steps to control hazardous energy
- Specific requirements for verification
40
- Each type of machine needs its own LOTO procedure

- Lockout must be used when a device can be locked out
- Tagout must be used when unable to use a lockout
20.5 Types of Employees

20.5.1 Authorized Employee
- An employee responsible for locking or tagging out machines to perform
service or maintenance on that machine.
- Employers train and authorize certain employees to remove guards and enter
the machinery’s point of operation to perform specific repair tasks under
LOTO controlled procedures.
- The tag or lock identification should be located as close as possible to the
control panel, switch, lever so that anyone else working in the area, affected
employees, who may try to operate the equipment is aware of the potential
danger.
- Authorized employees must alert affected employees that LOTO will be
conducted on equipment or machines in the area
**Awareness increases everyone’s safety.
20.5.2 Affected Employee

- An employee responsible for the operation of the equipment and who’s
regular work functions are affected by the service being done to the machine.
- Affected employees must understand:
o Lock out energy control procedures
o How to look identify LOTO equipment
o Too stay clear of equipment under LOTO
- Affected employees cannot:
o Assist authorized employees service machinery.
20.6 Work activities that require LOTO

- Constructing
- Installing
- Setting up
- Adjusting
- Inspecting
- Modifying
- Repairing
- Cleaning equipment
- These activities include lubrication, cleaning or un-jamming of machines or
equipment mand making adjustments and task where the employee may be
exposed to the unexpected power up or startup of the equipment or release of
hazardous energy.
41
20.7 Steps for LOTO Shutdown

20.7.1 Step 1: Prepare for Shutdown
- Know the type and magnitude of energy to be controlled.
- Know the hazards of the energy.
- Know the methods or means to control it.
- Notify affected employees that the Lockout task will be taking place.
20.7.2 Step 2: Shut Down

- Follow lockout procedures (if posted on equipment)
- Turn off equipment using normal controls
20.7.3 Step 3: Isolate Equipment

- Isolate equipment or disconnect from energy sources.
- Place all devices in the off or closed position.
20.7.4 Step 4: Apply Lockout Devices

- Attach lockout/tagout devices
- Only authorized employee can attach or remove lockout and tagout devices
- Devices must be durable
- Devices must identify person who applied them.
20.7.5 Step 5: Release Stored Energy

- Relieve stored energy
- Verify machine isolation from energy
- Relieve pressure in compressed air line
- Insert a block
- Continue releasing pressure until there is no possibility of re-accumulation
20.7.6 Step 6: Verification of Isolation (Test)

- Verify machine is de-energized
- Verify machine is isolated
- Press/turn on all start buttons (test)
- Place all start buttons/switches to the off position.
20.8 Restoring Energy (Startup)

- Inspect work area for tools left on line.
- Ensure employees are safe. Notify employees of startup (Clear)
- Start each function of the equipment separately (Controlled start up)
20.9 Lockout Devices

- Authorized employees are assigned their own Lockout device (lock)
42
- Device (lock) must be used for any other reason. (Such as locking lockers,
toolboxes, etc.)
- Per OSHA; a tag can be used in place of a lock. If used the tag must never be
removed or bypassed and must only be removed by the authorized used
labeled on the tag.
20.9.1 Devices could be

- Locks with hasp
- Tags
- Chains
- Wedges
- Key blocks
- Adapter pins
- Self-locking fasteners
20.9.2 Devices must have the following qualities

- Be durable
- Labeled and identified
- Be standardized in color, shape, or size
- Be substantial enough to prevent removal
20.9.3 Group Lockouts

- Each authorized employee must affix their personal lockout or tagout device.
- Each authorized employee must remove their device when service is
complete.
- Group lock boxes must be used when locking out multiple hazard sources.
20.9.4 Lockout in Progress Shift Change Procedure

- Lockout/Tagout protection must be continuous
- Lockout/Tagout protection must have an orderly transfer between employees
20.9.5 Device Removal

