Industrial Engineer Industrial Safety flashcards

32 cards. Read the term and the definition here. The deck at the top of this page is optional.

Safety management system

A documented, auditable framework of policy, planning, implementation, evaluation, and corrective action; ISO 45001 structures it around the Plan-Do-Check-Act cycle.

Hierarchy of controls

The order of control effectiveness: elimination, substitution, engineering controls, administrative controls, then personal protective equipment as the last resort.

Leading indicator

A measure of preventive activity, such as inspections completed or near-miss reports, that predicts future safety performance rather than recording past outcomes.

General Duty Clause

OSH Act Section 5(a)(1); requires employers to provide a workplace free from recognized hazards likely to cause death or serious physical harm when no specific standard applies.

Recordable injury criteria

Under 29 CFR 1904, an injury is recordable if it involves medical treatment beyond first aid, loss of consciousness, days away, restricted work, or transfer.

Permissible exposure limit

An OSHA regulatory limit on airborne contaminant concentration, usually an 8-hour time-weighted average, found in 29 CFR 1910.1000 tables Z-1 through Z-3.

Hazard versus risk

A hazard is a potential source of harm; risk is the combination of the likelihood of occurrence of that harm and its severity.

HAZOP guide words

Words such as no, more, less, as well as, part of, and reverse applied to process parameters to identify deviations from design intent during a hazard study.

Job hazard analysis

A task-based method that breaks a job into steps, identifies hazards for each step, and specifies controls for each step.

ALARP

As Low As Reasonably Practicable; residual risk is acceptable when further reduction would be grossly disproportionate to the benefit gained.

Bow-tie analysis

A diagram linking threats and preventive barriers on one side to consequences and mitigating barriers on the other, centered on a top event.

Layers of protection analysis

A semi-quantitative method that estimates the risk reduction provided by independent protection layers and compares mitigated frequency to a target.

NIOSH lifting equation

RWL = LC × HM × VM × DM × AM × FM × CM; the lifting index is load divided by RWL, and values above 1.0 indicate increased risk.

Anthropometric design rule

Design for the 5th percentile for reach and clearance limits, and for the 95th percentile for clearance and strength demands.

Cognitive workload

The mental demand of a task; it can be assessed with tools such as NASA-TLX, which rates mental, physical, temporal, performance, effort, and frustration demands.

Point-of-operation guard

A barrier or device that prevents the operator's hands, arms, or other body parts from entering the danger zone during the machine operating cycle.

Safety distance formula

D = K × T, where K is the approach speed (commonly 63 in/s or 1600 mm/s) and T is the total stopping time including device response.

Interlocked guard

A guard that stops hazardous machine motion when it is opened; the interlock must be designed so a single fault cannot defeat it.

LOTO six-step sequence

Notify affected employees, shut down, isolate all energy sources, apply locks and tags, release stored energy, and verify isolation before work begins.

Arc flash boundary

The distance from an electrical hazard at which incident energy equals 1.2 cal/cm², the threshold for a second-degree burn.

Group lockout

A method using a hasp or lockout device so that each authorized employee applies a personal lock that must remain until their work is complete.

Fire tetrahedron

The four elements needed for combustion: fuel, oxygen, heat, and the chemical chain reaction; removing any one element extinguishes the fire.

Flash point

The lowest temperature at which a liquid gives off enough vapor to form an ignitable mixture with air near its surface; flammable liquids are below 100 °F.

Means of egress

The continuous and unobstructed path of travel from any point in a building to a public way, comprising exit access, exit, and exit discharge.

TWA exposure formula

TWA = (C₁T₁ + C₂T₂ + … + CₙTₙ) / 8 hours, where C is concentration and T is time in hours; compared to the 8-hour permissible exposure limit.

Hearing conservation action level

An 8-hour time-weighted average noise exposure of 85 dBA; at or above this level, a hearing conservation program is required under OSHA rules.

Five Whys

A root cause technique that repeatedly asks why a condition or action occurred until a systemic cause is reached rather than stopping at human error.

Fault tree analysis

A deductive method starting from a top event and working backward through AND/OR gates to basic events that could cause it.

OSHA incidence rate

(Number of recordable cases × 200,000) / total hours worked; 200,000 is the base for 100 full-time-equivalent workers at 40 hours per week for 50 weeks.

DART rate

(Days away, restricted, or transfer cases × 200,000) / total hours worked; a lagging indicator of serious injury outcomes.

PSM threshold quantity

For a flammable liquid or gas, 10,000 lb in one location; for listed highly hazardous chemicals, the threshold is specified in OSHA Appendix A.

Management of change

A PSM element requiring review of the technical basis, safety and health impacts, procedure changes, training needs, and authorization before a process change.