Lumber Veneer Manufacturing Case Study: Reducing splinter injuries
Wood has been used for thousands of years as a building material for a wide range of applications. The demand for finished lumber pushes manufacturers to produce goods as efficiently and cost effectively as possible, which has a direct impact on the thousands of employees working in lumber and plywood mills across the world. Lumber manufacturing can be extremely hazardous work, and companies cannot afford to lose valuable production time because of injury. The work environment in lumber mills makes it critical that safety teams constantly evaluate application based hazards,and investigate PPE that reduces the likelihood of injury on the job.
Reducing Injuries for the Largest Engineered Wood and Plywood Producers
STOPPING SPLINTER INJURIES
While wood remains a trusted building and construction material, it can be very dangerous to manufacture and process. In the wood processing industry (handling dry lumber and veneer), wood splinters can have a devastating effect on worker safety and productivity. They range in size (as small as a needle to as large as a yard stick) and can be viciously sharp and jagged which poses a serious problem for production workers. Safety professionals have a critical decision to make when choosing PPE for these production workers, as many existing products such as leather and Kevlar do not have the ability to protect from sliver punctures.
WEYERHAEUSER LOOKS TO HEXARMOR TO MITIGATE SPLINTER PUNCTURE INJURIES
Forestry product giant Weyerhaeuser reached out to HexArmor in search of PPE capable of reducing or preventing the frequency of recordable splinter injuries on laminate and veneer lines. One Weyerhaeuser plant was experiencing 18 sliver injuries per month and had been unable to find a solution to this ongoing problem. The existing PPE was not doing its job, and Weyerhaeuser Safety Professionals were having trouble finding alternative PPE technologies to try -- this is when they called HexArmor. HexArmor worked directly with Weyerhaeuser’s safety team to explore the possible application of existing HexArmor technologies in new products designed specifically for Weyerhaeuser production facilities. HexArmor designers took the feedback from the dry lumber and veneer production facilities and designed new PPE based on the specific needs, demands, and personal preferences of Weyerhaeuser workers.
HEXARMOR PPE REDUCES PUNCTURE INJURIES TO ZERO
The reason behind HexArmor’s success at Weyerhaeuser is the unique puncture and cut protection from its proprietary technology called SuperFabric®. SuperFabric exceeds industry cut levels (ANSI and CE level 5), and provides puncture protection from wood slivers, metal burrs, and wire pokes. With the introduction of HexArmor gloves and arm guards to the Weyerhaeuser facility, recordable and first aid injuries in the laminate and veneer plant dropped from 18 injuries a month to ZERO! The collaborative work between Weyerhaeuser’s employees and safety team along with HexArmor developers resulted in new industry leading protection for stopping splinters.
Click here to learn about the product solutions HexArmor developed for Weyerhaeuser.
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Oil Drilling Case Study: Smash injuries targeted by large oil gas companies
In 2008, ExxonMobil, along with other industry leaders in the oil and gas industry, initiated an in-depth study of hand-injuries. These initial studies identified smash injuries as the leading cause of on-the-job hand injuries on drilling sites. The safety organization took action on the results of the study and established safety glove guidelines and standards to address impact injuries on drill sites.
Oil Companies Target Smash Injuries as Leading Cause of Hand Injuries in Upstream Production
Industry leaders initiate drill site hand injury study
For global petro-chemical service companies like ExxonMobil, contractor and employee hand injuries represented a disproportionate source of costly worker downtime and medical claims. In 2008, industry leading oil and gas companies conducted a large-scale study of upstream exploration operations to categorize the different types of hand injuries. The study found that more than half of the hand injuries were a result of a smash or contusion. These injuries most frequently occur while moving drill pipe, pushing tools, pulling chain, rigging up and down in frac applications, and securing pipe valves. As a result, several PPE manufacturers developed “advanced technology gloves” with varying levels of
impact protection.
The second highest cause of injuries reported was categorized as cut and puncture (laceration). As service companies like Halliburton and Schlumberger looked at the cause of hand injuries, they saw a very high percentage (approximately half) of injuries that were categorized as a laceration, puncture, or abrasion related. These results initiated a search for a higher level of hand protection capable of reducing or eliminating smash issues as well as cuts and punctures. Through extensive research, Halliburton and Conoco Phillips chose to partner with HexArmor to manufacture gloves for a field test. After hearing about the success of the Halliburton and Conoco Phillips field tests, ExxonMobil approved HexArmor gloves for similar tests to address smash, cut, and puncture injuries on their own drill sites.