- Lockout or tagout device must be removed by the authorized employee who
applied it.
- Device may be removed under direction of employer if authorized employee
unavailable.
- Employee is responsible for removal of locks when finished or during transfer.
- Steps supervisors must take before removing a lock or tag:
o Verify the authorized employee who applied lock is not at the facility.
o Take all reasonable efforts to contact the authorized employee.
o Verify the removal will not put anyone at risk of injury.
- Notice:
43
o Employee will be held accountable for the cost to replace any LOTO
locks that are lost or cut due to being left on equipment or machinery.
20.10 Summary
- Never place any part of your body into any part of an energized machine.
Even if you have on PPE. Even if it is simple maintenance, like unjamming a
part or for housekeeping. Hazardous Energy is deadly and dangerous.
- If you are an authorized employee:

o Never skip any part of the LOTO procedure.
o Use of only a tag out on equipment is permissible only if, it is not
possible for lock out to be affixed.
- If you are an affected employee:

o Never remove a tag out or lock out.
o Look for authorized employees in your work area and make sure you
understand what equipment and machines they are servicing.
o Never attempt service or maintenance yourself.
o If you have equipment problems follow the correct procedures for
reporting it.
44
21. Heat Stress
- When the body is unable to cool itself by sweating. Severe heat-induced

illnesses such as heat exhaustion or heat stroke can occur, and can result in
death.
- Factors leading to heat stress:
o High temperature and humidity
o Direct sun or heat
o Limited air movement
o Physical exertion
o Poor physical condition
o Inadequate tolerance for hot workplace
21.1 Heat Stress Illness

- Illnesses caused by the heat stress:
o Heat rash
o Heat clamps
o Heat exhaustion
o Heat stroke
- However, heat exhaustion and heat stroke are the most dangerous illnesses
because they can cause death.
21.2 Symptoms of Heat Exhaustion

- Heavy sweating and weakness
- Upset stomach or vomiting
- Mood changes such as irritability or confusion
- Headaches, dizziness, lightheadedness, or fainting
21.3 Heat Exhaustion – First Aid

- Move the victim to a cool area to rest. Do not leave him/her alone.
- Loosen and remove heavy clothing
- Give cool water to drink about a cup every 15 minutes.
45
- Fan the person, spray with cool water or apply a wet cloth to his/her skin.
- Call 911 if he/she does not feel better in a few minutes.
21.4 How to avoid Heat Stress

- Drink plenty of water or electrolyte drinks, even when not thirsty. Avoid
alcohol or caffeinated drinks before and during work.
- If you start feeling ill, stop what you are doing immediately and take steps to
cool down. Tell your supervisor.
21.5 Summary
- Heat stress is a serious matter.
- Take preventative measures to control heat stress
- Stay cool and rink proper fluids throughout the day
**A hasty decision may result in the wrong choice being made.
46
22. Job Safety Analysis (JSA)
22.1 Emergency Equipment Access Safety

PPE Required:
- Safety glasses
- Safety shoes
- Ear plugs
- All required PPE for each task.
Best/Safe Work Practices:

- Hazard:
o Blocked electrical panels can not be accessed quickly in the event of
an emergency or fire.
- Never place materials or carts in front of the electrical cabinets or safety
equipment.
- Maintain a 36” clearance in front of all electrical panels at all time.
- Keep EGRESS routes and emergency exits clear at all times.
- Keep eyewash station access clear and clean at all times.
22.2 Slips Hazards

PPE Required:
- Safety glasses
- Safety shoes
- Ear plugs
- Any other PPE base on task being performed
Instructions:
- Slip, Trip, & Fall Hazards
o Resin spills
o Water spills or leaks
o Oil leaks
o Air hoses, banding strap
47
o Hard plastic, scrap plastic

- All of the above items can create slip, trip, or fall hazards if not:
o Observed and corrected
o Immediately cleaned up
o Controlled (Absorbents)
o Safe guarded (Cones)
o Reported (Work Order)
- All of these hazards must be taken care of immediately to prevent anyone
from slipping or falling in them.
22.3 Work Area Housekeeping

