participant guide_spreads

3PARTICIPANT GUIDE TABLE OF CONTENTS

TABLE OF CONTENTS

MMoodduullee 11OOrriieennttaattiioonn

Welcome to UnitedSabine . . . . . . . . . . . . . . . . 6Agenda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Sexual Harassment . . . . . . . . . . . . . . . . . . . . . 8Facility Tour 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 10

MMoodduullee 22SSaaffeettyy

By the end of this module, you should be able to: . . . . . . . . . . . . . . . . 14

Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . 15Sabine River Works Kickoff . . . . . . . . . . . . . . 16Safety Basics . . . . . . . . . . . . . . . . . . . . . . . . . 17Safety Culture . . . . . . . . . . . . . . . . . . . . . . . . . . 18Deal Breakers . . . . . . . . . . . . . . . . . . . . . . . . . 19Housekeeping: Why Should We

Pay Attention to Housekeeping at Work? . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Fire Safety Portable Fire Extinguishers video . . . . . . . . . . . . . . . . . . 22

Dupont Fire Safety . . . . . . . . . . . . . . . . . . . . . 24Fume Release Safety

(Alarm Codes) . . . . . . . . . . . . . . . . . . . . . . . 25Hazwoper: Awareness Level . . . . . . . . . . . . . 27Fit for Duty presentation . . . . . . . . . . . . . . . . 28Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Lifting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Heat Stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Cold Weather Stress . . . . . . . . . . . . . . . . . . . . 34Bloodborne Pathogens . . . . . . . . . . . . . . . . . . 36Personal Commitment to Safety . . . . . . . . . . 39Vehicle Safety . . . . . . . . . . . . . . . . . . . . . . . . . 41Forklift / Powered Industrial

Truck (PIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 42Personal Protective

Equipment (PPE) . . . . . . . . . . . . . . . . . . . . . 44Selecting the Proper

PPE for the Job . . . . . . . . . . . . . . . . . . . . . . 45Properly Removing, Wearing

and Adjusting PPE . . . . . . . . . . . . . . . . . . . 46

MMoodduullee 33OOnn--TThhee--JJoobb TTrraaiinniinngg ((OOJJTT))

OJT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50OJT Day 3:

Boxline Process . . . . . . . . . . . . . . . . . . . . . 52Mapping of Boxline Process . . . . . . . . . . . . . 53OJT Day 4:

Start-Up / Change Over Process and Paperwork . . . . . . . . . . . . . . 56

Mapping of Start-Up / Change Over Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

OJT Day 5: Clean-Up Systems #1, 2, and 3 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Mapping of Clean-Up Systems #1, 2, and 3 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

OJT DAY Five: Clean-Up Systems #1, 2, and 3 Paperwork . . . . . . . . . . . . . . . . . . . . . . . . . . 64

GGlloossssaarryy ooff TTeerrmmss . . . . . . . . . . 66

TThhiiss mmoodduullee wwiillll ccoovveerr ttooppiiccss iinncclluuddiinngg::

• Welcome to UnitedSabine!

• Training Agenda

• Sexual Harassment

• Facility Tour #2

BByy tthhee eenndd ooff tthhiiss mmoodduullee,, yyoouu sshhoouulldd bbee aabbllee ttoo::

• Navigate the Participant Guide

• Define sexual harassment andUnitedSabine Harassment Policy

• Identify each basic phase of the boxline process

ORIENTATION

5PARTICIPANT GUIDE MODULE 1 ORIENTATION4 PARTICIPANT GUIDE MODULE 1 ORIENTATION

MODULE

1

Dear Associate,

Welcome to UnitedSabine!

We are excited to have you as part of the

UnitedSabine family. We believe you can help

UnitedSabine achieve our goals and contribute

to our success.

UnitedSabine is committed to distinctive

quality and unparalleled safety in all aspects of

our business. As part of the UnitedSabine

family, you will discover that the pursuit of

excellence is the most rewarding aspect of

your career with UnitedSabine.

This Participant Guide contains the key

policies, goals, benefits, and expectations of

United Sabine. If you have any questions,

please contact your immediate supervisor.

We hope that your experience at UnitedSabine

will be challenging, enjoyable, and rewarding.

We extend to you our personal best wishes for

your success and happiness. We are glad you

are a member of the UnitedSabine family.

Sincerely,

UnitedSabine Managementwel

com

eCLASS AGENDA

DDaayy 11:: OOrriieennttaattiioonnEEvveenntt

Welcome to UnitedSabineTrainer IntroductionIcebreakerSchedule and Building ReviewLunchHR PaperworkMeet the StaffParticipant GuideSexual Harassment BreakFacility Tour 2Dismissal

DDaayy 22:: SSaaffeettyyEEvveenntt

Recap: Day 1Safety OverviewBreakPersonal ResponsibilityLunchVehicle SafetyBreakPersonal Protective EquipmentPolicies and ProceduresDismissal

DDaayy 33:: OOJJTT ((BBooxxlliinnee PPrroocceessss &&PPaappeerrwwoorrkk))EEvveenntt

Boxline Review by PositionLunch Boxline Review by PositionDismissal

DDaayy 44:: OOJJTT ((SSttaarrtt--UUpp//CChhaannggeeoovveerr PPrroocceessss&& PPaappeerrwwoorrkk))EEvveenntt

Start-Up / Change Over ProcessLunchStart-Up / Change Over Process Dismissal

DDaayy 55:: OOJJTT ((CClleeaann--UUpp SSyysstteemm ##11,, 22,, && 33 PPrroocceessss &&PPaappeerrwwoorrkk))EEvveenntt

Clean-Up System #1, 2, & 3 ProcessLunchDocuments and PaperworkDismissal

11

22

33

44

55


SEXUAL HARASSMENT Sexual Harassment: You Make the Call LISTENING GUIDE

IInnssttrruuccttiioonnss Watch the video and fill in the blanks below.

During the training, you will learnhow to avoid situations that couldbe perceived as sexual harassment.You will view dramatized examplesof workplace interaction anddiscuss why those situations do ordo not depict sexual harassment. You will understand the gray areasof sexual harassment, enabling youto avoid harassing others. You willalso learn how to confrontinappropriate behavior in theworkplace.

KKeeyy PPooiinnttssWhen you complete this session,you should be able to:

• Discuss inappropriate sexualbehavior in the workplace

• Define “Quid Pro Quo” and“Hostile Environment” harassment

• Understand the court’s viewpointof perception over intention

• Describe ways to share humorappropriately

• Explain how harassment may beexperienced by a third party

• List examples of company liabilityfor sexual harassment

• Establish how to respond tosexual harassment

SScceennee 11:: IInnttrroodduuccttiioonn

1. In one year alone, there wereover ______________ charges ofsexual harassment filed with theEqual Employment OpportunityCommission (EEOC).

2. There continues to be______________ about whatsexual harassment is and what itis not. It is rarely a ____________________________ issue.

SScceennee 22:: IInnaapppprroopprriiaattee BBeehhaavviioorr

3. No means ______________ .

4. Being ______________ does notget you off the hook.

5. Most people believe sexualharassment is about sex. Inreality, sexual harassment isabout ______________ or theabuse of ______________ .

SScceennee 33:: ““QQuuiidd PPrroo QQuuoo””

6. “Quid Pro Quo” applies anytime asupervisor or someone withauthority ______________ orwithholds work-related benefits inexchange for sexually related favors.

SScceennee 44:: PPeerrcceeppttiioonn vvss.. IInntteennttiioonnss

7. Sexual harassment cases aregenerally based on the victim’s ______________ ofwhat happened rather than on the______________ of the person accused.

8. ______________ ______________can occur between a man and awoman, two men, or two women.

9. Overall, it’s probably safer to havea general ____________________________ policy in the workplace.

SScceennee 55:: HHoossttiillee WWoorrkk EEnnvviirroonnmmeenntt10. A hostile environment is anysexually oriented and______________ behavior thatcauses psychological discomfortand interferes with an employee’sability to carry out his or her job.

SScceennee 66:: IInnaapppprroopprriiaattee HHuummoorr11. It’s important to exercise______________ ______________when using humor in the workplace.

OObbjjeeccttiivveeTo define sexual harassment andUnitedSabine Harassment Policy.

OOvveerrvviieewwThis program, Sexual Harassment:You Make the Call, provides you withtools you need to identify the subtleforms of sexual harassment and tounderstand how perception plays akey role in determining sexualharassment complaints. Thisprogram is designed to promotediscussion on the subtle types ofsexual harassment so that confusionabout what constitutes sexualharassment can be minimized.

SScceennee 77:: TThhiirrdd--ppaarrttyy PPeerrcceeppttiioonn12. Sexual harassment can occurwhen a third party is made______________ by other people’sbehavior, even if the behavior is notdirected at the third party.

SScceennee 88:: CCoommppaannyy LLiiaabbiilliittyy13. Sexual harassment cases caninvolve ______________ , suppliers,and service people, and a companycan become liable if anyone inauthority is ______________ that anoutside party is sexually harassingan employee, and no actions aretaken to stop it.

SScceennee 99:: RReessppoonnddiinngg ttoo SSiittuuaattiioonnss14. Reasonable Person Standard:Would a ____________________________ find this behavior tobe sexual harassment?15. It’s the responsibility of______________ employees to followcompany policies and proceduresrelated to sexual harassment.

SScceennee 1100:: SSuummmmaarryy16. Taking responsibility foreliminating sexual harassmentbegins with ______________ .

DebriefQuestions

1. Is flirting at workappropriate?

2. It is important to maintain aseparation between personal andprofessional lives. Is this moreimportant for supervisors? Why?

3. How many of you haveencountered “space invaders” or“huggers” during your careers?How did you deal with them?


FACILITY TOUR #2 (GREEN LINE)

OObbjjeeccttiivveeTo observe and identify each phase of the boxline process.

IInnssttrruuccttiioonnss Please carry yourParticipant Guide with youon the tour to take notes.

You will start and end at the boxline, following this path:

Boxline

• Driving materials to boxline

• Building boxes

• Labeling boxes

• Filling boxes (Dumping)

• Capping boxes

• Driving boxes to palletsand loading docks

BaglineEssential materialsTower Pallet storageWest dock4XSmoke area/North dockNorth area/166East dock/Propane

storage areaBuilding 189Building 165Building 700G-UnitPoint out Building 192Towers

DebriefQuestions

OObbjjeeccttiivvee To recall basics of boxline process.

• Name the four main processes we saw today.

• Which process comes both first and last?

IInnssttrruuccttiioonnssCheck the correct box next to each description and note the page numberwhere you found the correct answer in the blank provided.

SCAVENGER HUNT

OObbjjeeccttiivveeTo increase familiarity with the Policy Book.

TTrruuee oorr FFaallssee

T F

T F

T F

T F

T F

T F

T F

T F

T F

T F

T F

T F

DDeessccrriippttiioonn

“Deal Breakers” are violations that will result in immediate termination.

Multiple people are allowed in the elevator at one time.

