Agenda

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Vita Cellular Foams

CARDINAL RULES

British Vita Group

Agenda
Vita Cellular Foams Page

CARDINAL RULES

Cardinal rules have been designed to provide clear guidance on critical

safety standards. They are in place for the benefit of both employees &
management & will assist the Company in its relentless pursuit of an
injury free workplace, ensuring the safest possible environment for
employees.

We believe all of our employees are able to work to these standards.

Cardinal rules are Safety Standards which if violated WILL result in

disciplinary action & could result in termination of employment.

British Vita Group

CARDINAL RULE No. 1

SMOKING & IGNITION SOURCES

Smoking is only permitted in designated areas. Misuse of ignition sources is
unacceptable.
SMOKING & IGNITION SOURCES

SMOKING IS ONLY PERMITTED IN DESIGNATED AREAS. MISUSE OF IGNITION

SOURCES IS UNACCEPTABLE.

Fire has been identified as one of the greatest risks, particularly in a foam
manufacturing environment.
• Smoking anywhere on site except in the designated areas will not be
tolerated, this is without exception.

Several years ago an employee was found smoking in one of the

buildings under the foam plant. After 20+ years of service the employee was
dismissed – Gross misconduct.
• On sites where the public may have access, employees are still only
permitted to smoke in designated areas.
• Refer to your site maps / supervision to establish the locations of the
designated areas.
• When visiting other sites ensure you establish where the designated
smoking areas are.
SMOKING & IGNITION SOURCES

• Ignition sources are not to be used ie. testing for FR foam may only be
carried out under controlled conditions (laboratory).

An employee was seen smoking in the foam curing area, the employee
stated that they were not smoking, they were just testing their lighter. The
employee was dismissed after 30+ years service.

• If you see a contractor, visitor, driver or an other employee smoking

outside of the designated areas you have a duty to approach them &
politely request that they put the cigarette out & report them
immediately to your supervisor.
CARDINAL RULE No. 2

VIOLATION OF SAFETY STANDARDS

No one will direct anyone to violate a safety standard or knowingly condone
the violation of a standard.
VIOLATION OF SAFETY STANDARDS
Employee in this instance means everyone. Operator, Charge hand,
Supervisor, Manager & Director.

No employee will instruct, request or direct another employee to carry out

any task which will violate a safety standard, be against any training
received or may place in jeopardy that employees or another employees /
contractors health and safety.

No employee will knowingly condone / agree for a task to be carried out if

that task violates a safety standard or places in jeapardy an individual or a
group of individuals health & safety.

All employees if instructed, requested or directed to carry out a task which

they know will violate a safety standard, must bring it to the attention of
Management.
CARDINAL RULE No. 3

FAILURE TO REPORT ANY ACCIDENT,

INCIDENT, NEAR MISS OR HAZARD
Everyone shall immediately report any accident, incident, near miss or
hazard to their immediate supervisor / line Manager.
FAILURE TO REPORT ANY ACCIDENT, INCIDENT, NEAR
MISS OR HAZARD
What is an accident?

An unplanned, uncontrolled event which has led to or could have led to

injury to people, damage to plant, machinery or the environment and/or
some other loss.

Examples:

1) Recent accident on laminator – employee sustained an injury to finger

whilst removing brackets from under heater on laminator. As the
operator did so the heater dropped and the worker sustained a cut
which required medical treatment

2) Trip accident in fabrication area – a worker was carrying foam from one
area to another when they tripped over work in progress left in the
walkway. They sustained bruising to hands and knees
FAILURE TO REPORT ANY ACCIDENT, INCIDENT, NEAR
MISS OR HAZARD
What is a Near Miss/Incident?

A near miss is an unplanned event that did not result in injury, illness, or
damage – but had the potential to do so. Only a fortunate break in the chain
of events prevented an injury, fatality or damage; in other words, a miss
that was nonetheless very near

Examples:

1. Standing under raised blocks held up by FLT whilst removing skins

2. Contractor walking round blind bend into path of FLT

3. Blocks being stacked unsafely on trailers and falling onto FLT

FAILURE TO REPORT ANY ACCIDENT, INCIDENT, NEAR
MISS OR HAZARD
What is a hazard?

Something that has the potential to cause injury/death of a person/s or

damage to or loss of equipment or property.

Hazards can range from trivial to serious and people’s perceptions of a

Situation vary.

To avoid any confusion ALWAYS report a hazard

NEVER ignore it or leave it for someone else to report.

