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ALLIANCE ANNUAL REPORT Occupational Safety and Health Administration and The Dow Chemical Company (Dow) April 10, 2006
I. Alliance Background Date Signed January 13, 2003 Date Renewed May 26, 2004 Evaluation Period January 13, 2005 – January 12, 2006 Overview The OSHA and The Dow Chemical Company Alliance focuses on using OSHA's and Dow's collective expertise to further enhance a culture of prevention while sharing proven practices and technical knowledge in the areas of, but not limited to, process safety management (PSM) and ergonomics. Implementation Team Members   OSHA:   Brett Besser Mark Briggs John Bugno Cathy Cronin Kevin Cummins Lee Anne Jillings Todd Jordan David O'Connor Lisa Ramber Beth Sherfy Salt Lake Technical Center (SLTC) Region VI Directorate of Standards and Guidance (DSG) Office of Training and Education SLTC Office of Outreach Services and Alliances (OOSA) SLTC DSG OOSA OOSA     Dow:   Joe Amos John Dizor Rick Holmes George King Dale Louda Tim Overton Jeannine Sohayda Mark Spence Regulatory Affairs Leader, West Virginia Personal Safety Expertise Leader Industrial Hygiene Expertise Leader Process Safety Technical Leader Washington Office Advocacy Leader Chief Process Safety Engineer EH&S Public Affairs H&S Regulatory Affairs II. Implementation Team Meetings   February 15, 2005 March 22, 2005 May 2, 2005 July 19, 2005 July 26, 2005 August 1, 2005 September 28, 2005 October 21, 2005 Alliance Program Hazard Communication Roundtable, Washington, DC Implementation Team Meeting, Teleconference Case Study Development Meeting, Teleconference Implementation Team Meeting, Teleconference Case Study Development Meeting, Teleconference Alliance Program Workgroup Promoting the Globally Harmonized System for Classification and Labeling of Chemicals Meeting, Washington, DC PSM Seminar for Region III Planning Meeting, Teleconference Implementation Team Meeting, Teleconference III. Results Events and Products Outreach and Communication Goals Develop and disseminate information on effective elements of safety and health programs at conferences, events, or through print and electronic media. Products OSHA Electronic Assistance Tools Through the Alliance, Dow representatives continue to provide expertise to review, maintain and update many of OSHA's Safety and Health Topics pages as well as OSHA's Ammonia Refrigeration eTool. OSHA Safety and Health Topics Pages The following representatives from Dow serve on the editorial boards of the following 8 OSHA Safety and Health Topics pages: Ammonia Refrigeration Don Jones, PE, CSP, Plaquemine, LA Chemical Reactivity Hazards Kenan Stevick, Midland, MI Emergency Preparedness and Response Susan Ripple, MS, CIH, Global industrial Hygiene Expertise Center; Midland, MI Health Care Facilities Susan Ripple, MS, CIH, Global industrial Hygiene Expertise Center; Midland, MI Isocyanates John Cikalo, Global Industrial Hygiene Expertise Center, Midland, MI Mark Spence, Global Industrial Hygiene Expertise Center, Midland, MI Motor Vehicle Safety Mark Spence, Global Industrial Hygiene Expertise Center , Midland, MI Process Safety Management George King, Process Safety Technology Center, Freeport, TX Radiation: Radiological Dispersal Devices/Dirty Bombs Susan Ripple, MS, CIH, Global industrial Hygiene Expertise Center; Midland, MI OSHA eTools Representatives of the OSHA and Dow Alliance serve on the editorial board of OSHA's Ammonia Refrigeration eTool: Randy Estep, Houston, TX Don Jones, Plaquemine, LA Mark Spence, Midland, MI OSHA and Dow Alliance Web Page OSHA continues to update the OSHA and Dow Alliance Web page on the Agency's Web site. The Web page features links to the Alliance agreement and related documents, information on activities and events, and milestones and successes. During the evaluation period, the Web page was updated to include information about Dow's PSM Seminar for Region III staff, which was November 16-17, 2005, in South Charleston, West Virginia and a link to the OSHA and Dow Alliance case study, Motor Vehicle Accident Case Study: "The Dow Chemical Company's Use of the 'Six Sigma' Methodology. For information on the number of visits to the OSHA and Dow Alliance Web page, please see the Alliance Program Reach table. Print and Electronic Media Articles on the OSHA and Dow Alliance, and products developed through it, have appeared in print and online publications, including: BNA Conference Report and OSHA's Alliance Quarterly Review. For more information on the articles, please see the Alliance Program Reach table on page 7. Events National Safety Council's Congress and Expo, Orlando, Florida, September 22, 2005 On September 22, 2005, Mark Spence participated on the panel entitled, "Successes with OSHA's Ergonomic Alliances," at National Safety Council's Congress and Expo in