Lock, Tag and Try is one of the Deal Breakers

Overtime is optional.

There are six types of excused absences: vacation, holiday, military leave, jury duty, bereavement, Family Medical Leave Act (FMLA).

It is the employee’s responsibility to keep current with their his or her badge.

An employee may leave their work area only when given permission.

Smoking is not allowed on any property near UnitedSabine.

Seatbelts are required in most vehicles on company property.

Employees should not discuss their wages with anyone other than theirsupervisor or the Human Resources Department.

You are allowed to share your badge with one person a day.

Lying is a “Deal Breaker.”

PPaaggee NNuummbbeerr

• Which process comes after the first?

• Which process is before the last?

• Which process looks the most difficult?

• What appears to be difficult about that process?


SAFETYMODULE

TThhiiss mmoodduullee wwiillll ccoovveerr ttooppiiccss iinncclluuddiinngg::

• Safety Overview

• Fire Safety

• Personal Responsibility

• Vehicle Safety

• Personal Protective Equipment (PPE)

• Policies and Procedures

13PARTICIPANT GUIDE MODULE 2 SAFETY12 PARTICIPANT GUIDE MODULE 2 SAFETY

2

15PARTICIPANT GUIDE MODULE 2 SAFETY

BY THE END OF THIS MODULE,

YOU SHOULD BE ABLE TO:

SSaaffeettyy OOvveerrvviieeww• Understand the value of

being safe.

• Explain the basics of safety at work.

• List the UnitedSabine Deal Breakers.

• Identify housekeeping practicesto promote safety.

FFiirree SSaaffeettyy• Identify a fume release.

• Understand how to respondduring a fume release.

PPeerrssoonnaallRReessppoonnssiibbiilliittyy• Define Fit for Duty requirements.

• Define ergonomics and identifyproper ergonomics.

• Identify safe lifting practices.

• Identify heat stress andprevention methods.

• Identify bloodborne pathogensand exposure areas.

VVeehhiiccllee SSaaffeettyy• Identify and cite the policies for

each vehicle on site.

• Identify the parts of a forklift orPowered Industrial Trucks (PIT).

• Explain how to operate a forkliftor PIT safely.

PPeerrssoonnaall PPrrootteeccttiivveeEEqquuiippmmeenntt• Determine when PPE

is necessary.

• Select the proper PPE for the job.

• Understand how to remove,adjust, and wear PPE properly.

• Understand the limitations of the PPE.

• Understand how to care for,maintain, use, and dispose of PPE properly.

SAFETY

OVERVIEW

OOvveerrvviieewwSafety is a part of your everyday life.You probably have many safe habitsyou perform daily, without eventhinking about them. This sectionwill help you be more prepared atwork and at home to act safely.

KKeeyy PPooiinnttss• Why work safely?

WHY WORK SAFELY?

IInnssttrruuccttiioonnss For each situation provided, consider the followingquestions, note your answers in the space provided:

• Why do you need to think about safety in this situation?

• What could happen?

• What should you do to prevent an accident?

SSiittuuaattiioonn

1. Changing a light bulb

2. Driving a vehicle

3. Climbing a ladder

4. Chopping down a tree

DebriefQuestions

14 PARTICIPANT GUIDE MODULE 2 SAFETY

SAFETY BASICS

WHY WORK SAFELY?

DDiirreeccttiioonnss Match the following terms and examples by drawing a lineto connect.

1. Risk2. PPE3. Environmental

stressor4. Control measure5. Accident6. Deal Breaker

A) Slipping on several pellets that wereleft on the floor

B) The chance someone will get burnedby the glue pot

C) Large fans used to cool the workarea on hot days

D) Cold weatherE) Bringing your cell phone on propertyF) Safety glasses and gloves


SABINE RIVER WORKS KICKOFF

OOvveerrvviieewwThe Sabine River Works Kickoffpresentation will explainUnitedSabine safety expectationsand goals for the next year. Thepresentation also covers statisticsfrom the previous year. Reviewingthese statistics helps identify areasfor improvement and focus. Thispresentation is updated yearly.

KKeeyy PPooiinnttss• Major incidents for previous year

• Reporting elevated acts pyramid

• Infraction types by policy, injury, body part

• Material handling incident statistics

• Top audit violations

IInnssttrruuccttiioonnss View the Sabine River Works Kickoff presentation. Answerthe questions below. Be prepared to discuss your answerswith the class.

1. What did you find most interesting about that presentation?

2. What will you make a commitment to remember?

3. What questions do you have about this information?

Additional notes:

DebriefQuestions

ActivitySSaaffeettyy means freedom from danger,risk, or injury. How do you stay safe when so many things could go wrong?

You stay safe by being aawwaarree!!

Educating yourself and others aboutsafety issues will keep accidents toa minimum and save lives.

This section explains general safetyconcepts and practices. Bybecoming familiar with the causesof accidents, you will be betterprepared to prevent them and knowwhat to do if they happen.

AAcccciiddeenntt:: An unplanned, unexpected,and undesired event, usually with anadverse consequence.

EEnnvviirroonnmmeennttaall ssttrreessssoorrss:: Workload,workspace, staffing, time pressures,noise, cold, and heat.

HHaazzaarrdd:: Anything that can cause harm.

HHuummaann ffaaccttoorrss:: Study of therelationships between humans, thetools they use, and the environmentin which they live and work.

IInncciiddeenntt:: Involves damage that islimited to parts of a unit, whether thefailure disrupts the system or not.

NNeeaarr mmiissss:: An event or situation thatcould have resulted in an accident,injury, or illness, but did not, eitherby chance or timely intervention.

NNeegglliiggeennccee:: Failure to use suchcare as a reasonably prudent andcareful person would use undersimilar circumstances.

RRiisskk:: The likelihood, high or low, thatsomebody or something will beharmed by a hazard, multiplied bythe severity of the potential harm.

RRiisskk mmaannaaggeemmeenntt:: Clinical andadministrative activities undertakento identify, evaluate, and reduce therisk of injury to patients, staff, andvisitors and the risk of loss to theorganization itself.

PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt((PPPPEE)):: Clothing or equipmentdesigned to protect employees fromserious workplace injuries orillnesses resulting from contact withchemical, radiological, physical,electrical, mechanical, or otherworkplace hazards. In addition toface shields, safety glasses, hardhats, and safety shoes, PPE includes

a variety of devices and garmentssuch as coveralls, gloves, vests,earplugs, and respirators.

CCoonnttrrooll mmeeaassuurree:: A policy orprocedure that reduces yourexposure to hazards.

DDeeaall BBrreeaakkeerr:: A violation that will lead to termination of your employment.

DEAL BREAKERS

Violating policies concerning any of the following might lead totermination of employment. This list is not all-inclusive.

• Smoking Policy

• Seat Belt Policy

• Employee badges

• Probationary period

• Fighting and aggression

• Sabotage

• Lying

• Negligent or irresponsible behavior

• Safety

• Stealing

• Wasting time

• Insubordination

• Violating laws

• Leaving company premises or work area


SAFETY CULTURE

An organization with a safetyculture prioritizes safety and treatssafety as important as any otherarea of the business. Safety cultureis more than avoiding accidents orreducing the number of accidents—although these actions are likely tobe the most apparent measures ofsuccess. Having a safety culturemeans doing the right thing at theright time in response to normal andemergency situations.

A safety culture is where:

• AAllll workers accept responsibilityfor the safety of themselves,their co-workers, and visitors.

• Safety is priority above financialand operational goals.

• Management encourages andrewards the identification,communication, and resolution ofsafety issues.

• Organizational learning fromaccidents is provided.

• There are appropriate resources,structure, and accountability tomaintain effective safetysystems.

The key to achieving that safetyculture is in:

• Recognizing that accidents arepreventable through followingcorrect procedures andestablished best practices

• Thinking safety constantly

• Seeking continuous improvement

UnitedSabine employees believe thatsafety is their most important job!

• Posting or removing notices

• Cell phones

• SP5: Lock, Tag and Try

• Alcohol and Drug Use

• Forklift

• Elevator

For more information about eachDeal Breaker, please refer to youremployee manual.


HOUSEKEEPING:WHY SHOULD WE PAY

ATTENTION TO HOUSEKEEPING AT WORK?

PURPOSE OF

WORKPLACE

HOUSEKEEPING

IInnssttrruuccttiioonnss Write your answers to the question in the

spaces provided.

Poor housekeeping can be a cause of accidents, such as:

HOUSEKEEPING

BENEFITS

IInnssttrruuccttiioonnss Check the correct answers.

What are some benefits of good housekeeping practices?

• Reduced handling to ease the flow of materials

• Fewer tripping and slipping accidents in clutter-free and spill-free work areas

• Decreased fire hazards

• Lower worker exposures to hazardoussubstances

• Better control of tools and materials

• More efficient equipment cleanup andmaintenance

• Better hygienic conditions leading to improved health

• More effective use of space

• Reduced property damage by improving preventive maintenance

• Less janitorial work

• Improved morale

The fact is that all these examples are benefits ofgood housekeeping practices. List any other benefitsyou can think of in the space below.

Effective housekeeping can eliminate some workplacehazards and help get a job done safely and properly. Poorhousekeeping can frequently contribute to accidents byhiding hazards that cause injuries. If the sight of paper,debris, clutter, and spills is accepted as normal, thenother serious health and safety hazards might occur.

Housekeeping is not just cleanliness. Housekeepingincludes keeping work areas neat and orderly; maintaininghalls and floors free of slip and trip hazards; and removingwaste materials (for example, paper and cardboard) andother fire hazards from work areas. Housekeeping alsorequires paying attention to important details such as thelayout of the whole workplace, aisle marking, the adequacyof storage facilities, and maintenance. Good housekeepingis a basic part of accident and fire prevention.

Effective housekeeping is an ongoing operation—not a hit-and-miss cleanup done occasionally. Periodic paniccleanups are costly and ineffective in reducing accidents.

Activity

Activity

To avoid hazards, you must clean up yourworkspace throughout workday. Although thiseffort requires some management and planning,there are many benefits.

UUnniitteeddSSaabbiinnee’’ss rruullee iiss:: NNoo mmoorree tthhaann ssiixx ppeelllleettss oonn tthhee fflloooorr!!


FIRE SAFETY

PORTABLE FIRE EXTINGUISHERS VIDEO

OOvveerrvviieewwThe Portable Fire Extinguishersvideo explains how to useextinguishers correctly to controlsmall fires. The program outlines thevarious types of fires and whichtype of extinguishing agents andextinguishers are best for each fire.The program also demonstrates thePASS method of extinguishing a fireand lists safety precautions toremember while fighting a fire.

KKeeyy ppooiinnttssWhen you complete this session,you should be able to:

• Understand how fires arecreated and how they can beextinguished.

• Know the different types ofextinguishers and which are beston various fires.

• Know how to perform the PASSmethod for using a portable fireextinguisher.

• Know the locations and classesof fire extinguishers in theirworkplaces.