FAILURE TO REPORT ANY ACCIDENT, INCIDENT, NEAR
MISS OR HAZARD
Why we MUST report all accidents/incidents , near misses or hazards.

To make the area or action safe to enable work to continue

To allow an investigation to be carried out to establish what happened

To inform others who could be affected by a similar event

To formally record the incident

To advise the HSE if the incident was serious

CARDINAL RULE No. 4

P.P.E (PERSONAL PROTECTIVE EQUIPMENT)

Specified P.P.E shall be worn to prevent serious injury or disease
P.P.E (PERSONAL PROTECTIVE EQUIPMENT)

LEGAL REQUIREMENTS

1. Every Employee must conduct risk assessment of tasks and machinery

2. PPE is to be provided as a last resort to control a hazard

3. PPE should be appropriate to the level of the risk

4. Provide relevant staff training in the use of the equipment

5. Provide storage and means to maintain the equipment

6. Must be free of charge and available to all

Employees Responsibility for their PPE

7. Take care of their PPE – maintain in good order as per any instruction

8. Wear the equipment where procedures or signage indicates

9. Report any loss or defective equipment

P.P.E (PERSONAL PROTECTIVE EQUIPMENT)

Equipment – Examples

Ear Protection – High risk noise area – Ear plugs, ear muffs.

Lungs, Respiratory – High risk areas where fumes/dust/mist is released.

Hands – Gloves, chemical resistant, cut resistant, gripper gloves, chain mail
gloves.

Feet – Risk of crushing/falling items – Safety shoes/boots

Body – protective suits, clothing, aprons high visibility clothing

Hi Viz wear must be worn on site at all times

Leather aprons for welding activities

General work wear

Eye Protection – Safety glasses, weld mask, goggles

Other – Safety harness – prevent fall from height

P.P.E (PERSONAL PROTECTIVE EQUIPMENT)
Means of Communication

Its good practice to indicate the appropriate PPE to be used for the task in
Procedures/SWP

Staff Training must be carried out showing how to use appropriate PPE

Mandatory warning signage placed in the workplace indicating areas which

PPE must be worn (see examples below).
CARDINAL RULE No. 5

POWERED VEHICLES (INCLUDING FORK LIFT

TRUCKS)
All powered vehicles must be operated by authorised, licensed users in a
safe & competent manner at all times, in line with training & procedures.
POWERED VEHICLES (INCLUDING FORK LIFT TRUCKS)

Powered vehicles can if not operated correctly cause serious injury to the
user and other people

This can be due to overloading, overturning or crushing of pedestrians etc

All powered vehicles must be checked before use

Site speed limits & safety rules must be obeyed at all times

Powered vehicles must only be used as intended by the manufacturer

Persons should only operate powered vehicles if they have been trained,
hold a valid license or certificate and have been authorised by the company
CARDINAL RULE No. 6

SAFETY EQUIPMENT
Intentional & unathorised interference, over riding, defeating & removal of
safety equipment will not be tolerated eg. Guards, trips, interlocks, fire
equipment etc.
SAFETY EQUIPMENT

Equipment and machinery have various hazards such as rotating parts, nips
or other movement that can cause serious injury

Guards, interlocks and other safety features or equipment shall not be

misused, defeated or removed in anyway which could injury or harm to any
person

If safety equipment is to be removed then isolations shall be in place and a

permit to work should be written which should include how safety will be
maintained during any work e.g. maintenance or cleaning

All safety equipment should be inspected before use and if found to be

faulty or damaged it should not be used. It should be withdrawn from
service and reported to the relevant person

If any equipment is found to be missing this should be reported to the

relevant person
CARDINAL RULE No. 7

ISOLATION OF PLANT & EQUIPMENT

Before undertaking any maintenance or cleaning activities all plant &
equipment shall be isolated & locked off from all energy sources by an
authorised person.
ISOLATION OF PLANT & EQUIPMENT

Typical Energy Sources

•Electrical

•Mechanical

•Hydraulic – Compressed Liquids

•Pneumatic – Compressed Gases

•Steam

•Stored energy
ISOLATION OF PLANT & EQUIPMENT

Typical Material Feeds

• Powders
• Liquids
• Gases
• Foam
• Steam
• Rolls
• Blocks
• Boxes
ISOLATION OF PLANT & EQUIPMENT

Routine Tasks - Maintenance and cleaning

•Follow procedures to isolate energy sources and material feeds

•Do not proceed if there is a possibility of any isolation being compromised

•Do not proceed if you are not trained, you are not authorised.

