Dow Corning INTERNAL
A day in the life of a
Dow Corning
Industrial Hygienist
Dow Corning INTERNAL
The Dow Corning Site at Barry, Wales
The site was established in 1957 by Midland
Silicones.
Manufacture of silicone intermediates and
final products.
Distillation / hydrolysis / compounding
processes.
Globally 12000 employees with 25000
customers and over 7000 products
At Barry we have approximately 600
employees and at times up to 600 extra
contract staff.
Dow Corning INTERNAL
Industrial Hygiene
As an Industrial Hygienist my job covers monitoring and
controlling exposure to :
• Noise
• Vibration
• Chemicals / vapors / lead etc
• Dusts (asbestos / crystalline silica)
• Radiation
• Ergonomics
• Biological Hazards
• Temperature
• EMF’s
Dow Corning INTERNAL
Looking at chemical and dust exposures
Where there is potential for workers to be exposed to
chemical vapors and dusts we use engineering controls
wherever possible.
Engineering controls include:
General Ventilation
Local Exhaust Ventilation
Vented enclosures
Sealed systems
Where these cannot be used or are not effective enough
we use RPE, as a last of defense for exposure.
Dow Corning INTERNAL
What do we use?
On our site we use the following forms of Respiratory
Protection.
• Breathing Apparatus
• Full face respirators
• Half face respirators
• P3 dust masks
• Air fed hoods
• Some nuisance odor masks
Dow Corning INTERNAL
A Cradle to Grave Approach
(or should that be cradle to retirement?)
TASK
PPE
PERSON
CONTROL
Dow Corning INTERNAL
Analysing the task.
TASK
For new processes :
1)
2)
3)
4)
Design out exposures.
Decide on engineering controls.
COSHH assessments to determine RPE required.
Carry out Industrial Hygiene monitoring to determine actual
exposures once processes are in place (and re-assess).
For existing processes :
1) Carry out Industrial Hygiene monitoring to determine actual
exposures.
2) Modify or re-design if possible.
3) COSHH assessments to determine PPE required (if not already
being used).
Dow Corning INTERNAL
Training the person
PERSON
All job roles aligned to a training matrix which identifies tasks that
require RPE, so before they start we know if they will need to use it.
Initial medical for potential RPE users includes lung function, blood,
and other tests to determine the persons suitability for wearing RPE.
The training matrix identifies that RPE wearers should have the RPE
training and a full face fit test for each mask before they carry out
any tasks.
They attend an RPE awareness session (or video) which explains
why RPE is used, how to use it and how to check it before use.
Dow Corning INTERNAL
Issue of the mask
RPE
Once the person has had the training he attends a Face Fit Test
Assuming they meet the criteria (clean shaved etc) they undergo the
test which is carried out by the Kit Issue Operative (Steve), or one of
the 4 other trained Fit Testers on site.
Assuming a PASS a mask is then issued to the operator and
facilities made available for storage and cleaning of the mask.
(BA wearers do not have their own masks, they book these out along
with the trolley packs).
Dow Corning INTERNAL
Control
PERSON
CONTROL
RPE
TASK
The trick to any system like
this is the element of control.
Dow Corning INTERNAL
Task Control
PERSON
CONTROL
RPE
TASK
1) COSHH Assessments
reviewed every 2 years or on
change of process (of
chemicals).
2) Periodic IH monitoring using
a QEA program to identify
potential issues.
3) HONK system for immediate
reporting of problems with
processes.
4) Continual improvement
program looking at new
technologies and techniques
to reduce exposures
Dow Corning INTERNAL
Person Control
1)
PERSON
2)
CONTROL
3)
RPE
4)
TASK
5)
6)
Annual Medical with lung
function / blood tests etc to
identify any problems early.
Annual repeat Face Fits for all
RPE that requires it.
RPE training package
redelivered every 2 years as
part of an automated training
system.
Training records available at kit
issue point so RPE does not go
out to untrained personnel.
Management of change system
to identify when people change
jobs.
Exit medical.
Contract Staff also have to have Face fits before masks are issued however they are not
Covered by the training matrix. Contracts set up to include responsibilities for contract
Companies to repeat fit tests / training)
Dow Corning INTERNAL
RPE Control
PERSON
1)
2)
CONTROL
3)
RPE
TASK
4)
5)
All RPE issued from one
location with access to training /
face fit records.
RPE issued by staff trained in Fit
Testing (to identify issues with
facial hair etc. before issue)
All RPE electronically tagged
and associated to the training
record of the wearer.
Tagging system recall’s all
masks once per year for
inspection / repair by Fit to Fit
Accredited staff.
Single point of contact for all
RPE issues (manned 24hrs).
Dow Corning INTERNAL
The Team
Fit Testers
Gareth & John
Kit Issue
Medical
Steve
Gerry and Chris
Tracked RPE
Training matrix / medical records
Fit test Results
Dow Corning INTERNAL
What Industrial Hygiene definitely isn’t !!!
There’s a pigeon in the tree outside my window that doesn’t look very well, can
you come and deal with it?
I have just rubbed my eye after eating chilli crisps, what should I do?
The drains in our mess room smell funny.
Can I have one of those respirators without filters? I find it hard to breath in this
one.
I find tests very stressful, can I nip out for a smoke before my face fit test?
If I comb my beard flat instead, will I still have to shave?
My brother passed his fit test and we look alike so I don’t need one.