• Understand the importance offollowing safety precautionswhile fighting a fire.


Portable Fire Extinguishers LISTENING GUIDE

9. Class C: Involve energizedequipment

like appliances, switches, panelboxes, and power tools.

10. Class D: Involve certaincombustible metals such asmagnesium, titanium, potassium,and sodium. They react violentlyto andcertain other chemicals.

11. We must know thethat is

burning and use the right type ofextinguisher for it.

TTyyppeess ooff EExxttiinngguuiisshheerrss

12. Some extinguishers can put outmore than class of fire. This ability dependson the type of extinguishing

used in theextinguisher.

13. Water is the most effectiveextinguishing agent for Class

fires.

14. should beused only on Class A or B fires.

15.

are used toextinguish Class D fires.

SSyymmbboollss aanndd MMaarrkkiinnggss

16. To help us identify the right typeof fire extinguisher for the

of fire, fire extinguishers aremarked with that provide this information at a glance.

What is something you learnedabout fires and portableextinguishers from this video?

Explain the PASS method. How can you tell if a fireextinguisher is unsafe to use?

Activity

DebriefQuestions

IInnttrroodduuccttiioonn

1. Fire is a involving the

rapid oxidation or burning of a fuel.

2. The four elements needed for afire to exist are:

•

•

•

•

SSuupppprreessssiioonn

There are four methods ofextinguishing a fire:

3. Removing the .

4. Diluting the .

5. the temperature.

6. Inhibiting the chain reaction.

CCllaasssseess ooff FFiirree

Four classes of fire have beenestablished to describe the materialthat is burning.

7. Class A: Consists ofcombustibles or

fibrous material

8. Class B: Are fueled by flammableor combustible ,gasses, greases, or similarmaterial such as gasoline,kerosene, paint thinners, andpropane.

FFiirree FFiigghhttiinngg TTeecchhnniiqquuee

17. Instructions for each specific typeof fire extinguisher are on the

. Read themthe emergency!

18. There are four basic steps whenusing the PASS method:

• Pull the .

• Aim the extinguisher nozzle at the of the flames.

• Squeeze the while holding the extinguisher upright.

• S the extinguisherfrom side to side.

19. Remember the following safetyprecautions:

• Do not block your of .

• the area immediately.

• Close any isolating the fire area.

• Notify your fire brigade or .

• Make sure the fire is out.

• Know the location of the fire extinguishers.

• Know the of extinguisher.

• Check the seal.

20. Report missing, , or damaged extinguishersimmediately.

DUPONT FIRE SAFETY

IInnssttrruuccttiioonnssView the DuPont Fire Safety presentation. Answer thequestions below. Be prepared to discuss your answerswith the class.

1. Name three things to remember when deciding when to fight a fire.

2. How can you make sure an extinguisher is energized?


24 PARTICIPANT GUIDE MODULE 2 SAFETY 25PARTICIPANT GUIDE MODULE 2 SAFETY

FUME RELEASE SAFETY (ALARM CODES)

When working in an environmentthat contains hazardous materials, it is important to know how toremain safe in event of a fumerelease emergency. Safetyprecautions are taken to preventfume releases, but on rareoccasions a release will occur.

The map given to you during theDuPont training will be your numberone resource in a fume releaseemergency.

If a fume release blast is heard:

1. Look at your map and codes todetermine where the releaseoccurred.

2. Look for a wind sock todetermine if you are up or downwind from the release.

FUME RELEASE SAFETY

IInnssttrruuccttiioonnss Your instructor will say a series blasts, use the spacebelow to note where you would go for safety.

Test one:

Test two:

Test three:

USING YOUR MAP

IInnssttrruuccttiioonnss Check the correct box to each description.


T F

T F

T F

T F

T F


Test alarms blast one round of three blasts at the beginning and end of the test.

Fire alarms blast two rounds of fire box number near the location of the fire.

There is an alarm for site evacuation.

All clear is announced by one round of two blasts.

68 and 62 are fire alarms that pertain to our area.

Activity

Activity

OOccccaassiioonnaallllyy tthheerree wwiillll bbee bbllaassttss tthhaatt iinnddiiccaattee aannaammmmoonniiaa rreelleeaassee.. TThheesseeaannnnoouunncceemmeennttss wwiillll ccoommeeoovveerr tthhee iinntteerrccoomm aanndd wwiillll ssttaattee wwhhiicchh aarreeaass aarree aaffffeecctteedd..

GGaass aallaarrmmss tthhaatt ppeerrttaaiinn ttoo oouurr aarreeaa aarree 1155,, 1166,, 1177,, aanndd 1199..

FFiirree aallaarrmmss tthhaatt ppeerrttaaiinn ttoo oouurr aarreeaa aarree 6622,, 6688,, 7711,,7744,, 9944,, aanndd 9966..

DUPONT FIRE SAFETY

OOvveerrvviieeww

This annual training course isdesigned to familiarize you withgeneral principles of fire extinguisheruse and the hazards involved withfighting early stage fires.

DebriefQuestions

KKeeyy ppooiinnttss• If you see a fire, have someone

or send someone to pull the firealarm or call the fire emergencyextension at your facility

• Keep the fire extinguisher in anupright position.

• Keep a safe distance from the fire.

• If the fire spreads or threatensyour escape route, get out.

• Know the locations of your firealarm pull boxes.

• Know the locations your fireextinguishers.

• Know the ratings of your fireextinguishers.

HAZWOPER: AWARENESS LEVEL

OOvveerrvviieewwHazardous waste containschemicals that can cause injuriesand, in some cases, death. It isimportant to be aware of thehazardous waste in your workenvironment so that you can preventthe release of waste. Thispresentation will explain whathazardous waste can do and how toavoid injury.

KKeeyy PPooiinnttss• Hazardous waste is dangerous.

• Chemicals can be enter the body many ways.

• First Responders at each locationare trained to take action.

• Prevent releases by closingcontainers, inspectingcontainers for damage and not overfilling.

• Liquid on the floor or table couldbe a chemical release.

• Evacuate the area and report therelease immediately.

• Secure the area in the event of a release to preventunnecessary exposure.

IInnssttrruuccttiioonnss Write your answers to the following questions in the spaceprovided below. Be prepared to discuss your answers.

1. What are some ways chemicals can enter the body?

2. Who will you notify in the event of a chemical release?


Additional comments:

DebriefQuestions


Fit for Duty PRESENTATION

OOvveerrvviieeww“Fit for Duty” refers to yourresponsibilities regarding yourpersonal physical and mental health.

KKeeyy PPooiinnttss• Troubled employees can affect

the business negatively.

• Interpersonal problems areidentified by specific behaviorsand physical symptoms.

• It is important to recognize anddiscuss declining behavior orperformance.

ERGONOMICS

OOvveerrvviieewwThe Ergonomics: Solving the Puzzlevideo highlights the importance ofergonomics and personalresponsibility in protecting yourselffrom musculoskeletal disorders. Thevideo outlines the signs andsymptoms of these disorders andtheir causes. The video also listscommon solutions to musculoskeletaldisorders and explains how to makeergonomics work for each employee.

KKeeyy PPooiinnttssWhen you complete this session,you should be able to:

• Understand what ergonomics is.

• Know what musculoskeletaldisorders are.

• Know what the symptoms are.

• Understand what causesmusculoskeletal disorders.

• Know how to prevent these disorders.

• Know how to use ergonomicprinciples to protect yourself.

FIT FOR DUTY

IInnssttrruuccttiioonnss Write your answers to the following questions in the spaceprovided below. Be prepared to discuss your answers.

1. What are three behaviors that identify a “Troubled Employee”?

•

•

•

2. What impact can personal problems have on your work performance?

3. What can you do to help to maintain a healthy workforce?


DebriefQuestions


Ergonomics: Solving the Puzzle LISTENING GUIDE



1. Wherever you look,is changing

our expectations and the way wework.

2. Customers expect faster service.So, companies redesignemployee

so they canwork faster.

WWhhaatt iiss EErrggoonnoommiiccss??

3. Ergonomics fits to instead ofmaking people fit their bodies totheir work.

4. Recent studies show that/

occupational injuries andillnesses stem from overuse orrepetitive motion.

5. Musculoskeletal disorders comefrom a task that

your bodybeyond its safe limits.

MMuussccuulloosskkeelleettaall DDiissoorrddeerrss

6. Often, adjusting the way youwork removes the

and takescare of the problem.

SSyymmppttoommss

7. If you have muscle fatigue orpain that disappears with

, it could be a symptomof a musculoskeletal disorder.

SSiiggnnss

8. A common sign of amusculoskeletal disorder is adecreased of

.

9. Decreased strength is another sign.

10. You may also experience a lossof .

11. Early diagnosis and can keep you well.

CCaauusseess

12. Six common causes ofmusculoskeletal disordersinclude:

• Lifting

• Repetitive

• Contact stress

• Extreme

• Vibration

• Awkward

IIddeennttiiffyyiinngg PPrroobblleemmss

13. To find the best way to preventmusculoskeletal disorders, youremployer needs your

.

14. Any time you suspect a work-related, musculoskeletaldisorder, itimmediately so the cause can beevaluated.

SSoolluuttiioonnss

15. Adjustable andare among the

most common ergonomicequipment found in today’sworkplaces.

16. In most cases, people are mostefficient and comfortableworking at about height.

17. Some ergonomic solutions focuson making your work positionmore .

18. Many ergonomic solutions areinventions suggested by alert

.

19. Most of the time, ergonomicsolutions are .

20. Changing your isone of the best ways to protectyour body from musculoskeletaldisorders.

21. When possible, you shouldand change the

position of your body.

MMaakkiinngg EErrggoonnoommiiccss WWoorrkk

22. Working better often meanstrying .

23. It takes fromeveryone.

24. If your company brings in newequipment or tools, learn to usethem .

25. Expect that it will taketo adapt to a new

way of doing your job.

26. If you give the changes a fair tryand still dislike them, talk to your

. Maybe somemodifications or adjustments areneeded.

27. Work smart. Bring the

instead of stretchingor bending to reach the work.

Activity

What are some symptoms ofmusculoskeletal disorders?

Why is it important to frequentlychange your body position andstretch routinely?

What was the most interesting or creative solutionyou recall from the video?

DebriefQuestions

LIFTING SAFETY

OOvveerrvviieewwThe Back Safety: Real, Real Life®

video was developed to encourageyou to always think about safety andavoid situations where you mightinjure your back. The video consistsof two parts. The first is refreshertraining on ways to recognize andavoid possible back hazards on thejob. The second part features aworksite dramatization. Using aninteractive questioning approach, wewill test your knowledge about backsafety during this dramatization.

KKeeyy PPooiinnttssWhen the you complete thissession, you should:

• Have a better understanding of how the back works.

• Know the proper liftingtechnique.

• Understand the “S” curve.

• Know how the 3 A’s can save you from back pain or injury.

