Space & Life Sciences Directorate Safety, Reliability, and Quality Assurance Office NASA Johnson Space Center, Houston, Texas 3/4/02Sean Keprta (281) 483-7896

3/4/02 Sean Keprta (281) 483-7896 Stacey Nakamura (281) 483-4345

1

Space & Life Sciences DirectorateSafety, Reliability, and Quality Assurance OfficeNASA Johnson Space Center, Houston, Texas

JSC Safety & Health Program is in Excellent Condition


2


• SOLAR Safety Courses:– JSC & WSTF currently using

• “Home grown” courses– WSTF Employee S&H Training

– JSC Safety Through Everyone’s Participation (STEP)

– Senior Manager’s Safety Course

• NSTC Courses– System Safety, Facility Systems Safety

– Currently planning next generation training• Expect a mixture of IBT and SOLAR CBT

– Current SOLAR content is great


3

Space & Life Sciences DirectorateSafety, Reliability, and Quality Assurance OfficeNASA Johnson Space Center, Houston, TexasJSC Team VPP Accomplishments

• United Space Alliance - Logistics Support Facility– STAR, 1997, Re-certified, July 2001

• JSC– STAR, May 1999, Re-certification scheduled July 29-Aug 2, 2002

• United Space Alliance – 600 Gemini Facility– STAR, July 2000

• United Space Alliance - USA Headquarters Building– STAR, July 2000

• United Space Alliance - Flight Crew Equipment (FCE) Facility– STAR, July 2000

• United Space Alliance - JSC Operations– STAR, July 2000

• SAIC– STAR, July 2000

• Brown And Root Services Pioneer– Merit, September 2000, STAR, January 2002

• Rigging and Welding Specialists– Merit, May 2001

RWS first sub to a sub to a prime

BRSP went for STAR even though knocked out of rebid


4

Space & Life Sciences DirectorateSafety, Reliability, and Quality Assurance OfficeNASA Johnson Space Center, Houston, TexasJSC Team VPP – Works in Progress

• Lockheed-Martin, SEAT Onsite and Offsite– STAR, August 2001

• NASA/JSC White Sands Test Facility– STAR, December 2001

• Honeywell Technologies @ WSTF– STAR, January 2002

• Oceaneering– Application targeted for April 2002

• Hamilton Sundstrand– Application targeted for March 2002

• Wyle Labs– Application targeted for April 2002

• Boeing (Sonny Carter Training Facility)– Planning complete, beginning implementation, March 2002

Simultaneous Applications

Simultaneous Site Visit

Simultaneous Flag Ceremony


5

Space & Life Sciences DirectorateSafety, Reliability, and Quality Assurance OfficeNASA Johnson Space Center, Houston, TexasJSC VPP – NASA Works in Progress

• Johnson Space Center– STAR May 1999

– Re-certification July 29-Aug 2, 2002

• White Sands Test Facility– STAR December 2001

• Sonny Carter Training Facility– Application to submitted December 2001

– *NASA Pre-assessment scheduled for April/May• Requesting HQ Code Q Support

• Ellington Field– Completing External Safety Survey action items

– Conducting Program and Procedures Review


6


WSTF and Honeywell VPP STAR Flag Ceremonies


7


WSTF VPP Status

WSTF / Honeywell VPP– OSHA Region VI Assessment performed

August 2001– Simultaneous NASA & Honeywell assessment– Assessment team included OSHA, SGE

(process safety), and New Mexico State OSH (observers)

– Pilot VPP assessment review for New Mexico OSH program (WSTF app. used as template)

– Over 100 maintenance items corrected concurrent with assessment activities


8


WSTF VPP Status (cont’d)

WSTF / Honeywell VPP– Four “Star contingency” items identified

• Improve hazard recognition -- training provided

• Plan and implement machine guarding -- long and short term machine guarding plan in place

• Institute effective ladder inspection process -- now subject to user inspection and annual integrity audit

