That tool is information, presented in the form of equipment safety data sheets. The one-page descriptions are the brainchild of Joseph G. Boris, the packaging manager for the unit of Copley Chicago Newspapers in Plainfield, Ill.

In 1998, the data sheets helped cut the number of Occupational Safety and Health Administration recordable accidents in the round-the-clock department from 13 between January and June to two since July—and wins the 1999 TechNews Best Practices Award for health and safety.

“It’s innovative—that’s what sets them apart,” says Don Hensel, NAA’s environmental-services manager. The cut in recordable accidents can be viewed as an “exceptional” achievement, he adds.

Boris concedes the idea wasn’t entirely his. “I stole it,” he says, from a widely used form for the safe handling of hazardous chemicals. Safety had become an issue at Fox Valley as the facility switched from producing evening to morning newspapers in April 1997, at the same time boosting its output of zoned weeklies and taking on a major commercial-printing account.

“Our safety program blew up in our face,” Boris says. As three shifts a day were implemented six days a week, 11 accidents occurred in the second half of 1997.

With the safety of more than 100 people at risk, and such accidents costing an average of $3,500 each, Boris decided to focus on each piece of equipment. He detailed Colleen Corniels, one of six packaging supervisors, to develop the single-page sheets for each of more than 30 pieces of machinery.

“When I originally designed the sheet,” Corniels says, “I wanted to make it something in which I could incorporate the biggest hazards and something that would be common to every piece of machinery.” Drawing on her technical experience, she extracted crucial data about each machine from manufacturers’ documentation and from the technicians who regularly work on inserters, stackers, strappers and other hardware.

The data sheets provide accident-prevention information, such as warnings specific to a given machine, safety requirements for using a machine, the steps needed to ensure a device is safely shut down for maintenance, and lists of personnel authorized to use or service equipment. For example, users of automatic guided vehicles, which move reels of paper around the work area, are alerted to the fact that the vehicles guide themselves automatically and therefore start and stop unexpectedly—and also contain high voltage.

Since the sheets were introduced in April, employees have attended weekly or semi-weekly training sessions at which information is reviewed, questions are asked and dedication to safety is reinforced.

THE WINNERS Pre-Press Press Post-Press Materials Table of Contents

The training sessions have proved integral to bringing workers up to speed and keeping them there, says Production Manager Brian Hutson. “The goal is to put the information out there,” he says, “not just throw it out there and make it sit, but to make sure people know what’s there.”

Boris attributes the program’s success to the department’s supervisors, who bring a positive attitude and genuine concern to the training sessions.

“When people work for us,” he concludes, “people are safer.”