31PARTICIPANT GUIDE MODULE 2 SAFETY: PERSONAL RESPONSIBILITY30 PARTICIPANT GUIDE MODULE 2 SAFETY

Back Safety: Real, Real Life LISTENING GUIDE



1. Did you know that by liftingimproperly, something thatweighs as little as 10 lbs can put

lbs of pressureon your back?

2. Every year, more thanworkers hurt

their backs.

3. Most back injuries are.

TThhee tthhrreeee AA’’ss

4. The three A’s to back safetyinclude:

• A

• A

• A

AAwwaarreenneessss

HHooww tthhee BBaacckk WWoorrkkss

5. The vertebrae are separated bywhich are filled

with to absorbshock and keep the vertebraefrom grinding together.

6. The in yourback are what move thevertebrae around.

7. All these parts working togetherprotect the core of your nervoussystem — known as the

.

HHooww ttoo PPrrootteecctt tthhee BBaacckk

8. Clearly, the activity responsiblefor most back injuries is

.

9. Keep your back in aposition as

much as possible.

AAttttiittuuddee

10. With a “Safety first” attitude,you’re less likely to takeunnecessary .

AAccttiioonn

11. is the mostimportant of the three A’s.

SSttaayy iinn tthhee SSaaffeettyy ZZoonnee

12. Your Safety Zone extendsapproximately from your

to yourextending

forward about the length of yourarms.

13. When you bend over to pick upsomething below your SafetyZone, your bears the burden.

14. Lift and set down loads in onemovement.

15. Use on muscles

that have been involved inrepetitive reaching or bending.

16. Prolonged canbe almost as stressful as lifting.

17. Regular willhelp to keep your back strongand in shape.

18. Keep your work areas clear fromthat can cause

you to trip or lose balance.

19. No load is worth risking your.

20. Use andwhen available.

TTeessttiinngg YYoouurr KKnnoowwlleeddggee

Carefully watch the real-lifescenarios and note any unsafe orunwise behaviors you observe in theexamples.

21. Following the three A’s to back safety (Awareness,Attitude, Action) can save youfrom a lot of:

•

•

•

Activity

What are the three A’s to a safety andhealthy back?

What is one unsafe action you rememberfrom any of the dramatizations?

DebriefQuestions

HEAT STRESS

MMaajjoorr DDiissoorrddeerrss

15. Heat cramps can occur whenyou profusely anddrink lots of water but don’treplenish the youhave lost in sweating.

16. Heat exhaustion occurs whenyour body’s cooling system canno longer do its .

17. If you think a co-worker issuffering from heat exhaustion,first move the victim into the

or a cooler areaand cool them off as fast aspossible.

18. If treated properly, heatexhaustion has no known

effects. But if nottreated immediately, heatexhaustion can turn into heatstroke with very little warning.

HHeeaatt SSttrrookkee

19. Heat stroke occurs when yourbody has depleted itself of

and supplies, when sweating is nolonger effective and thereforeyou stop perspiring, and yourbody temperature soars to

levels.

20. Early symptoms of heat stroke are:

- Body temperature of 105 and above

- Absence of

- Excessively hot, red or flushed, dry skin

- Rapid

- Difficulty breathing

- Headache or dizziness

- or delirium

- Weakness

- Nausea or vomiting

21. Advanced symptoms include:

- Seizures and convulsions

- of consciousness

- Deep

- No detectable pulse

- Body temperature over degrees

22. Never give to anunconscious victim.

23. If you have suffered from heatstroke in the past, you may be

susceptible to heatdisorders for the rest of your life.

WWoorrkkppllaaccee PPrraaccttiicceess

24. One of the best ways to preventheat stress is by graduallygetting used to the heat in your

.

25. Another way to control theeffects of heat is by following

work procedures.

Heat Stress: Don't Lose Your Cool LISTENING GUIDE



1. Did you know aboutpeople die from

heat-related illnesses each year?

RRiisskk FFaaccttoorrss

2. Heat stress happens when yourbody has to work

to cool itself.

3. Heat stress disorders include:

- Sunburn

- Heat

- Heat exhaustion

- Heat

4. Anyone who works in hot, or hotand conditions, isat risk.

5. Other people at risk are workerswho wear -

protective suits.

6. The risk of heat stress increaseswith several factors such as:

- Aging

- Pregnancy

- Obesity

- physical condition

- Alcohol or drug use within the previous hours

7. The risk of heat stress alsoincreases with chronic illnessessuch as:

- Hypertension

- Circulatory problems or

- A recent illness that caused

- A current infection or fever

BBooddyy TTeemmppeerraattuurree

8. Your body likes to stay at anaverage temperature of around

degrees.

9. The process of handling heat iscalled -

.

10. The evaporation of becomes the body’s mostimportant cooling method.

11. Most people will lose about aof sweat an hour

when working in extreme heat.

12. When your body can no longereffectively control its coretemperature, its natural defensesmay just

. Then, your corebody temperature can rise to adangerous level, possibly leadingto heat stroke.

MMiinnoorr DDiissoorrddeerrss

13. Sunburn can keep your bodyfrom itself properly.

14.develops in situations whereyour sweat cannot evaporateand stays trapped close to theskin, such as in a hot, humidwork area or when wearingheavy or tight clothing.

Activity

What factors increase a person’s risk ofheat stress?

How can you lower the temperature of aheat stroke victim while waiting formedical assistance?

What smart work procedures should befollowed to control the effects of heat?

What are some ways that working in theheat can cause accidents on the job?

DebriefQuestions


OOvveerrvviieewwThe Heat Stress: Don’t Lose YourCool video was developed to urgeyou to protect yourself from theeffect of heat stress while on the job.

KKeeyy PPooiinnttssWhen you complete this session,you should:

• Better understand heat stressdisorders.

• Know the signs and symptoms ofheat stress and heat stroke.

• Understand the basic steps toaid a victim of heat stress orheat stroke.

- Alternating with less

strenuous work

- Taking in cool rest areas

- Rotating physically-demanding tasks among workers

PPeerrssoonnaall RReessppoonnssiibbiilliittiieess

26. is acrucial way to control heatstress.

27. Drinking “” is a good way to

replenish fluids and electrolyteslost.

28. Your eating are animportant part of controlling heatstress.

29. Salt are notrecommended since they causedehydration and are notabsorbed quickly into the system.

30. Ideally, you’ll want to wear, light-colored

clothes.

CCoonncclluussiioonn

31. You can make your jobby understanding

the effects of heat stress, byknowing the symptoms andtreatments for heat stressdisorders, and by takingprecautions.

COLD WEATHER STRESSCOLD STRESS

IInnssttrruuccttiioonnss Answer the following questions by circling one of the options.

1. Cold weather stress is as serious as heat stress, thetwo main injuries from cold weather stress are:

a. Gangrene and stroke

b. Hypothermia and frostbite

c. Hypothermia and the Flu

d. Stroke and fracture

2. One of the best ways to protect against cold stress isto dress in layers.

a. True

b. False

3. Some symptoms of frostbite include:

a. Waxy, numb skin

b. Confused behavior

c. Loss of consciousness

d. None of the above

4. When it rains, you should wear waterproofclothing to protect yourself from cold stress.

a. True

b. False

Activity

Have you ever suffered any injuries from cold weather stress?

What should you do if you notice symptoms of injury?

DebriefQuestions

OOvveerrvviieewwCold stress or hypothermia can affectworkers who are not protectedagainst cold. Cold is a physical hazardin many workplaces. When the bodyis unable to warm itself, serious cold-related illnesses and injuries mayoccur, leading to permanent tissuedamage and even death.

KKeeyy PPooiinnttssWhen you complete this section,you should

• Understand the effects ofoverexposure to cold.

• Understand the environmentalfactors that can worsen these effects.

• Know the appropriate controlmeasures.

Knowing this information can helpyou avoid hypothermia and frostbite.

CCoorree TTeemmppeerraattuurree:: The body tries tomaintain an internal (core)temperature of approximately 98.6ºF(37ºC). This is done by reducing heatloss and increasing heat production.

Under cold conditions, bloodvessels in skin, arms, and legsconstrict, decreasing blood flow toarms and legs. This processminimizes cooling of the blood andkeeps your internal organs warm. Atvery low temperatures, reducingblood flow to the extremities canresult in lower skin temperature andhigher risk of frostbite.

WWiinndd--cchhiillll involves the combinedeffect of air temperature and airmovement. The higher the windspeed and the lower the temperaturein the work environment, the greaterthe insulation value of the protectiveclothing required.

HHyyppootthheerrmmiiaa:: The body's failure tomaintain its deep core temperature.

Lower body temperatures presentthe following signs and symptoms:

• Persistent shivering

• Irrational or confused behavior

• Reduced mental alertness

• Poor coordination

• Reduction in rational decision-making

FFrroossttbbiittee is a common injury causedby exposure to severe cold or bycontact with extremely cold objects.Frostbite occurs more readily fromtouching cold metal objects thanfrom exposure to cold air. That'sbecause heat is rapidly transferredfrom skin to metal.

The body parts most commonlyaffected by frostbite are:

• Face

• Ears

• Fingers

• Toes

Frostbite symptoms vary, are notalways painful, but can include:

• A sharp, prickling sensation

• Skin that looks waxy and feels numb

• Blistering

HHooww ccaann II pprrootteecctt aaggaaiinnsstt ccoolldd ssttrreessss??

• Be aware and be prepared.

• Recognize the signs and symptoms of overexposure in yourself and others.

• Ensure you are medically fit to work in excessive cold.

• Eat high-calorie foods when working in cold environments.

• Select protective clothing to suit the cold, the job, and the level of physical activity.

• Wear several layers of clothing rather than one thicklayer. Air captured between layers acts as an insulator. Clothing should not restrict flexibility.

• If conditions are wet as well as cold, ensure that the outer clothing worn is waterproof or at least water-repellent. Wind-resistant fabrics may also be required under some conditions.

• Use hats and hoods to prevent heat loss from the head and to protect ears. Face covers might also be necessary under certain conditions.

• Do not wear tight-fitting footwearbecause it restricts blood flow.Footwear should be largeenough to allow wearing eitherone thick or two thin pairs of socks.

• Do not wear too many socks. Itcan tighten fit and harm rather than help.

• If you get hot while working, open your jacket but keep your hats and gloves on.


FFrroossttbbiittee iiss aa ccoommmmoonn iinnjjuurryy..

• What can happen when you can't tell who issick and who is healthy?

• What are the three bloodborne pathogens ofspecial concern to us?

• Why is casual contact with coworkers safe?

• What are some hazards faced when a coworker gets a bleeding cut?

• What are some risks associated withmaintenance? Janitorial? Laundry?

DebriefQuestions


11. You aren’t likely to get theseviruses during the

course of theworkday, but it could happen inunusual circumstances.

12. Even tiny orin the skin can

be “doorways” for HIV, HBV, orHCV to enter your body.

RRiisskkyy SSiittuuaattiioonnss

13. To keep yourself safe, you mustlearn to recognize

and know howto respond safely.

14. Risky situations generally fall intothree areas:

• and

• after

• Routine andactivities.