PPE Required:
- Safety glasses
- Safety shoes
- Hearing protection
- Dust particulate mask available (Voluntary use only)
- Face shield or goggles (When blowing with air hose)
Instructions:
- Organization:
o Work area must be clean and organized at all times.
o Maintain a well organized and efficient work area.
o Everything has a specific location and all workers are aware of those
areas.
o Pick up trash and debris immediately such as film, bad cores, plastic,
banding, machine parts, etc.
- Work performance:
o Always be aware of your surroundings. Looking in the direction of
travel at all times to prevent fall hazards.
o Do not carry or transport items hat block your vision.
o Do not run. Maintain a safe working speed.
o Do not exceed the plant safe working speed.
o Do not exceed the plant safe lifting limits (55lb)
o Minimize use of compressed air around the line when line is running.
Use broom to sweep up trash.
o Goggles must be worn along with safety glasses when compressed air
is used for blowing down.
22.4 Hand Protection Glove Use

PPE Required:
- Safety glasses
48
- Safety shoes
- Ear plugs
- Correct gloves for the job task
Instructions:
- Disabling hand and finger injuries include:
o Amputations, burns, lacerations, and fractures.
- Gloves shall be used whenever possible to protect your hands. Remember,
gloves DO NOT offer 100% protection.
- There are many types of gloves, so be sure you have the right glove for the
job.
o Heat resistant gloves resist heat, they are not heat proof.
o Cut resistant gloves resist cuts, they are not cut proof.
o Cut resistant work gloves shall be worn at all times while working with
blades and while stringing up machines in areas where blades are
present.
o Cut resistant gloves may also be worn when performing impact risk
task such as handling pallets, metal, banding, tensile, etc.
- Note:
o Protect your hands at all times. Wear hand protection when possible
o Think about the job task
o Select the right type of hand protection for the job task.
o Wear hand protection. Use it to protect your hands when possible.
o Do not wear gloves stringing up around moving film or equipment, or
handling finished product.
22.5 Dalmec Material Handler Safety Parking Instructions

Parking Instructions: Normal Operations
- The Dalmec manipulator may be parked with the probe placed inside the
extended pipe on the parking station or 3-4 feet above the floor in or near the
work station or packaging area.
- Never under any circumstance shall the Dalmec manipulator be parked above
any object or structure where it could leak down and come to rest on the
structure in the event of air loss.
Parking Instructions: Abnormal Operations (transport, power loss, extended

downtime or other potential loss of air situations.)
- The Dalmec manipulator must be parked with the probe placed inside the
extended pipe-parking station.
- The parking station must be positioned as low on the center post of the
Dalmec unit as possible without causing a tripping or fall hazard based on the
work area. The airline must be rolled up in manner that it is protected.
49
- Refer to the LOTO procedure (LO-Dalmec-01) Portable Dalmec Roll handling

system for transport and LOTO procedure (LO-Dalmec-02) – stationary
Dalmec Roll handling system LOTO to safely secure the unit in a safe
position.
22.6 Safe Cutting Procedures (Excessive Force) Rolls, Boxes &

Cardboard
PPE Required:
- Safety glasses
- Safety shoes
- Cut resistant gloves (both hands)
- Cut resistant sleeves (both arms)
Instructions:
- Always cut away from your body or torso. Never pull the knife toward your
body or torso.
- Remember the hand not holding the knife is part of your body. Keep fingers,
hands, and other body parts clear of the blade path at all times.
- Do not over extend your reach while cutting. Maintain balance.
- Use extreme caution and be aware of other employees while cutting.
- Cut resistant gloves and sleeves must be worn on both hands and both arms
while cutting.
- Always wear cut gloves when changing out blades.
- Always place old blades in a blade disposal container stationed near all lines.
22.7 Safety Handling of Pallets, Core, & Film Rolls