Engineering the ideal glove solution
HexArmor’s ability to design and engineer products that address smash injuries as well as cuts and punctures created an opportunity to work directly with the safety teams in these large oil and gas companies. All parties realized that while competitive ‘advanced technology’ gloves provided some protection against impact injuries, they did not offer the level of protection needed to prevent cut and puncture injuries.
HexArmor took feedback from field workers on oil rigs and drill sites and used these insights to develop a full line of high performance hand protection that addressed smash issues plus the cut and puncture problems that had not been solved by previous manufacturers. Using proprietary technologies like IR-X™ smash guards and SuperFabric® material, HexArmor was able to help companies like ExxonMobil push their hand protection program to a higher level of safety.
Click here to read about the solutions HexArmor developed for these large oil and gas drillers.
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Oil Refinery Case Study: Working with steel shims for pump maintenance
Maintenance workers in refineries regularly use stainless steel slotted shims to level and maintain pumps, motors, and machines. While steel shims provide optimal efficiency in maintaining equipment, they also create a dangerous hazard for hands at work. Since pump and machine maintenance is an ongoing process, workers are constantly handling shims, which increases the potential for injury.
Stainless Steel Shim Lacerations Prevented With Hexarmor Hand Protection
Maintenance worker has multiple injuries working with shims
While a slotted shim is a common, helpful tool for maintenance workers in oil refineries, the shim’s handy tab and corners can become sharp hazards that can cause serious injury. The often paper thin stainless steel shims can be razor sharp, and are easily capable of slicing through ordinary leather maintenance gloves, Kevlar, or cotton work gloves. HexArmor had interviewed a refinery maintenance worker who received several recordable lacerations to his thumb and index finger, as well as smash injuries to his knuckles while working with steel shims. One recent injury required stitches, and due to the location of the wound, the worker was off the job for two weeks. After these costly incidents, the safety team began looking for a better hand protection solution.
HexArmor provides needed protection from razor sharp shim edges
Before returning to work after the injury, HexArmor provided the same worker with a pair of Chrome Series 4026 mechanics’ gloves. While performing routine maintenance using a metal shim, the worker received an almost identical type of cut from the shim. This time, however, his hand was not cut and he did not have to leave work that day.
While the sharp edge of the shim slashed the exterior synthetic leather covering the finger and palm of the glove, it had no effect on the SuperFabric® underneath. HexArmor products with SuperFabric® exceed ISEA and CE Level 5 cut protection, which played a huge role in saving this worker’s finger.
This worker continued to use the same HexArmor gloves for weeks after the incident, claiming that: “They were just as good as ever.” In order to create this casestudy, we had to bargain with the worker to give up his HexArmor gloves for a new pair – a small price for progress in designing the best PPE in the business.
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Mining Case Study: Conveyor Belt Maintenance
Mining is a global enterprise that supplies the precious and base metals that drive, power, and build the world’s largest industries. These mining operations can be divided into three basic types: underground mining, open pit mining, and surface mining. While the methods of mining and products that are mined in each operation may differ, production operations and the hazards of maintaining production are relatively the same.
Hexarmor Engineers a World of PPE Solutions for Global Mining and Maintenance Operations
CONVEYOR BELT SPLICING: ONE OF MANY HAZARDOUS MINING MAINTENANCE TASKS
Engineering the right type of PPE for mine workers and maintenance crews is critical in keeping ores and base metals moving efficiently and productively around the world. In almost all mining operations, high capacity industrial belt conveyors are used to transport ores throughout the mine or production facility. The belts in these conveyors are subjected to tons of rough ores and metals each day, and continually require maintenance to splice frayed belt pieces back together. Splicing is hazardous work for maintenance crews: one inch thick belts (sometimes constructed with fiber and steel) are sliced with two-handed box cutters before being spliced back together with steel staples. Maintenance crews are often positioned on their knees during these dangerous cutting operations and must pull knife blades directly toward them - not the most ideal work environment. Recordable injuries from deep punctures and lacerations are often serious - and in some cases, life-threatening.
HEXARMOR ENGINEERED A NEW LEVEL OF PROTECTION AGAINST PUNCTURES AND LACERATIONS WITH THE DEVELOPMENT OF A DEDICATED CONVEYOR BELT CHAP
HexArmor designers and engineers answered the call of a major mining company that had been experiencing a high level of recordable injuries (punctures and lacerations) in its belt conveyor splicing operations. After conducting an onsite review of the company’s maintenance operations, and working directly with the company’s safety committee, HexArmor engineered a conveyor belt chap designed to deflect the cutting blades and knives used in belt splicing maintenance. The result: belt conveyor maintenance and installation injuries were completely eliminated after the introduction of the HexArmor chap.