AAcccciiddeennttss aanndd IInnjjuurriieess

15. If someone is injured, protectbefore you offer

assistance.

16. Be sure to put on a pair of-

gloves.

17. In the rare instance where bloodis spraying, protect your eyes,nose, and mouth with

and a mask.

18. If you get blood on your skin,wash it off as soon as possiblewith nonabrasive

and.

CClleeaannuupp AAfftteerr AAcccciiddeennttss

19. Always restrict access tocontaminated areas untilproperly .

20. Cleanup personnel must wearto protect their

hands from contact with blood orother potentially infectiousmaterials.

21. With large amounts of blood,they should also put on

to protect theirwork clothes.

22. Use absorbents such asdisposable tosoak up the blood then clean thearea with an approveddisinfectant solution.

RRoouuttiinnee JJaanniittoorriiaall aanndd MMaaiinntteennaannccee AAccttiivviittiieess

23. Be alert for sharp objects suchas broken orused syringes when emptying

containers.

24. When handling laundry or trash:

a. Always carry bags from the .

b. Never hold them your body.

c. Never place a hand to support them.

25.is one of the best defensesagainst spreading infection,including HBV, HCV, and HIV.

26. If you get blood or body fluids onyour gloves, clothes, or shoes,

them as soon aspossible and place them in asealed bag.

27. If you think you may have beenexposed to HIV, HBV, or HCV,don’t . Report theincident immediately to yoursupervisor.

Bloodborne Pathogens:Take Precautions LISTENING GUIDE

IInnssttrruuccttiioonnss Answer the following questions by circling one of the options.

Activity


1. Bloodborne pathogens aredisease-causing organisms thatare by contactwith blood or with

that arecontaminated with blood.

2. A bloodborne pathogen may notcause any symptoms for

; maybe not ever.

3. It’s possible for infected peopleto and

fine and tospread the pathogen withoutknowing they are

.

4. Three bloodborne pathogens —all viruses — of special concernare:

•

•

•

5. These viruses are carried in the, semen, vaginal

secretions, and body fluidscontaining blood.

6. HIV is the virus that causes.

7. Hepatitis B and Hepatitis C areboth viral infections that affectthe .

8. Eventually, you couldfrom these

diseases.

HHooww HHIIVV,, HHBBVV,, aanndd HHCCVV aarree SSpprreeaadd

9. In addition to the blood and bodyfluids previously mentioned,these viruses also can be passedfrom pregnant women to their

.

10. To actually get one of thesediseases, the virus must getinside your body. This mostcommonly happens during

with an infectedpartner or when intravenousdrug users share

that arecontaminated.

BLOODBORNE PATHOGENS

OOvveerrvviieewwThe Bloodborne Pathogens: TakePrecautions video was developed toteach you the facts aboutbloodborne diseases at work: whatthey are, how they spread, and howto prevent exposure. The programintroduces HIV, HBV, and HCV andexplains that these diseases arespread by contact withcontaminated blood and body fluids,not by casual contact with co-workers. Because some workplacesituations could lead to exposure toblood or body fluids, you must learnto recognize these situations andtake precautions to protect yourself.

The video describes how you canidentify risky situations and showshow accidents and injuries can putyou at risk. Avoiding exposureduring emergencies and accidentsand during routine maintenance andjanitorial work is covered, alongwith how to handle such situationsproperly. Finally, the video reviewseveryday precautions that can helpprevent the spread of bloodbornepathogens and other diseases at work.

KKeeyy PPooiinnttssWhen you complete this session,you should:

• Know what bloodbornepathogens are.

• Understand how they aretransmitted.

• Know how to handle bloodbornepathogens.

• Be able to protect yourself andyour coworkers.


AAvvooiiddiinngg eexxppoossuurree iiss tthheebbeesstt pprreevveennttiioonn..

PERSONAL COMMITMENT

TO SAFETY

IInnssttrruuccttiioonnssAfter reading the commitment to safety, add your reasons for commitment in thespace provided, sign and date.

I will take the extra time and effort needed to be safe on every job.

I will be aware of my surroundings and stop any unsafe practices and report anyincidents I observe.

I will wear my Personal Protective Equipment when required because I know itserves a good purpose.

I will maintain a clean, safe environment and be mindful of possible incidents.

I commit to safety, no matter where I am, what I am doing, or what excuses are tempting.

I commit to safety because:

•

•

•

•

Signed:

Date:



VEHICLE SAFETY

OOvveerrvviieeww

At this facility, we use several typesof vehicles including sweepers,scooters, trains, automobiles andforklifts, which are also known asPowered Industrial Trucks (PIT). Youmight also notice bicycles on thefacility grounds. (Bicycles are forDuPont employees only.)

KKeeyy PPooiinnttss• SSwweeeeppeerr

- Large vehicle used to clean the streets of our campus.


VEHICLE POLICIES

IInnssttrruuccttiioonnss Circle the answer to the questions below.

Activity

1. You must wear the following PPE while driving a scooter.

- Please keep a safe distance from these vehicles.

- As an employee of UnitedSabine, you will not be required to drive a sweeper.

• SSccooootteerrss::

- Small vehicle used to transport mainly people from building to building.

- There are specific rules and guidelines about who can drive the scooters.

• TTrraaiinnss::

- You will need to watch for train movement on the campus.

- Flashing blue lights will indicate a train is moving in a particular area.

- Do not try to run ahead of the train, wait patiently for it to pass before crossing the tracks.

• AAuuttoommoobbiilleess::

- UnitedSabine employees may not drive automobiles on the plant campus.

• FFoorrkklliifftt::

- Powered Industrial Trucks (PITs) are used in our facility.

- You must complete a forklift training course and be certified before operating a forklift.

a. Safety glasses, gloves,hard hat, and ear plugs

b. Safety glasses, gloves,and hard hat

c. Safety glassesand gloves

d. Safety glasses

4. Should you operate a vehicle that isdanger-tagged as hazardous to thedriver or others?

a. Yes b. No

5. Train movement is common on ourplant campus. Notification ofmovement in a particular area is donewith green flashing lights.

a. True b. False

2. A vehicle that has faulty brakes, inoperative lights,damaged seat belts, or other defects, must not beoperated until repaired.

a. True b. False

3. What should you do if you notice defect on a vehicle in operation?

c. Sketch a picture of the defect.

d. All of the above.

a. Report such defect to supervision.

b. Try to correct the defect yourself.

FORKLIFT / POWERED INDUSTRIAL TRUCK (PIT)

1. What is a suspended load? When is this allowed?

2. Name three things on the pre-operation checklist.

3. Who is qualified to operate a PIT?

PARTS OF A PIT

IInnssttrruuccttiioonnssLabel the parts of this PIT by placing the letter for the corresponding word in each box.

Activity

OOvveerrvviieewwForklift or Powered Industrial Trucks(PIT) are commonly used at thisfacility. You must be certified tooperate a forklift. Upon completion ofthis section of the training, you willnot be certified, but you willunderstand the fundamentals offorklift use.

KKeeyy PPooiinnttssWhen you complete this section,you should:

• Understand the definition of aPIT, suspended load, unattended PIT.

• Know the qualifications of a PIT Operators.

• Know pre-operation checklist items.

• Know what PPE is required foroperating a PIT.

A. Backup alarm — Sounds when forklift is backingto warn others.

B. Solid, cushion or pneumatic tires — Vary basedon the use of the forklift.

C. Data/name plate — Identifies the make/model,weight and rated capacity of the forklift.

D. Parking breaks — Must be used when parked orwhen no one is operating the forklift.

E. Warning device (horn) — Is used to warn others.

F. Seatbelt — Must be worn. If not present, reportthis to your Lead for installation.

G. Overhead guard — Must be present when theforklift is capable of lifting loads higher than theoperator’s head or operated in areas wherethere is a hazard from falling objects.

H. Lights — Are used in locations where there isinadequate light.

I. Load backrest extension — Provides addedstability when traveling with large loads.


DebriefQuestions

Forklift Fundamentals: Get the FactsPRESENTATION

IInnssttrruuccttiioonnss Watch the presentation: Forklift Fundamentals: Get the Facts.

Activity


PERSONAL PROTECTIVE EQUIPMENT (PPE)

TYPES OF PPE

IInnssttrruuccttiioonnssList five examples of PPE in the space provided.

1.

2.

3.

4.

5.

Activity

OOvveerrvviieewwPPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE))includes all clothing and other workaccessories designed to create abarrier against workplace hazards.

KKeeyy PPooiinnttssPPPPEE RReeqquuiirreemmeennttss::

Occupational Health and SafetyAdministration (OSHA) requireseach employer to train employeeson these key points:

• Perform a written hazardassessment.

• Select appropriate PPE toprotect workers.

• Maintain a written recordindicating that all employeeshave been properly trained in thefollowing before performing anyjob task requiring PPE:

- Determining when PPE is necessary

- Selecting the proper PPE for the job

- Properly removing, adjusting, and wearing PPE

- Understanding the limitations of the PPE

- Properly caring for, maintaining, using, and disposing of PPE

WWeeaarriinngg tthhee rreeqquuiirreeddPPPPEE wwiillll hheellpp kkeeeeppyyoouu ssaaffee..

SELECTING THE PROPER PPE FOR THE JOB

SELECTING PPE

IInnssttrruuccttiioonnssTurn to paaggee 5533 in your Participant Guide and review the job list of required PPE.

When you begin On-The-Job-Training, you will see these flow charts again.

Activity

PPE NEEDS

IInnssttrruuccttiioonnssAnswer the questions in the space provided.

1. What PPE is the box builder required to wear while filling the glue pot?

•

•

•

2. Who is required to wear ear plugs on the boxline?

•

•

3. What two pieces of PPE should all workers on the boxline have on at all times?

•

•

Activity

Each job function you perform will require PPE.


PPE LIMITATIONS

IInnssttrruuccttiioonnssCheck the correct box to each description

Activity POLICIES AND

PROCEDURES

IInnssttrruuccttiioonnssYour instructor will distribute policies.Please read and sign theacknowledgement that you have readand understood each policy.

Activity

Try on and adjust your hard hats,gloves, steel toe boots, ear plugs,and safety glasses. If you havequestions about the fit, ask yoursupervisor to assist you.

Things to look for:

• Each piece of PPE should fitsnugly—not too tight or loose.

• Inspect your PPE for damage. Ifyou notice damage, show yoursupervisor.

• Move around in your PPE tomake sure your range ofmovement has not been altered.

UUnnddeerrssttaannddiinngg tthhee lliimmiittaattiioonnss ooff tthhee PPPPEE

PPE helps prevent hazards fromcausing injury; however, PPE doesnot make you invincible. It isimportant to follow all safetyprocedures in conjunction withwearing PPE. In addition to usingPPE appropriately, remember thatevery piece of PPE has limitations.Examples include:

• Gloves that develop small holes

• Respirator cartridges becausethey generally do not indicatewhen they need replacement

Even appropriate PPE does notprovide a 100% guarantee of safety!