PPE Required:
- Safety glasses
- Safety shoes
- Ear plugs
- Hand protection: Cut gloves
Instructions:
- Hazards
o Objects stood up on end such as pallets, cores, rolls of film stood up
on end creates a serious impact hazard.
o Risk:
 Object can fall over or is knocked over and hits someone on the
leg, shin, etc. causing an injury.
- Never:
o Stand objects up on the end.
o Lean objects up against an object or wall.
50
- Facts:
o Pallets can have sharp edges, exposed nails, and can cut or break a
bone if they fall over.
o Cores can weigh up to 25 or 35 lbs. and have sharp edges that can
cause serious cuts or impact injuries, if they fall over and hit a leg or
foot.
o Film adds additional weight to the cores and can cause serious injuries
or broken bones if they fall over and hit a leg, foot or head.
- Corrective Action:
o Store all pallets lying down flat on the floor.
o Store empty cores in a core cart/rack or Gaylord box. Never stand on
the end.
o Store rolls of film lying flat on a pallet. (Band, if double stacked)
22.8 Safety & Equipment Access
PPE Required:
- Safety glasses
- Safety shoes
- Ear plugs
- Work or cut gloves
- Any other required PPE base on task being performed
Instructions:
- Blocked electrical panels
- Must maintain a 36” clearance in front of all electrical panels at all times. (No
exceptions)
- Keep electrical panel doors closed when in use.
- Electrical panels may be accessed by electrical personnel only.
Safety Equipment:
- Must maintain a clear access to all safety equipment including fire
extinguishers, eyewash stations, egress routes/exits, etc.
- Do not block this equipment with pallets, forklifts, Gaylords, pallet jacks, etc.
- Do not cover fire extinguishers with coats, tool pouches, etc.
22.9 Knife Use Procedures

PPE Required:
- Safety glasses
- Safety shoes
- Cut resistant gloves (Both hands)
- Cut resistant sleeves (Both arms)
Instructions:
51
- A utility knife should ONLY be used to perform a cut task that is deemed not
able to cut using an approved retractable safety knife or J-knife.
- Use only work provided knives on the job.
- A self-retracting safety knife must be used when possible.
o A regular Stanley utility knife may be authorized by the Department
Manager or Supervisor and issued to the employee for the duration of
that specific cut task only.
- Cut resistant gloves and sleeves are required and must be worn on both
hands and both arms during cutting task and both arms during cutting task
and excessive force cuts.
- Always follow safe cutting, blade change, and blade disposal procedures.
- Always cut away from body parts.
22.10 Manual Spindle Shaft Pulling & Loading

PPE Required:
- Safety glasses
- Safety shoes
- Ear plugs
- Gloves
- Shaft puller tool
Purpose:
- Use the shaft pulling cart and core handler/loader to minimize manual lifting of
the spindle shafts.
Instructions:
1. Use the shaft cart to align and manually pull the shaft from the finished rolls
onto the cart. Use puller tool (if needed).
2. Carefully load cores onto the empty spindle shaft.
3. Carefully push the shaft cart over and inline on front of the winder.
4. Carefully guide the drive end of the shaft into the winder cradle.
5. Carefully lift and lower the chuck end of the shaft into the winder cradle end of
winder.
6. Lock in the shaft, align cores and air up shaft.
- Watch hand placement at all times.
22.11 Spindle Shaft Safety