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Pulp and Paper Case Study: Slitter blade maintenance
In the pulp and paper industry, maintenance workers and millwrights are constantly exposed to cut and laceration hazards on their hands and arms during slitter-blade change-outs and other blade maintenance operations. While reducing cuts and slashes was a priority, giving these specialized workers the exact dexterity and feel required to remove and replace blades efficiently was the key to providing the right PPE for the job.
Providing Cutting Edge ppe For The Paper And Pulp Industry
The challenge of changing out sharp slitter blades
Changing out circular slitter blades like this is hazardous work for pulp and paper millwrights. Working in confined spaces surrounded by sharp blades increases the exposure to cuts and lacerations for both hands and arms – it also demands PPE that allows maximum dexterity and feel to perform blade change-outs quickly and efficiently.
HexArmor finds solution for tough maintenance tasks
Working with paper-mill industry leaders like Weyerhaeuser, Georgia Pacific, and Kimberly Clark, HexArmor provided a full range of protective glove and arm guard solutions to mitigate millwright and maintenance crews’ risk of cuts and lacerations in handling and replacing straight edge doctor blades and circular slitter blades. HexArmor discovered that maintenance workers had traditionally used
leather gloves or gloves made of materials that offered no more than ISEA and CE Level 2 (less than 1000 grams) cut protection in these tasks. In cases where manufacturers had mandated improved PPE
like Kevlar, trials of Kevlar gloves failed – rejected by unions and workers because of insufficient cut protection, poor fit, and unacceptable dexterity and grip characteristics.
Since maintenance workers and millwrights play such a critical role in keeping production lines running, having the right level of protection and dexterity is key to a stronger and safer paper and pulp facility. Slitter blades and other circular blades can come in many different sizes, weights, and can be saturated with grease or have no coating at all. With a variety of hazards in play, it is critical to keep the workers in the best protection for the application.
HexArmor ensures the protection and quality of its PPE by testing to ISEA Level 5 Ratings for cutresistance, and also field tests products for industrial puncture protection from wires, wickers, slivers, and glass. Since dexterity and grip requirements vary by specific application, HexArmor leveraged its relationships with industry leaders in paper and pulp mills to adjust recommendations based on company and plant specific needs.
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Grocery Produce and Meat Department Case Study: Reducing hand injuries in national grocery chains
HexArmor NXT 10-302 reduces cut injuries by 44% after first year of use
Employees in the meat and produce departments at Kroger, a large national grocery chain were using standard Spectra cut gloves to handle knives and change cutting blades on machinery. The gloves provided some levels of cut protection, but the fiber-based gloves were bulky, ill-fitting, and scratchy, which caused problems with getting employees to actually wear the PPE. The safety team was tasked with finding gloves that would offer a higher level of cut protection that was comfortable and had higher dexterity in hopes of increased employee wear-compliance.
HexArmor was brought in to learn more about the issues at the store level and took surveys of actual end users. The following issues were found with the Spectra gloves:
- Too bulky and ill-fitting
- Loose fingertips bunch up and get caught in machinery or get in the way of cutting
- Did not sanitize or wash well, gloves were easily discolored and retained odor
- Did not protect from accidental knife slips where tip could penetrate between the fiber
HexArmor introduces NXT 10-302 as solution to cut injuries and compliance
The results from the survey helped guide the recommendation to implement a large trial of the NXT™ 10-302 in the meat and produce departments. Gloves were used in various food preparation and machine maintenance applications, and the stores saw an immediate acceptance of the NXT 10-302 as a highly comfortable solution that provided better protection than the Spectra gloves. All of the
testing sites saw an increase in compliance, as well as longer usage and improved cut injury data, while using the NXT 10-302.
Click here to read HOW HEXARMOR REDUCED CUT INJURIES BY 44% AND INCREASED USER COMPLIANCE
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Oil and Gas Case Study: Collaborating with industry leaders to create better PPE
Designing high performance hand protection with global petro-chemical companies
For global petro-chemical service companies like ExxonMobil and Halliburton contractor employee hand injuries represented a disproportionate source of costly worker downtime and insurance claims. ExxonMobil initiated an in-depth study of hand-injuries and established safety glove guidelines and standards3 in 2008. Initial studies identified smash injuries as the leading cause of on-the-job hand injuries. Industry partner and contractor Halliburton, collaborating with ExxonMobil’s efforts, refined hand-injury research and discovered that while smash and pinch injuries were significant in oil field work (approximately 45% of all hand injuries), cut and puncture wounds also represented a higher than expected percentage of hand injuries (nearly 50% of all hand injuries) than initially thought.