Orlando, Florida. Mr. Spence discussed the ergonomics case study, "The Dow Chemical Company's Use of the 'Six Sigma' Methodology", which describes the Six Sigma methodology and how Dow used it to successfully address ergonomics hazards in the company's design and construction division. Other panelists included Paula White, Director, Directorate of Cooperative and State Programs, USDOL-OSHA and a representative from the OSHA and Graphic Arts Coalition Alliance. Gain a better understanding of the diversity of methods and processes for addressing health and safety challenges in the workplace. Develop ways for communicating effective approaches including cross-training, job aids, and usability studies. Events Chemical Reactivity Hazard Management Seminar, Atlanta, Georgia, September 26, 2005 On September 26, 2005, Cal Towns, Process Safety Advisor for The Dow Chemical Company's Global Chlorinated Organics Business, served as a speaker at the workshop, "Managing Chemical Reactivity Hazards: A Workshop for Non-Chemists," held during the Chlorine Institute's 2005 Fall Meeting in Atlanta, Georgia. The workshop, organized by the OSHA and Chemical Reactivity Hazards Management Alliance, provided information on chemical reactivity hazards and strategies and tools for identifying and preventing reactivity accidents at manufacturing facilities. Approximately 20 representatives from small chemical manufacturers, warehouse facilities, distributors and batch processors attended the workshop. Process Safety Management Workshop, South Charleston, West Virginia, November 16-17, 2005 Through the Alliance, in 2003 Dow and OSHA developed a workshop, "OSHA's Process Safety Management (PSM) Standard: The Dow Approach," discussing the various aspects of the PSM standard, including process safety information, process hazard analysis procedures and management of change, and how Dow Chemical Company implements the PSM Standard in its workplaces. The Alliance hosted another session of the workshop on November 16-17, 2005, at The Dow Chemical Company's West Virginia, Operations, in South Charleston, West Virginia. The workshop was attended by 30 OSHA staff from OSHA's National and Region III Offices and West Virginia Consultation Project. It also included time for attendees to tour Dow's facilities. The PSM workshop built on the success of two previous workshops hosted by the OSHA and Dow Alliance for OSHA staff from Regions IV, V, and VI. Provide OSHA with opportunities, where appropriate and agreeable to both parties, to experience hands-on information sharing in Dow's facilities to "test run" ideas and to gain a better understanding for real world impact and applications. During this evaluation period, no products or resources have been developed to meet this Alliance goal. Promoting the National Dialogue on Workplace Safety and Health Goals Encourage Dow worksites, and personnel to act as industry liaisons and resources for OSHA's cooperative programs and Compliance Assistance Specialists. During this evaluation period, no products or resources were developed to meet this Alliance goal. Seek opportunities to participate in stakeholder groups and other forums for providing input into the development of safety and health standards and guidance for the chemical industry. Events Alliance Program Hazard Communication Roundtable, Washington, DC, February 15, 2005 Matt Sczepanski, Mark Spence and Imogene Treble attended the Alliance Program Hazard Communication Roundtable, which was February 15, 2005, in Washington, DC. The Roundtable brought together 18 Alliance Program participants to identify hazard communication compliance assistance projects and activities that they could work on together. The Promoting the Globally Harmonized System for the Classification and Labeling of Chemicals (GHS) Workgroup was established at the Roundtable meeting. Promoting the GHS Workgroup August 1, 2005, Washington, DC – Mark Spence attended the Promoting the GHS Workgroup meeting. The Workgroup identified a number of compliance assistance tools that it could develop to support OSHA's plans to adopt the GHS as part of its Hazard Communication Standard. Identify and enhance methods and processes to evaluate the effectiveness of the Alliance and to encourage the continuous improvement of workplace health and safety practices and communication. During this evaluation period, no products or resources were developed to meet this Alliance goal. Share information on proven practices of Dow worksites with others in industry through outreach directly by Dow and also through OSHA. Products "Motor Vehicle Accident Case Study: The Dow Chemical Company's Use of the 'Six Sigma' Methodology" Through the Alliance Program, Dow worked with OSHA to develop a motor vehicle case study, "The Dow Chemical Company's Use of the 'Six Sigma' Methodology," which