• Ensure integrity inspection performed and documented on all fall protection equipment -- now inventoried and subject to annual integrity audit


9



WSTF / Honeywell VPP– Contingency items were not formally noted in

OSHA’s final report because of their confidence in WSTF’s corrective action process

– All items have since been addressed– Formal VPP approval December 2001– Flag ceremony conducted February 26, 2002

with OSHA, NM OSH, NASA HQ, JSC, and Honeywell Corporate


10



WSTF / Honeywell VPP

Biggest Hurdles– Gaining understanding that VPP is above requirements

This was particularly difficult when challenged to provide “regulations” for good Job Hazard Analysis practices - a good lesson in OSHA “expectations”

– Ensuring that employee concerns (regulatory or not) are addressed objectively by management

– Managing perceptions - use PEP as a measuring stick for effective communication


11



WSTF / Honeywell VPP

What Works– Benchmark, benchmark, benchmark

Include labor representatives in benchmarking

– Use frequent peer & mock assessments

– HQ PV process is a good preparation

– Let employees learn the regulations

– Turn your safety & health professionals into consultants

Answer questions and resist temptation to direct compliance because “you know what’s best”


12


JSC Team Safety Metrics Status

Category Actual Goal StatusLost Workday Case Frequency Rate

0.24 0.2 R

OSHA Recordable Rate (includes days away, restricted duty, & medical treatment)

1.2 0.93 R

Severity Rate 6.1 6.0 R

Days Away 277(172 from previous FY

LWDCs)

N/A N/A

Close Calls 235 N/A N/A

•GreenGreen = Meets or exceeds JSC Goal YellowYellow = Does not meet JSC Goal, but within 15%•RedRed = Does not meet JSC Goal, not within 15%


13


JSC Vision: Hurt No One – Zero OSHA RecordablesCenter Top 3 (BBS) Categories to Attack:

Eyes on Path

Line of Fire

Repetition


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Eyes on Path


15


JSC Team FY02 LWDC Total Below FY01 Total Onsite Cases Only

JSC Team Lost Workday Case Comparison FY99 / 00 / 01 / 02

2828

24

21

17

15

11

6

2322

2018

17

13

4

26

28

32

6

11

13

16

21

33

40

38

2

995

79

0

5

10

15

20

25

30

35

40

45

Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep

Cumulative Lost Workday Cases FY99





16


JSC Has Reduced Lost Workday Case Rates for FY94-00 LWDC Frequency Rates for FY01 - FY02 are Greater than FY00 Rate

JSC Team Lost Workday Case Frequency Rate

ONSITE - Lost Workday Case Frequency Rate History

1.08

0.67

0.61

0.3 0.28

0.43

0.290.35

0.36

0

0.2

0.4

0.6

0.8

1

1.2

FY

94

FY

95

FY

96

FY

97

FY

98

FY

99

FY

00

FY

01

FY

02

DuPont LWDC Frequency Rate = 0.1


17


JSC Team Lost Workday Cases FY94- FY02

91

58

51

3228 26

40

9

35

0

10

20

30

40

50

60

70

80

90

100

FY94 FY95 FY96 FY97 FY98 FY99 FY00 FY01 FY02

# C

ases


18


JSC Team Onsite Lost Workday Cases/Rates FY94-02

91

58

51

32

9

28 26

4035

0.43

0.67

1.08

0.61

0.4

0.350.3 0.28 0.29

0

20

40

60

80

100

120

140


0

0.2

0.4

0.6

0.8

1

1.2

Lost Workday Cases LWDC Frequency Rate


19


JSC Team LWDC by BBS Category - FY01

0

2

4

6

8

10

12

14

16

JSC Team LWDC by BBS Category - FY02

0

1

2

3

4

5

6

7

8

JSC Team Top 6 BBS Categories - OSHA Recordable - FY01

0

10

20

30

40

50

60

70

JSC Team Top 6 BBS Categories - OSHA Recordable -

FY02

0

2

4

6

8

10

12

14

16

18

20


20


JSC Team LWDC by Category- FY01

12

3 32

1 1 1 1 1

15

0

2

4

6

8

10

12

14

16

18

20

JSC Team LWDC by Category - FY02

6

1 1 1

0

1

2

3

4

5

6

7

8

9

10


21


JSC Team LWDCs By Organization FY02

0

1

2

3

4

5

BRSP (JA) Wyle Labs(SA)