SEARCHING FOR SOLUTIONS AND SETTING INDUSTRY STANDARDS
With ExxonMobil establishing industry safety standards for protective oil and gas field gloves, and Halliburton fully engaged in the hazard discovery process, the next logical step was to find a glove on the market capable of meeting the new industry standards, or locate a technical glove designer and manufacturer capable of engineering a safety glove capable of reducing or eliminating debilitating hand-injuries associated with the oil and gas drilling, transportation, construction and refining processes.
Research conducted by ExxonMobil and Halliburton, of safety gloves available on the market, revealed that most construction gloves offered little protection against cut, puncture, smash and pinch injuries. Some of the glove manufacturers contacted resisted modification of glove designs to meet the new industry standards due to lack of design and engineering assets or resistance to the costs involved in retooling production lines.
One company, however, welcomed the challenge of designing and engineering a technical glove to meet the demands of tough oil and gas field applications: HexArmor.
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Industrial gas turbine manufacturer Case Study: Lacerations eliminated
A major manufacturer of industrial gas turbines was experiencing at least five lacerations per year to the forearm/hand. They tried many competitive products but none were able to solve this growing problem. HexArmor® Arm Protection was brought in as a trial project, and to the surprise of the safety managers, there were no recordable laceration injuries for one full year while our arm guards were being tested. Now a large majority of employees wear HexArmor® products every day, and the manufacturer has not only reduced injuries, but also lowered overall spending on safety equipment.
HexArmor® adds value and keeps end users safer in their work environments.
25 Recordable lacertation injuries over 5 years reduced to ZERO with HexArmor
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Steel Production Case Study: Large steel producer experiences $1.7 million injury cost reduction
One of the largest steel producers in the world had a plant operation that was experiencing a dangerous amount of laceration injuries per year. Safety professionals brought in a variety of different PPE technologies to combat the high rate of injury, but could not find a solution able to perform at an acceptable level. They estimated $11,000 absorbed for every injury, not including lost time and productivity.
Plant was experiencing 168 lacerations per year before HexArmor® was implemented
HexArmor® was called to evaluate numerous applications and investigate the types of hazards employees were encountering. After analyzing the companies needs, HexArmor® recommended a full-line of hand and arm solutions that would not only solve the high laceration issue, but would also save the steel producer a large amount of it's safety budget. - Recommended solutions *saved the steel producer over $1.7 million in injury expenses* - Plant had *ZERO recordable lacerations after one year of use*, and continues that rate today - Company mandated *HexArmor® products are required to be worn* for certain applications
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Waste and Recycling Case Study: Waste Mgmt needle issues lead to ppe collaboration
Workers on recycle sorting lines are exposed to needles in waste streams every day, increasing the likelihood that a worker will come in contact with an exposed, contaminated needle. HexArmor saw an opportunity to engineer a solution for these sorters using its advanced technology and worked with Waste Management, Inc. to spearhead an anti-needle program that has virtually eliminated needle injuries to date.
Working With Large Recycler To Eliminate Needle Injuries On Sorting Lines
Rising number of needles in recycle streams creates need for better PPE
Waste Management Inc.’s (WM) increased recycling and sorting demands brought workers in contact with sharps and needles hidden in plastic bottles and containers. Each year recycling workers are exposed to approximately two-to-three billion improperly disposed needles. Exposure to contaminated needles created an unacceptable health risk for employees and the company.
HexArmor collaborates with WM to develop needle protection solutions
HexArmor designers worked directly with WM’s safety team to create a series of protective gloves that had the capability to resist needle sticks and punctures, as well as resist cuts from broken glass shards, steel, wire, and wood splinters commonly encountered in recycling operations. The collaborative nature of the HexArmor/WM relationship led to the development of a mandated hand and arm protection program for recycle sorters that requires operators and line workers to exclusively wear HexArmor products while on the job.
HexArmor’s SuperFabric® technology was the key to preventing needle sticks and punctures from sharps, as well as offering optimal resistance to cuts in a wide range of recycling and sorting tasks. SuperFabric® stopped needle sticks at the point of attack to protect workers’ health and safety. In addition to developing a complete line of recycling and sorting gloves, HexArmor has developed needle-resistant Arm Guards, which are now also required in the Waste Management Recycling Protection Mandate.
HexArmor continues to collaborate with WM on improving current products, and engineering advanced solutions that offer superior protection and extended service in a wide range of waste handling and recycling applications.
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