Non -Routine Tasks - Maintenance Fault Finding

Wherever practicable lock off all energy sources

If it is not practicable to lock off all energy / feeds then -:

• Ensure you lock off all non essential energy sources and feeds
• As a minimum carry out a visual risk assessment and make a written note of actions
taken to ensure the task is carried out and completed safely.
•Do not proceed if not qualified and competent

•Do not proceed if you are not in full control of the task

•Do not proceed if the safety of yourself or other can be compromised

CARDINAL RULE No. 8

WORKING AT HEIGHT
Only to be undertaken by trained & competent personnel, utilising
equipment specified for the task as detailed in the Risk Assessment and/or
Permit to Work and/or Safe Working Practice.
WORKING AT HEIGHT

• Biggest cause of workplace fatalities. We have recently had two

fatalities within the group, both of which were due to falls from height.
• 87% of all major injuries are caused by ‘low falls’ ie. below 2 metres
• The Working at Height Regulations (WAHR) revoked the construction
regulations which specified the 2 metre rule. There is no recognised
height.
• The WAHR place a duty on the duty holder :- ‘Where work has to be
carried out at height, then the duty holder shall take suitable &
sufficient measures to prevent, so far as is reasonably practicable, any
person falling a distance liable to cause personal injury’.
• This duty recognises that injury can occur from a fall of any height, not
just from above 2 metres.
WORKING AT HEIGHT

What is work at height?

• Work at height means work in any place, including at or below ground
level, where a person could fall a distance liable to cause personal
injury.
• This includes access & egress from that place of work
• This does not include permanent stairways.

Work at height should be :-

Properly planned

Appropriately supervised

Those working at height should be :-

Trained & competent or if being trained supervised by a competent

person

A RISK ASSESSMENT MUST BE COMPLETED WHERE THE CONSEQUENCE OF

ANY FALL IS LIKELY TO CAUSE INJURY
WORKING AT HEIGHT
AVOID – PREVENT – MINIMISE
• Avoid work at height, if you don’t have to go up there then DON’T.

The bulk tanks at Caligen have recently been painted. This was
accomplished from ground level using poles. The need to work at height was
avoided.
• Prevent falls
Use an existing place or means of access
Use the most suitable way of working
Select the most suitable equipment
• Minimise the distance & consequences

If the work activity you are to undertake is not covered by a generic risk
assessment and/or safe working practice a Working at Height permit must
be obtained.
Ladder Use - The risk assessment must justify the use of a ladder
Low risk - Short duration - Site conditions dictate
Use good practice – Ladder trained
WORKING AT HEIGHT

• Other requirements

Avoid risks from fragile surfaces

Prevent falling objects

Warn about danger areas

Inspect work equipment

Persons at work should :-

Follow instructions & training

Advise employer of hazards/risks to health & safety

A contractor was observed using a cherry picker, working at height, painting the office block (5
metres height). The contractor did not have a harness on. He was instructed to get a harness and
was queried re. permit to work. This had also not been obtained. He was instructed to get both. This
was verified. He was then seen later, again at height without a harness, when asked where it was he
lifted it up from the floor of the cherry picker. He was told to immediately put it on & if seen again
without it he would be escorted off site. He was then observed later wearing the harness, but it was
not clipped on. The contractor was escorted off site.

IF IN ANY DOUBT STOP & SEE YOUR SUPERVISOR

CARDINAL RULE No. 9

ELECTRICAL HAZARDS
Only persons authorised by the company are permitted to carry out
electrical work.
ELECTRICAL HAZARDS

Electricity can be dangerous. It can cause death and serious burns

Electrical work is work on any electrical system i.e. from changing a plug or light
fitting (Lamp) to work on plant and machinery

The Electricity At Work Regulations 1989 (EAW) under the Health and Safety at
Work etc Act 1974 provide the regulations under which we must work

EAW Regulation (16) states that: No person shall be engaged in any work activity
where technical knowledge or experience is necessary to prevent danger or, where
appropriate, injury, unless he possesses such knowledge or experience, or is under
such degree of supervision as may be appropriate having regard to the nature of
the work.

The only persons who can work on electrical systems within Vita are those who
have been authorised to do so

The authorisation will be given in writing normally at the start of each year to the
persons who may carry out electrical work

Any faulty equipment shall not be used and should be reported immediately to the
maintenance department, this could be damaged cables on a portable appliance,
or a piece of equipment that does not work when operated