PPrrooppeerrllyy ccaarriinngg ffoorr,, mmaaiinnttaaiinniinngg,,uussiinngg,, aanndd ddiissppoossiinngg ooff PPPPEE::

The PPE issued to you is yourresponsibility.

To ensure each piece of PPE works properly:

• Check PPE daily for cracks, wornspots, and holes.

• Clean and properly store yourPPE to decrease wear and tear.

• If you notice issues with yourPPE, notify your supervisorimmediately.


PROPERLY REMOVING,WEARING,AND

ADJUSTING PPE


Hard hats can withstand any amount of pressure.

Safety glasses protect your eyes from pelletsand other debris.

Ear plugs should be replaced when theybecome dry and cracked.

Safety boots have steel toes and should fitcomfortably.

Any glasses are considered “safety glasses”if worn at work.


T F

T F

T F

T F

T F

48 PARTICIPANT GUIDE MODULE 3 ON-THE-JOB TRAINING (OJT)

ON-THE-JOB TRAINING (OJT)

This module will cover topics including:

• Watching the entire step-by-step process

• Performing each step on boxline

• Completing paperwork required for the boxline

By the end of this module, you should be able to:

OOJJTT DDaayy 33:: BBooxxlliinnee PPrroocceessss aanndd PPaappeerrwwoorrkk• Perform the processes on

the boxline

• Correctly complete boxline paperwork

OOJJTT DDaayy 44:: SSttaarrtt--uupp // CChhaannggeeoovveerr PPrroocceessssaanndd PPaappeerrwwoorrkk• Perform the Start-up /

Change Over Process

• Correctly complete Start-up /Change Over paperwork

OOJJTT DDaayy 55:: CClleeaann--uupp SSyysstteemm ##11,, 22,, aanndd 33 PPrroocceessss aanndd PPaappeerrwwoorrkk• Perform the processes

on the Clean-up System

• Correctly complete Clean-up System paperwork

49PARTICIPANT GUIDE MODULE 3 ON-THE-JOB TRAINING (OJT)

MODULE

33

44

55

3

51PARTICIPANT GUIDE MODULE 3 ON-THE-JOB TRAINING (OJT)

OOvveerrvviieewwOn-the-job Training (OJT) describestraining that is given in a normalworking situation, using the actual tools,equipment, documents, or materials thatyou use after you complete the training.Over the next three days, you willwatch, practice, and discuss boxlineprocesses with employees whocurrently work the boxline.

Each day, you will return to theclassroom, review the processflowchart, and discuss what waslearned. Most employees lookforward to OJT because the traininggives them a chance to practiceeach of the tasks that will berequired with an expert close by tooffer assistance.

OJT

50 PARTICIPANT GUIDE MODULE 3 ON-THE-JOB TRAINING (OJT)

KKeeyy PPooiinnttss• The team members you are

observing are not in training.They cannot leave their positionsor risk making mistakes.

• Be respectful of the expertsharing workspace with you. Ifthey need you to stand in aspecific area, or remain quietwhile they concentrate on aspecific task, please comply.

• Badges must be clipped inside apocket. Don’t wear anything thatcould accidentally fall into thefilled boxes.

• If you have any questions, feelfree to ask the Team Lead oryour trainer.

• Make sure you have theappropriate PPE on for eachposition.

OOvveerrvviieewwToday, you will take a closer look ateach position on the boxline. Youwill begin by watching the entireprocess from the green line. Then,you will be assigned to watch theprocess of an individual position.After shadowing each position, wewill meet in the classroom.

OJT DAY 3: BOXLINE PROCESS

WATCH ENTIRE PROCESS

FROM THE GREEN LINE

IInnssttrruuccttiioonnssReview the process flow Semi-Automatic Boxline with PE Liner Mapping found on ppaaggee 5533 of your participant guide.

Activity

1. Name the four positions on the boxline.

•

•

•

•

2. What could happen if the box builder doesn’t insert a liner correctly?

3. What did you find most interesting?

4. What challenges do you think you will face working this position?

5. How does the performance in each position affect the next positionand final product?

DebriefQuestions

DriverDelivers packaging materials to boxline (pallets, flat boxes, flat caps, PE liners, glue chips and tie wraps)

Required PPE- Safety glasses- Safety shoes- Hard hat- Ear plugs

Required Quality Checks Driver

1. Visually inspect PIT daily and document on inspection sheet.2. Inspect and pull needed material supplies from warehouse and move to designated boxline areas.

Driver1. Removes finished boxes (2 boxes/trip) from the conveyor. 2. Loads into trailer.


Required Quality Checks Driver

1. Inspect finished boxes for correct product and bar code labels with correct placement on box and for no box damaged.2. According to specified frequency, weigh boxes with floor scale and document on box weight check sheet.

Builder1. Builds boxes2. Places liners on and in box3. Moves box onto conveyor4. Places glue chips into melting container for gluing device and monitors.

Required PPE- Safety glasses- Safety shoes- Gloves

Required Quality Checks Builder

1. Takes samples from the dumper operator to the quality operator area and document into quality operator log book.2. Monitor glue pot during packaging process.

Dumper1. Advances pallet through gluing station and onto pallet/box staging station2. Advances box squarely onto pallet3. Places (1) product label and (1) bar code label on the box4. Places second bar code label on top corner of box.5. Advances box with liner to dump (fill) station.6. Fills box with product (1,102lbs.).7. Closes and ties wrap liner.8. Assists placement of lid (cap) onto box.9. Advances box to end of conveyor.10. Advances box to end of conveyor.

Required PPE- Safety glasses- Safety shoes- Hard hat- Gloves

Required Quality Checks Dumper

1. Takes samples from the dump station as specified per the Attachment 1 sheet.2. Documents samples and type taken on Attachment 1 sheet. 3. Visually inspects box for contamination.

Capper1. Places (1) product label and (1) bar code label on the box2. Builds box caps (lids).3. Places lid (cap) onto box.

Required PPE- Safety glasses- Safety shoes- Gloves

Required Quality Checks Capper

1. Take samples as specified on the "Attachment 1" sheet2. If required take "temperature"3. If required take "Vacuum Test" sample and fill out

Boxing Line vacuum test form1. Visually inspect top of box liner for contamination

Documents on "Bag Line Run Log": 1. All information required on top section of the form and: From to To Times, Lapsed Time Code, Type, Lot #, Pounds, Customer, Purge and Remarks (if applicable)

Support Processes:1. START-UP/RESTART PROCESS2. CLEAN-UP SYSTEM PROCESS3. GENERATING BAR CODE LABEL PROCESS4. PURGING PROCESS

Mapping (Semi-Automatic) Boxline With (”PE” Liner) Process

5. SAMPLING PROCESS6. BUILDING BOXES7. LABELING BOXES 8. DUMP PROCESS 9. BUILDING CAPS (LIDS)

Documentation:1. ATTACHMENT "1"2. ATTACHMENT "2"3. PACKAGING ASSIGNMENT SHEET4. LOT RECORD SHEET5. boxline RUN LOG

52 PARTICIPANT GUIDE MODULE 3 ON-THE-JOB TRAINING (OJT) 53PARTICIPANT GUIDE MODULE 3 ON-THE-JOB TRAINING (OJT)

ON THE JOB PRACTICE

IInnssttrruuccttiioonnssYour trainer will assign you to a specific position on the

boxline to practice with a team member who is currently assigned tothat position.

While on the line:

• Think about things you might want to review again in the classroom.

• Don’t be afraid to ask questions. It is better to ask, than to make acostly mistake.

• Be aware of what time you need to return to the classroom fordebriefing.

Activity

1. What do you think about what you experienced today?

2. What questions do you have about each position?

3. Is there anything you think could keep you from performing these tasks?

DebriefQuestions

CLOSER LOOK AT

EACH POSITION

IInnssttrruuccttiioonnssYour trainer will assign you to a specific position on theboxline to observe.

While on the line:

• Take a mental note of each step you observe.

• If you are given an opportunity to practice the task, and you feel confident you can accomplish the task successfully, feel free to practice.

• Your trainer will let you know what time to return to the classroomfor debriefing.

Activity

IInnssttrruuccttiioonnssAnswer the following questions in the space provided. Be prepared to share your responses with the class.

1. What PPE is required to work this line?

2. Who closes and tie wraps the liner?

3. Who moves the box onto the conveyor?

4. Who labels the box?

5. Who monitors the glue pot?

6. What do you do at each position when the Metal Alarm sounds?

DebriefQuestions

55PARTICIPANT GUIDE MODULE 3 ON-THE-JOB TRAINING (OJT)54 PARTICIPANT GUIDE MODULE 3 ON-THE-JOB TRAINING (OJT)

CCR (CentralControl Room) Capper

1. Go to CCR (Central Control Room).2. Acquire Packaging Assignment Sheet and Lot Record Sheet.


Clean-up System(if required) Dumper

1. Perform clean-up of system as specified in Clean-Up System Work Instruction.2. Document completion of clean-up on Cleanup System Checklist.3. Submit completed Cleanup System Checklist to quality operator.

Purge System(if required) Dumper

1. Perform system purge as specified in Purge System Work Instruction.

Bar Code AreaCapper

1. Pull The SF 3-ring binder.2. Enter the next sequence SF number and complete all but the "Lbs. of Total Lot" and "Finished By" columns.3. Record SF number onto the Packaging Assignment Sheet. In the Special Instructions section enter the boxline that will be running the product.4. Record the number of pounds that will be packaged on the Lot Record Sheet and Packaging Assignment Sheet.

Required PPE- Safety glasses- Safety shoes

Support Processes:1. GENERATING BAR CODE LABEL PROCESS2. CLEAN-UP SYSTEM PROCESS3. PURGING SYSTEM PROCESS

Documentation:1. ATTACHMENT 12. ATTACHMENT 23. PACKAGING ASSIGNMENT SHEET4. LOT RECORD SHEET5. SF 3-RING BINDER & LOG SHEET6. PRODUCT CLEANUP SYSTEM SHEET

Mapping of Start-Up/Change Over Process

- Aquire from the Quality Operator the: • Attachment 1 Sheet • Attachment 2 Sheet • Product Cleanup Systems Sheet (if required)

Quality Operator Area Capper

Bar Code LabelsBuilder

1. Remove bar code labels from previous run lot number and turn into shift supervisor/office. Dumper2. Make bar code labels for the next scheduled lot number as specified in the Generating Bar Code Label Work Instruction and Attachment #2. Builder3. Place bar code labels on boxline (Dump Station Area). Builder

Product LabelsBuilder

1. If product is different than previous run lot product labels, then return them to the warehouse storage location.2. If line callout is different, change liner.3. Go to storage area on line and pull product labels or the product scheduled to run as specified in Attachment 2. If not in storage area go to the warehouse storage.4. Place product labels at the dumper and capper areas.



IInnssttrruuccttiioonnssReview the process flow Start-up / Change overProcess found on ppaaggee 5577 of your participant guide.