PPE Required:
- Safety glasses
- Safety shoes
- Ear plugs
- Tideland tool or J-knife
52
Procedures:
- Remember to release air pressure from the spindle shaft after index is
complete and prior to attempting to remove the spindle from the winder turret.
- Hands and fingers should never be used to press and release the air release
valve on any spindle shaft. Use the Tidland air release tool or a J-Knife to
press the air valve.
- Always make sure that hands and fingers are clear of moving equipment
(manual or automatic) at all times.
- Be aware of hand placement at all times when placing the spindle in and out
of the winder turret and when using a shaft dolly cart/automatic shaft puller to
pull or push the shaft.
- Never lift any spindle alone all spindle shafts lifted must be the required safe
wight limits and must be lifted by two employees if moved or loaded manually.
- Shafts that are over 110 lbs. must be removed and placed into the winder by
mechanical means only.
o Crown lift or Hoist system
- Never use a finger to release the air from a spindle shaft.
53
APPENDICES
Appendix A.
Appendix B.
54
Appendix C.
Appendix D.
55
Appendix E.
Appendix F.
56
Non-Routine Task Hazard Analysis (NRTHA) Non-Routine Task Hazard Analysis (NRTHA)
Directions: If one of the 9 tasks listed is perf ormed, a DOCUMENTED NRTHA is C. Building Operation / Process
required. During the analysis, if a shaded box is marked, immediately STOP , contact 1 Y N Will w ork have potential building systems impact?
the Maintenance Manager and/or EHS Manager for assistance. 1. a Y N Fire Monitoring/Suppression/Annunciation systems.
NON-ROUTINE, HAZARDOUS TASKS ( c h e c k t a s k s t ha t a p p l y ) : 1. b Y N Safety Show er / Eye Wash.
1 Roof w ork 1. c Y N Evacuation Speakers (if applicable).
2 Non-standardized Lockout Procedure 1. d Y N Security Systems.
3 Safety, Security, Lighting, Water System s Interruptions 2 Y N Does w ork involve construction or demolition?
4 Rigging 3 Y N Does w ork involve interruption or redirecting vehicles / pedestrians?
5 Ne w Che micals or Non-standard Use Does operation need to stop to perform task safely?
4 Y N
6 Work at heights (feet > 4 ft.) If "Y", contact Operations, Maintenance and Safety.
7 Moving unsecured and / or non-palletized load
8 Equipm ent m oved / e quipme nt modification After com pletion of the NRTHA, document signatures of em ployees
9 Ne w e quipm ent involved w ith task . Signatures acknowle dge that pote ntial risks have
TASK DESCRIPTION: be en evaluated and actions have been im pleme nted to eliminate or
A. Gene ral Walk -Through: m itigate these ide ntified risk s.
1 Do I have the prints / draw ings / schematics I need? LEAD PERSON SIGNATURE DATE
Y N
If "no" contact Maintenance Manager
Are all crew members f amiliar w ith the area and task?
2 Y N
If "N", brief crew on area and task !
3 Y N All tools / equipment in SAFE w orking order? CREW MEMBER SIGNATURES DATE
4 Y N Crew members need additional training to SAFELY perf orm task?
5 Y N ADDITIONAL personnel required to complete task SAFELY?
B. SAFETY: NOTE - ALWAYS Use appropriate PPE for the tas k!!!
SECURE WORKING AREA
1 Y N Elevated w ork w ithin 20 feet of pedestrian aisle edge?
1. a Y N If "Y" to question 1, barriers, caution tape, cones deployed?
LOCKOUT
2 Y N Lockout required? (If "Y", answ er questions 2.a - 2.d)
2 .a Y N Is Lockout equipment identifiable to a single individual?
2 .b Y N Do I know how to LOTO this equipment SAFELY and COMPLETELY?
2 .c Y N Need access to additional / diff erent LOTO Equip?
Will w ork require removal of LOTO for testing?
2 .d Y N
If "Y", follow LOTO procedures after testing!!
FALL HAZARDS
3 Y N Will w ork involve fall exposure (feet > 4 feet from floor)?
(If yes, a - c)
3 .a Y N Can I perform from mobile elevated w ork platf orm? NOTES
3 .b Y N Will I be surrounded by (min) 42" guardrails?
3 .c Y N Fall equipment required? (If yes, 1 - 3)
3 .c .1 Y N Do I have the proper Fall arresting equipment?
3 .c .2 Y N Fall Arresting equipment in good w orking condition?
3 .c .3 Y N Do I have an identified and certif ied anchorage point?
Will w ork require rigging (restrain, lif t, move equip/parts)?
4 Y N
If "Y" STOP! Contact Maintenance & Safety Im me diately!
CHEMICAL SAFETY
5 Y N Are new /unfamiliar chemicals required for this task? (If yes, a - h)
5.a Y N Am I trained in the safe use of chemical?
5.b Y N Do I know w here to obtain MSDS?
5.c Y N Chemical containers correctly labeled?
5.d Y N Will I need to transfer to a secondary container?
5.e Y N Does secondary container have correct labeling?
5.f Y N Is there adequate ventilation in the area?
5.g Y N Correct PPE for safe use of chemical? * IF NO SHADED BOXES ARE CHECKED:
Y N Potential for spills?
5.h If the NRTHA is complete and NO shaded boxes are checked,
Y N Do I know the location of the chemical/f luid spill kit?
proceed with your normal pre-task assessment then complete
POWERED INDUSTRIAL EQUIPMENT SAFETY
6 Y N Is PIT required to move Unsecured and/or non-palletized load?
the assigned task.
6 .a Y N Is the load attached or banded to the pallet?
6 .b Y N Can I move the load w ithout af fecting adjacent items? ** IF SHADED BOXES ARE CHECKED:
6 .c Y N Do I have a clear travel path and secured the load?
WORKING ENVIRONMENT If shaded blocks are checked, approval of the Maintenance
7 Y N Will w eather potentially prevent safe completion? Manager or Site Leader is required and, if possible, a general
Do I need to raise my voice to overcome area noise? area review by the plant EHS. Operations Management must be
8 Y N
If "Y", us e appropriate hearing protection !! notified. This will help ensure that all tasks have been properly
9 Y N Is there adequate airflow in area to perf orm task? analyze
10 Y N Will w ork generate odors/fumes?
57