InformationSystems/CS

(GA)

IMPASS(GA) LockheedMartin (CA)

Johnson Eng.(DA)

Kelsey-Seybold (SA)

Space FamilyEdu. (AH)


22


JSC Team LWDC by Location FY02

0

1

2

3

4

5

6

7

8

9

10

JSC Site B261 SCTF / 920 L B8 E135 SCTF / 920 N B211


23


JSC Team Lost Workday Case Frequency Rates vs Close Calls

195

998

1161

60

409

456

994

741

0.43

0.280.3

0.350.4

0.61

0.67

1.08

0

200

400

600

800

1000

1200

1400

FY94 FY95 FY96 FY97 FY98 FY99 FY00 FY01

Lost W

orkday C

ase Frequen

cy

0

0.2

0.4

0.6

0.8

1

1.2

Close Calls LWDC Frequency Rate

Clo

se C

alls

Close Call Reports Have Declined for FY01,

Lost Workday Rates Have Increased


24


JSC Team Onsite OSHA Recordable Cases/Rates FY94-02

206

159148 143 143 139

171

213

50

1.6

2.2

1.9

1.51.61.6

1.81.8

2.4

0

50

100

150

200

250

300

350


0

0.5

1

1.5

2

2.5

3


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• Enhancements to Mishap Prevention - JSC– Off-The-Job Safety Initiative

• Part of the “Safety-Triad”– Flight / Ground / Home

– Emphasis on Contractors• Contractor Safety Forum

– First Baby Steps in Behavior Based Safety• Awaiting New JSC Center Director’s “Go”

– Promote VPP among Contractors– Maintain VPP Certification


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• Enhancements to Mishap Prevention - JSC– Root Cause Training (over and over again)

• Pursuing COTS Software• United Space Alliance is using “REASON”• Pushing to have “Root Cause” facilitation software linkage in

IRIS2

– Re-Affirm Top Management Commitment to S&H Program

• Assisting in New Center Director Transition

– Aggressive Cof F / M&O Budget Partnering with JSC Center Operations Directorate

• 2002 PEP results – employee write in comments– “Where’s the safety fix-it money?”

• Need Code Q Support during HQ-level POP Process


27


WSTF Strategic Planning for Injury Reduction

Objective 5-1“Reduce each year’s injury and severity rates by 20 percent per year from the 1998–2000 baseline.”– This is an aggressive objective to ensure WSTF

pursues improvement from VPP application baseline.

– WSTF philosophy -- “If zero is possible we must target it to have hope of achieving it.”


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Achievements• NASA, HTSI, & Lynx (environmental

subcontractor) all met 20% reduction in 2001• Additional 20% reduction achievable for ALL

WSTF employees in 2002– Significant improvement is evident in L&M

(construction & logistics subcontractor) performance since Summer 2001



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Identifying Obstacles

Analysis with Keystone, Safety, Management, and HSE personnel of: – VPP gaps and assessment results

– PEP scores and perceptions

– Strategic Planning brainstorming efforts

– Keystone inputs

– Behavior Based Safety concepts

– Unfinished business



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The 4 Greatest Obstacles

#1 Winning Leadership Hearts and MindsSupervisors/Leads must demonstrate safety leadership and be accountable for injury PREVENTION before the event

#2 Bolstering Employee ResponsibilityEmployee safety maturity is growing, but some do not take it as a personal responsibility for themselves AND their co-workers.