Activity

1. What tasks are being done at each activity location?

•

•

•

•

2. What tasks did you find most interesting at each activity location?

3. What appeared challenging about the tasks at each activity location?

4. Who is responsible for each activity location?

5. What PPE is required for each activity location?

•

•

•

6. What documentation do you need for each activity location and how is it documented?

DebriefQuestions


OJT DAY 4:

START-UP / CHANGE OVER PROCESS

• Be familiar with the SF binder.

• Be able to identify Attachment 1 and 2 sheets.

• Know the required PPE in each area.

OOvveerrvviieewwThe start-up / change over process is onlyperformed by the Dumper and a Lead. Today, youwill participate in the paperwork and process steps.

KKeeyy PPooiinnttss• Get the proper paperwork from the control room.

• Record information in the bar code area.

• Collect proper paperwork from the qualityarea and create labels.


CLOSER LOOK AT

EACH ACTIVITY

IInnssttrruuccttiioonnssYour trainer will assign you to a specificposition on the boxline to observe.

While on the line:


• If you are given an opportunity to practice the task,and you feel confident you can accomplish the tasksuccessfully, feel free to practice.

• Your trainer will let you know what time to return tothe classroom for debriefing.

Activity ON THE JOB

PRACTICE

IInnssttrruuccttiioonnssYour trainer will assign you to a specific

position on the boxline to practice with a teammember who is currently assigned to that position.

While on the line:

1. Think about things you might want to reviewagain in the classroom.

2. Don’t be afraid to ask questions. It is better toask, then to make a costly mistake.

3. Be aware of what time you need to return to theclassroom for debriefing.

Activity

IInnssttrruuccttiioonnssAnswer the following questions in thespace provided. Be prepared to shareyour responses with the class.

1. What is the first work area visited in the Start-up /Change over Process?

2. Who is responsible for the Start-up / Change over Process?

3. After reviewing the flow chart, which task seemsmost challenging?

4. How will you overcome that challenge?

DebriefQuestions 1. What do you think about what you

experienced today?

2. What questions do you have about each activity locaton?

3. Is there anything you think could keep you fromperforming these tasks?

DebriefQuestions

CLOSER LOOK AT

EACH ACTIVITY

IInnssttrruuccttiioonnssYour trainer will assign you to a team

member who is performing the clean-up system processfor you to observe.

While on the line:


• If you are given an opportunity to practice the task,and you feel confident you can accomplish the tasksuccessfully, please feel free to practice.

• Your trainer will let you know what time to return tothe classroom for debriefing.

Activity ON THE JOB

PRACTICE

IInnssttrruuccttiioonnssYour trainer will assign you to a specific

position on the boxline to practice with a teammember who is currently assigned to that position.

While on the line:

• Think about things you might want to reviewagain in the classroom.

• Don’t be afraid to ask questions, it is better toask, then to make a costly mistake.

• Be aware of what time you need to return tothe classroom for debriefing.

Activity

IInnssttrruuccttiioonnssAnswer the following questions in thespace provided. Be prepared to shareyour responses with the class.

1. What is the first work area visited in the Clean-upSystem Process?

2. Who is responsible for the Clean-up SystemProcess?

3. After reviewing the flow chart, which task seemsmost challenging?

4. How will you overcome that challenge?

DebriefQuestions

1. What do you think about what you experienced today?

2. What questions do you have about each activity locaton?

3. Is there anything you think could keep you fromperforming these tasks?

DebriefQuestions


IInnssttrruuccttiioonnssReview the process flow Clean-Up SystemWith Scalperator #1, 2 and 3 Mapping foundon ppaaggeess 6622--6633 of your participant guide.

Activity

1. What tasks are being done at each activity location?

•

•

•

•

2. What tasks did you find most interesting at each activity location?

3. What appeared challenging about the tasks at activity location?

4. Who is responsible for each activity location?

5. What PPE is required for each activity location?

•

•

•

6. What documentation do you need for each activity location, and how is it documented?

DebriefQuestions


OJT DAY 5:

CLEAN-UP SYSTEMS #1, 2,AND 3 PROCESS

OOvveerrvviieewwThe Clean-up System Process is completed by two teammembers. This task is not performed on every shift, soyour on-the-job practice might not be in a live environ-ment today. When you are required to perform the taskslisted in this process you will have the necessary supportand team member to perform the tasks with you.


13. T

horo

ughl

y bl

ow o

ff w

eigh

ts a

nd d

oor.

14. U

sing

com

pres

sed

air,

blow

out

cha

mbe

r

from

top

to b

otto

m, u

ntil

all l

oose

pel

lets

and

sn

akes

kins

are

rem

oved

.15

. Tho

roug

hly

blow

off

scal

pera

tor r

eel

un

til a

ll lo

ose

pelle

ts a

nd s

nake

skin

s

are

rem

oved

.16

. Tho

roug

hly

blow

out

beh

ind

reel

to

re

mov

e al

l loo

se p

elle

ts.

17. T

horo

ughl

y bl

ow o

ut in

side

of r

eel.

18. V

isua

lly in

spec

t cha

mbe

r to

ensu

re

al

l loo

se p

elle

ts h

ave

been

rem

oved

.19

. Use

com

pres

sed

air t

o re

mov

e "fi

nes"

and

loos

e pe

llets

from

wip

er b

lade

s.20

. Use

com

pres

sed

air t

o bl

ow o

ut th

e

"fine

s ch

ute"

to re

mov

e al

l fin

es th

at h

ave

ac

cum

ulat

ed fr

om p

revi

ous

lot.

21. C

lose

doo

r com

plet

ely

whe

n fin

ishe

d.22

. Rem

ove

plex

igla

ss d

oor.

23. M

ove

hand

le u

p an

d do

wn

7 tim

es to

disl

odge

loos

e pe

llets

.

CO

NT

RO

L R

OO

M (

CC

R)

1. T

ags

out s

yste

m in

con

trol r

oom

.

Req

uire

d P

PE

- Sa

fety

gla

sses

- Sa

fety

sho

es-

Lock

s-

Lock

tags

Fill

out

blu

e sa

fety

tag

(in

ink)

wit

h th

e fo

llow

ing

info

rmat

ion

in b

lock

lett

ers:

4. G

roup

: Con

tract

or

5. F

irm: U

nite

dSab

ine

6. N

ame

of E

mpl

oyee

:

LE

VE

L A

: E

LU

TIA

TO

R1.

Tak

e of

f and

cle

an d

oor.

2. C

lean

insi

de o

f elu

triat

or.

3. R

epla

ce d

oor.

Req

uire

d P

PE

- Sa

fety

gla

sses

- Sa

fety

sho

es-

Hard

hat

- Ea

r plu

gs-

Glov

es-

Face

shi

eld

- Lo

cks

- Lo

ck ta

gs

1.

Rem

ove

door

by

taki

ng o

ff w

ingn

uts.

2.

Plac

e w

ingn

uts

on ri

dge

abov

e op

enin

g.3.

Pl

ace

door

on

deck

aga

inst

elu

triat

or.

4.

Clea

n do

or u

sing

com

pres

sed

air.

5.

Clea

n do

or m

ount

ing

ledg

e of

pel

lets

6.

Clea

n do

or u

sing

com

pres

sed

air.

7.

Clea

n do

or m

ount

ing

ledg

e of

pel

lets

.8.

Bl

ow o

ut th

orou

ghly

with

com

pres

sed

air

fro

m to

p to

bot

tom

, inc

ludi

ng fu

nnel

, unt

il

all l

oose

pel

lets

are

rem

oved

.

9.

Look

for c

rack

s or

cr

evic

es w

here

pelle

ts o

r sna

kesk

ins

m

ight

han

g.10

. Vis

ually

insp

ect

ch

ambe

r to

ensu

re

al

l loo

se p

elle

ts

ha

ve b

een

rem

oved

.11

. Rem

ount

doo

r and

tight

en w

ingn

uts.

LE

VE

L C

:SC

AL

PE

RA

TO

R #

1

1. L

ock

and

tag.

2. C

lean

top

of

sc

alpe

rato

r.3.

Ope

n sc

alpe

rato

r #1

door

.4.

Cle

an w

eigh

ts.

5. C

lean

reel

s.6.

Cle

an w

iper

bla

des.

7. C

lean

“fin

e” c

hute

s.8.

Cle

an s

crew

.

Req

uire

d P

PE

- Sa

fety

gla

sses

- Sa

fety

sho

es-

Glov

es-

Face

shi

eld

- Lo

cks

- Lo

ck ta

gs

1.

Turn

"Sta

rt" s

witc

h to

"RUN

" pos

ition

.

Scal

pera

tor s

houl

d st

art r

unni

ng.

2.

Turn

-off

mai

n di

scon

nect

leve

r.3.

Tu

rn “

Star

t” s

witc

h to

"RUN

" pos

ition

.

Scal

pera

tor s

houl

d no

t run

. 4.

Pl

ace

whi

te "D

ANGE

R" T

ag o

n St

art

(F

ield

) sw

itch.

5.

In

stal

l loc

k an

d w

hite

"DAN

GER"

tag

on

m

ain

disc

onne

ct.

6.

Usin

g co

mpr

esse

d ai

r, th

orou

ghly

blo

w

to

p of

sca

lper

ator

unt

il al

l loo

se p

elle

ts

an

d sn

akes

kins

hav

e be

en re

mov

ed.

7.

Undo

all

4 qu

ick

latc

hes

and

open

doo

rs

co

mpl

etel

y.8.

Us

ing

com

p res

sed

air,

thor

ough

ly b

low

out f

rom

top

to b

otto

m, u

ntil

all l

oose

pelle

ts a

nd s

nake

skin

s ha

ve

be

en re

mov

ed.

9.

Visu

ally

insp

ect c

ham

ber t

o en

sure

all

lo

ose

pelle

ts h

ave

been

rem

oved

.10

. Clo

se d

oors

and

refa

sten

with

LE

VE

L B

: EL

UT

RIA

TO

RR

OTA

RY V

ALV

E1.

Tur

n on

/off

rota

ry v

alve

to c

lear

elut

riato

r sys

tem

.

1. H

old

switc

h to

"STA

RT" p

ositi

on fo

r 5 s

econ

ds.

2. R

elea

se fo

r 2 s

econ

ds.

3. R

epea

t ste

ps 1

and

2.

1. R

easo

n: C

lean

up

syst

em

2.

Tag

loca

tion:

Bld

g. 5

343.

Equ

ipm

ent N

ame:

Req

uire

d P

PE

- Saf

ety

gla

sses

- Saf

ety

sho

es

Map

ping

of C

lean

-Up

Syst

em P

roce

ss W

ith S

calp

erat

or #1

- Har

d ha

t- E

ar p

lugs

- Glo

ves

- Fac

e sh

ield

LE

VE

L D

: KIC

K V

ALV

E1.

Alig

n ki

ck v

alve

to li

ne.

LE

VE

L H

UH

: HO

LD

UP

HO

PP

ER

1. C

lean

doo

r.2.