Safety Training Manual

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Safety Training Manual

Uploaded by

Copyright:

Available Formats

Berry Global (Washington, GA)

1. Berry Safety Absolutes

1.1 Employee Accountability

Any violation of these safety absolutes could/will result in disciplinary action up to

1.2 Failure to LOTO Equipment

(LOTO) procedures must be followed when working on equipment with the

1.3 Reaching into Moving Equipment

1.4 Failure to Secure Trailers Before Entry

All semi-trailers must physically be restrained with a mechanical barrier restraint

1.5 Operating a Forklift Before Being Training and Certified

1.6 Failure to Wear Required Fall Protection

When exposed to an unprotected elevated surface greater than 4 feet (1.219

1.7 Unauthorized Entry of a Confined Space

Permit required confined spaces can only be entered by authorized

1.8 Other Berry Safety Rules

2.1 Danger Zones and Injury Types

2.2 Keep Out of the Danger Zone

2.3 Impact Resistant Glove Policy

2.4 Recommended Impact Resistant Gloves

2.5 Why Focus on Hand Safety?

o The majority of injuries at Berry includes lacerations.

3. Personal Protective Equipment (PPE)

3.2 Employee Responsibility

3.3 Hazard Assessment

3.4 PPE (Extrusion Operations)

3.5 Eye Protection

3.6 Hand & Arm Protection

3.7 Foot Protection

3.8 Dress Code

Responsibility: It is the responsibility of the department managers,

4.2.2 Tobacco Use

4.2.3 Restroom Facilities

- It is the responsibility of each employee to ensure that all cleanliness

4.2.5 Maintenance in WIP/FG Areas

4.2.6 Personal Hygiene

5.1 Short- and Long-Term Corrective Actions

5.2 Incident and Injury Reporting Requirements

5.2.3 Incident Scene

6.1 Basic Rules of Proper Lifting

6.2 Job Duties where Lifting Hazards Exist

6.3 Weight Limits

7. Blood Borne Pathogens

7.1 Training Objectives

7.2 What are Blood Borne Pathogens?

7.3 Other Modes of Transmission

7.4 Exposure Control Plan

7.5 Recognize Exposure

- Before entering a scene...STOP.

7.6 PPE Use and Protection Procedures

7.7 Reduce Exposure

7.8 Exposure Procedures

7.9 Medical Records

- All medical records are confidential to the employee only.

7.10 Hepatitis B Vaccine

7.11 Response to Potential Exposed Worker

7.12.2 Clean Hands

- A confined space is a large enough area to enter and perform work.

8.1 Permit Required

- Entry into a permit-required confined space is not a one-person job. It

8.2 Entry Permit

8.2.1 Entry permit components:

8.2.2 Alternate Entry Requirements