was posted on OSHA's Web site in December 2005. ("Six Sigma" is a process-oriented approach to problem solving that emphasizes a four-step improvement methodology of measure, analyze, improve and control). The motor vehicle accident case study discusses how Dow applied the "Six Sigma" management system strategy to successfully reduce motor vehicle accidents in the company's Hydrocarbons and Energy business unit. The motor vehicle accident case study has been added to a number of OSHA's Web pages, including the OSHA and Dow Alliance page, Compliance Assistance page and Motor Vehicle Safety and Health Topics page. Work together to develop new approaches and practices to address health and safety risks. During this evaluation period, no products or resources have been developed to meet this Alliance goal. Share data supporting the solutions to ergonomic hazards developed by Dow, as well as examples of hazard recognition strategies and analytical tools with OSHA and others in the industry to encourage wide implementation. Promote their implementation through print and/or electronic media, promotion at conferences, or other means of reaching out to others in industry. During this evaluation period, no products or resources have been developed to meet this Alliance goal. Other Issues Hurricane Katrina Response Through the Alliance Program, Dow offered to donate personal protective equipment (PPE) for OSHA to use as part of its Hurricane Katrina and Rita response efforts. The PPE, which will include hard hats, gloves and protective vests, will be used by OSHA's Region IV and VI Offices. OSHA and Dow are working together to coordinate Dow's PPE donation in compliance with the Department of Labor's requirements for donations from nongovernmental entities. Executive Summary During the 2005-2006 evaluation period and final year of the first Alliance renewal agreement, OSHA and Dow worked together to further enhance a culture of prevention while sharing proven practices and technical knowledge in the areas of, but not limited to, PSM and ergonomics. Through the Alliance Program, OSHA and Dow developed several compliance assistance resources with information about the Alliance and ergonomics. The OSHA and Dow Web site on OSHA's Web page provides links to the Alliance agreement, related documents, activities and events, and milestones and successes. Representatives from Dow serve as members of a number of OSHA's Safety and Health Topics page's editorial boards, including Ammonia Refrigeration, Chemical Reactivity, Health Care Facilities and PSM. Dow representatives also are members of OSHA's Ammonia Refrigeration eTool's editorial board, which OSHA developed with input from the Dow and the American Meat Institute Alliances in 2004. As part of the OSHA and Dow Alliance's outreach efforts, Mark Spence participated on a panel entitled, "Successes with OSHA's Ergonomic Alliances," at the National Safety Council's Congress and Expo on September 22, 2006, in Orlando, Florida. Mr. Spence discussed the "Ergonomics Case Study: The Dow Chemical Company's Use of the Six Sigma Methodology." Other panelists included Paula White, Director, Directorate of Cooperative and State Programs, USDOL-OSHA and a representative from the OSHA and Graphic Arts Coalition Alliance. The OSHA and Dow Alliance also developed a "Motor Vehicle Accident Case Study: The Dow Chemical Company's Use of Six Sigma Methodology," which was posted on OSHA's Web site in December 2005. The case study describes the Six Sigma methodology and how Dow used it to successfully reduce motor vehicle accidents in the company's Hydrocarbons and Energy business unit. Through the Alliance, Dow and OSHA developed a workshop, "OSHA's Process Safety Management (PSM) Standard: The Dow Approach," discussing the various aspects of the PSM standard. The Alliance hosted another session of the seminar on November 16-17, 2005, at the Dow Chemical Company's West Virginia, Operations, in South Charleston, West Virginia. It was attended by 30 OSHA staff from OSHA's National and Region III Offices and West Virginia Consultation Project and included a tour Dow's facilities in South Charleston, West Virginia. The PSM workshop built on the success of two previous workshops hosted by the Alliance on October 13-14, 2004, in Plaquemine, Louisiana and September 16, 2003, in Arlington Heights, Illinois. In addition, on September 26, 2005, Cal Towns, Process Safety Advisor for The Dow Chemical Company's Global Chlorinated Organics Business, served as speaker for the workshop, "Managing Chemical Reactivity Hazards: A Workshop for Non-Chemists," during the Chlorine Institute's 2005 Fall Meeting in Atlanta, Georgia. The workshop, organized by the OSHA and Chemical Reactivity Hazards Management Alliance, provided information on chemical reactivity hazards. Approximately 20 