Cle

an h

oppe

r cha

mbe

r.

LE

VE

L B

OX

LIN

E: S

LID

E G

AT

E/

DU

MP

SP

OU

T

1. C

lean

slid

e ga

te/d

ump

spou

t.

24. R

epla

ce p

lexi

glas

s do

or.

25. U

nlat

ch s

crew

doo

r and

blo

w o

ut w

ith

co

mpr

esse

d ai

r unt

il al

l loo

se p

elle

ts,

sn

akes

kins

, and

fine

s ar

e re

mov

ed.

26. P

ull d

oor o

ut to

allo

w re

sidue

to fa

ll out

.27

. Use

com

pres

sed

air t

o re

mov

e al

l sna

kesk

ins.

1. C

over

all

prod

uct b

oxes

at t

he p

acka

ging

line

(em

pty

and

full)

.2.

Rem

ove

both

doo

rs b

y un

latc

hing

the

2

latc

hes.

3. U

se c

ompr

esse

d ai

r to

thor

ough

ly b

low

out s

cale

s to

rem

ove

all l

oose

pel

lets

an

d sn

akes

kins

.4.

Vis

ually

insp

ect s

cale

s to

ens

ure

all l

oose

pelle

ts h

ave

been

rem

oved

.

5. C

lose

and

rela

tch

both

doo

rs.

6. O

pen

scal

e do

or b

y lo

osen

ing

2 w

ingn

uts.

7. U

se c

ompr

esse

d ai

r to

thor

ough

ly b

low

out s

cale

s to

rem

ove

all l

oose

pelle

ts a

nd s

nake

skin

s.8.

Vis

ually

insp

ect s

cale

s to

ens

ure

all

lo

ose

pelle

ts h

ave

been

rem

oved

.9.

Clo

se a

nd re

latc

h do

or.

LE

VE

L D

: M

AG

NE

TS

1. C

lean

mag

nets

.2.

Cle

an m

agne

t pot

.

LE

VE

L: B

OX

LIN

E:

PAC

KA

GIN

G S

CA

LE

S

1. P

reve

nt c

onta

min

atio

n.2.

Cle

an s

cale

s.

Req

uire

d P

PE

- Sa

fety

gla

sses

- Sa

fety

sho

es-

Hard

hat

- Ea

r plu

gs-

Glov

es-

Face

shi

eld

1. R

emov

e do

ors

by u

nscr

ewin

g th

e

2 w

ingn

uts.

2.

Rem

ove

all 4

mag

nets

and

che

ck fo

r

met

al o

n m

agne

ts. I

f you

find

met

al,

re

port

it to

DuP

ont Q

ualit

y Op

erat

or

imm

edia

tely

.3.

Use

com

pres

sed

air t

o th

orou

ghly

clea

n m

agne

ts.

4. R

eins

tall

all 4

mag

nets

.

5. C

lose

doo

r and

rein

stal

l 2 w

ingn

uts.

6. R

emov

e po

t und

er m

agne

ts.

7. U

se v

acuu

m h

ose

to s

uck

all l

oose

pelle

ts fr

om p

ot. D

o no

t dum

p lo

ose

pe

llets

on

roof

.8.

Use

com

pres

sed

air t

o cl

ean

all r

esid

ue

fro

m p

ot.

9. R

eins

tall

pot u

nder

mag

nets

.

1. U

se le

ver t

o al

ign

kick

val

ve to

pro

per s

yste

m

(R

ight

sid

e is

box

line

#1. L

eft s

ide

is b

oxlin

e #2

.2.

Cal

l CCR

to v

erify

kic

k va

lve

is a

ligne

d co

rrec

tly.

qu

ick

latc

hes.

11. L

ift d

oor u

p to

ope

n an

d bl

ow o

ff

ledg

e co

mpl

etel

y.12

. Pul

l wei

ghts

bac

k an

d fo

rth 7

tim

es to

ensu

re n

o lo

ose

pelle

ts a

re st

uck o

n to

p

of d

oor.

3. U

se c

ompr

esse

d ai

r to

thor

ough

ly b

low

out H

UH c

ham

ber f

rom

top

to b

otto

m u

ntil

al

l pel

lets

and

sna

kesk

ins

are

rem

oved

.4.

Vis

ually

insp

ect c

ham

ber t

o en

sure

all

lo

ose

pelle

ts h

ave

been

rem

oved

.5.

Clo

se a

nd s

ecur

e do

or.

1. O

pen

HUH

door

by

lo

osen

ing

win

gnut

s.2.

Use

com

pres

sed

air t

o cl

ean

al

l loo

se p

elle

ts fr

om b

acks

ide

of

doo

r and

doo

r led

ge.

Req

uire

d P

PE

- Sa

fety

gla

sses

- Sa

fety

sho

es-

Hard

hat

- Ea

r plu

gs-

Glov

es-

Face

shi

eld

1. U

se c

ompr

esse

d ai

r to

blow

all

loos

e pe

llets

from

slid

e ga

te a

nd d

ump

spou

t.R

equi

red

PP

E- S

afet

y g

lass

es- S

afet

y s

hoes

Req

uire

d P

PE

- Saf

ety

gla

sses

- Saf

ety

sho

es

- Har

d ha

t- E

ar p

lugs

- Glo

ves

- Fac

e sh

ield

Req

uire

d P

PE

- Saf

ety

gla

sses

- Saf

ety

sho

es

- Har

d ha

t- E

ar p

lugs

- Glo

ves

- Fac

e sh

ield

- Har

d ha

t- E

ar p

lugs

- Glo

ves

- Fac

e sh

ield


REVIEWING AND

COMPLETING PAPERWORK

IInnssttrruuccttiioonnssReview the completed paperwork examples. Answer the following questions.

1. List an example of something that would be acceptable in the fieldmarked Code (11):

2. What does the Lot # field represent?

3. How often does this form get completed?

4. Where does this form get turned in?

5. Would it be a good idea to allow someone else to complete yourpaperwork? Why or why not?

Activity FFoorrmm NNaammee Lot record sheet

Assignment sheet

Required Sampling forPackaging/Hopper CarsProcedure# CSD-9 Att. 1-Every lot

Box weight check sheet-Procedure # 4 Att-1- Every lot

Direct Box Weight Data Sheet-Procedure # 4 Att- 2 - Every lot

Cleanup system checklist-Procedure #2- Att.1-Every lot

Partial box procedure-Procedure#13-Att. 1

Boxing line vacuum test-Procedure#24-Att.1-Surlyn Products only

150C/150CW/CM4987WTemperature monitoring-Procedure18 Att. -Elvax product only

Elvax/Bynel Package TemperatureChecklist-Procedure 18 Att. 2-Evlax/Bynel product only

Blender and Package Sample Log-SML001

WWhheerree UUsseedd1) Boxlines: 1 and 22) Bag Lines: 1 and 23) Direct Boxline: 3, 165, and 7004) HC (Hopper Car) Areas: 166 and 189

1) Boxlines: 1 and 22) Bag Lines: 1 and 23) Direct Boxline: 3, 165, and 7004) HC (Hopper Car) Areas: 166 and 189

1) Boxlines: 1 and 22) Bag Lines: 1 and 23) Direct Boxline: 3, 165, and 7004) HC (Hopper Car) Areas: 166 and 189

1) Boxlines: 1 and 22) Direct Boxlines: 3, 165, and 700

1) Direct Boxlines: 165 and 700

1) Boxlines: 1 and 22) Bag Lines: 1 and 23) Direct Boxline: 3 and 1654) HC (Hopper Car) Areas: 166

1) Boxlines: 1 and 22) Direct Boxlines: 3, 165, and 700

1) Boxlines: 1 and 22) Bag Line: 1 3) Direct Boxline: 700

1) Boxlines: 1 and 22) Bag Line: 1 3) Direct Boxline: 3 and 1654) HC (Hopper Car) Areas: 166

1) Boxlines: 1 and 22) Bag Line: 1 3) Direct Boxline: 3 and 1654) HC (Hopper Car) Areas: 166

WWhheenn UUsseeddUsed on every lot runNote: Used to verify AssignmentSheet Information is correct.

Used on every lot run


Used on every lot run for1st/Midde/Last

Used on every lot run for every box produced


Used on every lot run wherepartial is 200 lbs.

Used on every lot run whereSurlyn products are produced

Used on every lot run where Elvax products are produced

Used on every lot run where Elvax products are produced

The following table lists:

• The name of each form requiredat UnitedSabine

• Where to use each form

• When to use each form

If you have questions about whatneeds to be completed for eachposition and line, refer to this table.

OJT:

PAPERWORK

OOvveerrvviieewwEach position at UnitedSabinerequires documentation of thetasks performed. Over the lastthree days, you have observed andpracticed most of the tasks on theboxline including requiredpaperwork. For this section of thetraining, we are going to take acloser look at the paperwork youwill be required to complete uponcompletion of this course.

KKeeyy PPooiinnttss• Reviewing and

completing paperwork

• When to use each type of form

GLOSSARY OF TERMS

BBuuiillddeerrPerson who builds the box, places liner in thebox, moves the box onto the line, and adds glueschips to glue pot as needed.

CCaallll--oouuttPerson who is scheduled off from work, but whomust report to work unless called by supervisorto not report to work.

CCaappppeerrPerson who builds the box cap, seals the liner,places cap and labels onto the finished box, and records boxline activities onto Boxline Run Log.

CCCCRRCentral Control Room

CCUUSSClean-Up System

DDeeaall BBrreeaakkeerrUnsafe or unauthorized activity that can result intermination from UnitedSabine and DuPont.

DDrriivveerrPerson who delivers raw materials andpackaging to the line using PIT equipment andremoves finished products (Boxes or Pellets)from line to trailer or warehouse location.

DDuummppeerrPerson who places and aligns boxes on a pallet,places labels onto box, fills the box and conveysthe box to the next operation. This personperforms system clean-up and sampling.

EEsssseennttiiaall MMaatteerriiaallssLocation where packaging and labelingmaterials are located.

HHUUHHHold-Up Hopper

IISSOO 99000011A set of certification standards for qualitymanagement. UnitedSabine is ISO 9001 certified.

LLooaaddiinngg DDoocckkArea where finished product is placed in trailers and paperwork is generated to shipfinished product.

MMSSDDSSMaterial Safety Data Sheet

OOSSHHAAOccupational Safety and Health Association

PPaalllleett SSttoorraaggeeLocation where pallets are stored.

PPIITTPowered Industrial Truck (Forklift)

PPPPEEPersonal Protective Equipment

SSPPDuPont Safety Procedure

SSPP11Safety Orientation Program and General PlantSafety Rules

SSPP55Lock, Tag & Try. Lock out energy source, placepersonal tag on lockout item, and test/try toconfirm the energy source is not on.

TTiigghhtteenn--UUppTo eliminate gaps between boxes on the emptybox conveyor.

66 PARTICIPANT GUIDE GLOSSARY OF TERMS