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The 4 Greatest Obstacles

#3 Sharpening Awareness Must continue to develop continuous awareness

of hazardous circumstances, conditions, and behaviors

#4 Programming Hazard AbatementHazard identification and noncompliance processes are improving, but abatement efforts are inconsistent and inefficient



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Task Work Breakdown Structure

Boxes marked in red are 2002 priority tasks.


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DRAFT Manager's VPP Checklist DRAFT

Management Leadership & Employee Involvement:

Get the entire team involved: employees and management

SUB-ELEMENTS

I have communicated and demonstrated my commitment to Safety & Health leadership. 1.1 Mgt. Commitment1.2 VPP Commitment

I have periodic safety meetings or discuss safety topics in routine meetings with my employees. 1.1 Mgt. Commitment1.2 VPP Commitment

I follow and enforce JSC's Safety and Health program 1.4 Written S&H Program

I consider Safety & Health in my budget planning. 1.3 Planning1.6 Auth. & Resources

I emphasize accountability by incorporating Safety & Health in my employees’ Position Descriptions and Performance Plans. I also hold my support contractors to the same requirements.

1.7 Line Accountability1.8 Contract Worker Coverage

My employees are the “energy” in my Safety & Health program. 1.9 Employee Involvement


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WorksiteAnalysis:

Find the hazards

I ensure that all tasks and equipment are reviewed for Safety & Health impact, both before use, periodically during use and whenever changes are made.

1.3 Planning2.1 Mgt. Understanding2.3 Pre-Use Analysis2.4 Hazard Analysis

I routinely inspect my work areas for safety, health, and fire hazards. I also involve my employees in the inspection. I track discrepancies found to closure

2.5 Routine Inspections

My employees report hazards they find and without fear of reprisal (they can also report hazards anonymously). I track these hazards to closure.

2.6 Employee Hazard Reporting System

I ensure that mishaps / incidents are thoroughly investigated and that remedial and corrective action is implemented.

2.7 Accident/Incident Investigation System


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Hazard Prevention & Control:

Eliminate all the hazards you can, control the rest

I make sure identified hazards are:Posted for employee viewing,Eliminated or controlled, andTracked to closure.

3.1 Certified Professional Resources3.2 Hazard Elimination and Control3.5 Hazard Correction Tracking

I make sure my employees utilize the JSC clinic for injuries or illnesses and I make sure my employees are up to date on physical exams, if required.

3.6 Occup. Healthcare Program

If required, I ensure that my equipment is maintained. 3.4 Prev. Maintenance

When appropriate, I take disciplinary action for Safety & Health infractions. 3.7 Disciplinary System

I have emergency plans and procedures. 3.8 Emergency Procedures


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Safety & Health Training:

Train & equip employees to work safely

I train and equip my:ManagersSupervisorsEmployeesTo work safely - including training on PPE and annual training & drills in emergency procedures. I include safety and health training in my employees' training plans.

4.1 Program Description4.2 Supervisors4.3 Employees4.4 Emergencies4.5 PPE4.6 Managers


37Sean Keprta (281) 483-7896 Stacey Nakamura (281) 483-4345

3/4/02

Arms make a 90o angle at elbows and forearms parallel to the floor. Elbows kept close to the body. Wrists straight.

Monitor 18-24 inches away from the eyes. The top line of type at or slightly below eye-level.

Monitor and keyboard directly in front of user. Input devices, such as mouse, adjacent to keyboard.

Feet should rest firmly on the floor or a foot rest.

If documents are used, document holder positioned next to the monitor screen

Ears, shoulders, and hips aligned maintaining the back’s natural curves

Lower back fully supported. Use lumbar support cushion if necessary.

Legs make a 90o angle at the knee and thighs parallel to the floor


38


Remember:The best ergonomic advice is to

take frequent breaks.A one-minute micro break every hour is

recommended.

In other words:If you sit at a workstation for

hoursand don’t move,

you will eventually experience pain.