representatives from small chemical manufacturers, warehouse facilities, distributors and batch processors attended the workshop. The Alliance implementation team members also worked with other Alliance Program participants throughout the year. Dow participated in the Alliance Program Hazard Communication Roundtable in Washington, DC, on February 15, 2005. Dow also attended the Alliance Program's Promoting the GHS Workgroup meeting on August 1, 2005. Alliance Program Reach Type of Activity (Conference, Training, Print and Electronic Distribution, etc.) Number of Individuals Reached or Trained OSHA and The Dow Chemical Company Web page on OSHA's Web site 4,649 Dow representative serve on eight of OSHA's Safety and Health Topics pages' editorial boards: Ammonia Refrigeration Chemical Reactivity Hazards Emergency Preparedness and Response Health Care Facilities Isocyanates Motor Vehicle Safety Process Safety Management Radiation: Radiological Dispersal Devices/Dirty Bombs Data Not Available OSHA's Ammonia Refrigeration eTool Data Not Available February 15, 2005: Alliance Program Hazard Communication Roundtable, Washington, DC Dow Participated 18 March 2005: "Hazcom Roundtable Address MSDSs, Compliance Assistance Issues," Alliance Quarterly Review 300 June 16, 2005: "OSHA Alliance Successes Cited by Agency Official at Safety Conference," BNA Conference Report Data Not Available August 1, 2005: Alliance Program's Promoting the Globally Harmonized System for Classification and Labeling of Chemicals (GHS) Workgroup Meeting, Washington, DC 12 September 22, 2005: "Successes with OSHA's Ergonomic Alliances," National Safety Council's Congress and Expo, Orlando, Florida Speakers: Mark Spence, Dow Paula White, OSHA 50 September 26, 2005: "Managing Chemical Reactivity Hazards: A Workshop for Non-Chemists," Chlorine Institute's 2005, Fall Meeting, Atlanta, Georgia Speaker: Cal Towns, Dow 20 November 16-17, 2005: Process Safety Management Workshop, "OSHA's Process Safety Management (PSM) Standard: The Dow Approach," South Charleston, West Virginia Dow Speakers: Andy Altman Joe Amos Steve Barron Jeff Blatt Brenda Brown Tami Clark Mike Cunningham Jeff Goad Don Hanks George King Clark McCoy Brenda Meyers Kim Smith Dave Veazey Giles Watson OSHA Speakers: Stan Elliott, OSHA Elizabeth Sherfy, OSHA 30 December 2005: "Chemical Reactivity Hazards Workshop a Tutorial on Hazards Recognition, Possible Safety," Alliance Quarterly Review 300 December 2005: "Workshop Emphasizes Benefits of Process Safety Management at Dow," Alliance Quarterly Review 300 December 2005: "The Motor Vehicle Accident Case Study: The Dow Chemical Company's Use of Six Sigma Methodology," Data Not Available TOTAL 5,679 IV. Upcoming Milestones During the Alliance's next year, OSHA and Dow will renew the Alliance agreement and continue to promote awareness of the Alliance Program and workplace safety and health issues, including ergonomics and PSM. The Alliance implementation team members will also continue to maintain and update the OSHA and Dow Alliance Web page on OSHA's Web site. In addition, Dow representatives will review and provide OSHA with information for the Agency's Ammonia Refrigeration eTool and Safety and Health Topics pages. OSHA and Dow will also work together to finalize a third case study on fleet safety, which will be posted on OSHA's Web site. In addition, the OSHA and Dow Alliance will develop a short PowerPoint® presentation for use with the motor vehicle and fleet safety case studies. The slides will be available on OSHA's Web site for speakers who want to use Dow's case studies in a presentation. The OSHA and Dow Alliance will also develop new topics for developing additional case studies.   In addition, Mark Spence offered to serve on a proposed workshop panel at the 2006 National Safety Council's Congress and Expo in San Diego, California. The proposed panel will highlight the many case studies developed through the Alliance Program, and include representatives from the Graphic Arts Coalition and The Steel Group Alliances. The OSHA and Dow Alliance implementation team will identify Regional Offices within OSHA that would like to attend Dow's workshop, "OSHA's Process Safety Management (PSM) Standard: The Dow Approach." The workshop discusses the various aspects of the PSM standard. Dow will finalize its donation of personal protective equipment (PPE) for OSHA to use as part of its Hurricane Katrina response efforts. The PPE, which will include hard hats, gloves and protective vests, will be used by OSHA's Region IV and VI Offices. OSHA and Dow are working together to coordinate Dow's donation in compliance with the Department of Labor's requirements for donations from nongovernmental entities. Report prepared by: Elizabeth Sherfy, Alliance Coordinator, Office of Outreach Services and Alliances, April 10, 2006.