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• NASA LLIS– JSC Chief Engineer is the Center of Gravity

• Pulling together all programs and line organizations

– JSC Safety Comment:• NASA needs to keep pushing “Project

Management” training

• Cannot assume LLIS content will solve root cause problem of “poor project management training and in-experience”


40


BACKUP CHARTS


41


JSC Safety & Health Program Structure

Em ergency O perations C enter O fficeC enter O perations D irectorate

W illiam C . R oehR obert T. G affney

Safety & H ealth Forum s

Environm en tal H ealth C on tractorKelsey-Seybold Inc .

H ouston F ire D epartm en tEM S

O ccupational H ealth O fficeSpace & L ife Sciences D irectorate

D r. C . R ossSean R . Keprta

Safety and F ire P rotection C on tractorM un iz Engineering Inc .

H ouston F ire D epartm en t

Safety & Test O perations D ivis ionSafety, R eliab ility, & Q uality Assurance O ffice

S tacey T. N akam ura

C enter D irector

D SAH O : B . R andy S tone


42


JSC Occupational Health

Medica l C linic Industria l H ygiene

Industria l H ygiene Tra ining R adio log ica l Safety

Environm enta l H ealth Laboratory Medica l Manned Test Support

Em ployee Assistance P rogram

JSC Medic O N EJSC Medic TW O

H ouston F ire D epartm entEMS

Em ergency R esponse (Medica l)

Tota l H ealth P rogram

O ccupational H ealth O fficeSpace & L ife Sciences D irectorate

D r. C . R ossSean R . Keprta


43


JSC Occupational Safety

Safety Engineering Safety P rogram D evelopm ent

Safety Awareness Safety Tra ining

F ire D etection & Supression System sMaintenance & O perations

JSC F ire P rotection Specia lists H ouston F ire D epartm ent

Em ergency R esponse(F ire & Safety)

Safety & Test O perations D ivis ionSafety, R eliab ility, & Q uality Assurance O ffice

S tacey T. N akam ura


44


JSC Emergency Operations

Em ergency O perations C enter Em ergency P reparedness P lanning

Em ergency P reparedness D rills

Security Safety F ire P rotection H ealth / Medica l

Environm enta l Public Affa irs Facilities C om m unications

JSC Em ergency R esponse Team

Em ergency O perations C enter O fficeC enter O perations D irectorate

W illiam C . R oehR obert T. G affney


45


JSC Safety & Health Forums

JSC Safety Action Team Mentored by D SAH O

Em ployee Mem bership

JSC C ontractor Safety ForumC haired by C ontractor Affa irs S /C C hair

Facility Manager SystemC enter O perations D irectorate

Michael Scott, C oord inator

E m ergency O perations C en ter M anager O ccupational H ealth O f f icer

O ccupational S afety B ranch C h ief F ac ility M anager C oordinator

Fundam entals S /C C ontractor Affa irs S /C

Environm ental S tewardship S /C

C oordination SubC om m ittee

Executive Safety C om m ittee C haired by D SAH O

Senior S taff Mem bership

JSC Safety & H ealth Forum s

C enter D irectorD SAH O : B . R andy S tone



White Sands Test Facility

WSTF Safety & Health Functions

QARSO-WSTFNS3/David Loyd

Medical OperationsOccupational Health

Services ContractRay Gruben CHS

WSTF TEAMProgram Assurance

Bill Blohm HTSI

JSC Space & Life SciencesSA/Dave WilliamsSD/Sean Keprta

JSC SR&QANA/John CasperNS/Stacey Nakamura

JSC WSTFRA/Joe Fries

WSTF TEAMM. Leifeste HTSI

•Safety & Health•Emergency Prep.•Quality Engineering

•Industrial Hygiene•Occupational Health Consultation

•Safety & Medical•Fire Protection & EMS•Quality Assurance•Security

Documents

Space & Life Sciences Directorate Safety, Reliability, and Quality Assurance Office NASA Johnson Space Center, Houston, Texas 3/4/02Sean Keprta (281) 483-7896