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Topic: DIARY OF AN OSHA INSPECTOR

The Industry Standard Alibi

January 15, 2007

FEBRUARY 13, 2006:

You don't want to tick off an OSHA inspector. Trust me on this one.

We don't expect you employers out there to be our friend. But we expect cooperation and respect. I'm not talking just about how you deal with us when we show up at your site. I'm talking about your attitude toward OSHA standards

Every once in a while some smart aleck will tell me that he - or she - doesn't have to follow an OSHA standard because it's not "realistic" or because "it's not how we do things in our industry." Nothing burns Ol' Nick's bacon more than hearing something like this. That's just what happened today. And if I sound upset, that's because I am.

10:28 A.M.

I didn't start the day in a bad mood. Just the opposite. It's the day before Valentine's Day and I got my roses for Mrs. O ordered nice and early. So I'm feeling kind and gentle.

That should be good news for U.R.D. Pitts Generating Corp.--the employer I'm on my way to see. Pitts is one of the good guys in our area. Quiet. No incidents. No complaints. A few years ago, I inspected the place. But it was a programmed inspection. [Editor's Note: A scheduled inspection as opposed to one in response to a complaint or referral from an agency.] The place was squeaky clean.

So I was surprised to hear that we got a complaint about Pitts. It was from a supervisor. Check that, a former supervisor who got laid off. It's pretty common for employees to report problems with their ex-companies once they get the pink slip.

But I talked to this guy and I don't think he was just blowing smoke. He was sharp. An engineer. And he knows the OSHA standards, at least the lockout/tagout (LOTO) standard. He claims that Pitts is taking shortcuts with LOTO. I'm taking a ride to the Pitts plant to check it out.

11:51 A.M.

Turns out the engineer was right. It's a group LOTO situation.

The standard says that devices must be attached to machines locked out during service or maintenance. This alerts people that the machine is being worked on and shouldn't be energized. Group lockout is okay as long as each employee authorized to work with the machine attaches a personal lockout or tagout device when work begins and removes it when the work is over. Or they can all sign off on one master tag.

Pitts isn't doing this. Instead of having each employees attach a personal device or sign off on a master tag, they're keeping a master list of all workers covered by the work. Then they're having one supervisor go around and tell each worker when the lockout or tagout device has been attached and when it's been removed. The supervisor then checks off each name on the list after he delivers the message to the employee.

I suspect that the supervisor who blew the whistle was keeping the master list while he was working for Pitts. That's how he knew what was going on.

12:20 P.M.

Taking shortcuts with OSHA standards is never a good thing, especially when it involves LOTO. I've seen too many machine accidents in my time.

But while I can't condone it, what Pitts is doing isn't the worst thing I've ever seen. It's pretty easy to abate [Editor's note: Abate is OSHA-speak for correct.] Knowing Pitts, it's probably just an honest mistake. And since, nobody's gotten hurt, thank God, I'm not necessarily going to issue a citation. All I want is to get it fixed before somebody does get hurt.

At least this is what I'm thinking until I step into the office of one Lou Sitania, the Pitts plant manager, for the closing conference. I explain the problem and ask him to make sure it's abated within 15 days. Sitania just sits there at his desk staring into space. Then he takes off his glasses and starts rubbing the bridge of his nose. Finally, he speaks.

"Mr. O'Shay, have you ever worked for a power company?"

"No," I say.

"I didn't think so. You see, if you had, you'd know that our lockout procedure is totally in line with industry practice."

I'm trying to stay calm. "I don't care if it's industry practice, the OSHA standard says that each employee has to affix a personal device or sign a master tag."

"With all due respect, Mr. O'Shay, that's completely inefficient and unnecessary. That's why nobody in our industry does it that way."

"I didn't come here to debate, Mr. Sitania. I'm issuing you a citation for violating the OSHA lockout standard. You will receive a notice by certified mail informing you of the fine amount and abatement requirements."

Sitania's expression doesn't change. "You might as well cite every power company in America, Mr. O'Shay."

"Goodbye, Mr. Sitania. I will show myself out."

The Moral

OSHA is not an ivory tower. We make the effort to consult and cooperate with industry. That's why a lot of the OSHA standards incorporate industry practices. Or they leave room for employers to use discretion when it comes to implementing the standard.

But doggone it, if an OSHA standard does specify a method and you don't follow it, you're breaking the law. The fact that the OSHA method isn't the industry standard is no defense. If you think the industry way is better, lobby to have the OSHA standard changed. But never, never debate it with an OSHA inspector. That's one argument you can't win. All you're going to do is tick off the inspector.

And you don't want to tick off an OSHA inspector. Trust me on this one.

**************
Happy Valentine's Day, and remember. I'll be watching you.

Nick O'Shay
OSHA Inspector

THE CANADIAN PERSPECTIVE

The Canadian system works the same way: If an industry standard contradicts an OHS regulation, the latter prevails. Nick's angry reaction is just what a Canadian employer can expect if it tries to debate the merits of an OHS standard with an inspector.

One part of the story that doesn't apply to Canada: The group lockout rules. They differ from province to province.


POINT/COUNTERPOINT

Nick O'Shay Faces His Critics

Dear Inspector O'Shay,

I have been in the safety business for nearly 30 years, and I can tell you this: A safety professional's work life is challenging enough without your throwing highly combustible liquids onto a fire. You see, I do not particularly care if I "tick off the OSHA inspector" right now, Inspector O'Shay, especially when he is so unprofessional as to use a valuable publication like SafetyXChange to vent his spleen. Let's examine your threatening tirade:

"I'm feeling kind and gentle. That should be good news for the employer I'm on my way to see."  What would have happened if "Mrs. O" had gotten angry with you that morning and got you "ticked off" before you even walked in the door at Pitts? You would probably have stuck them with a $70,000 per exposure Willful Violation. You could have, you know. How is that? Well, allow me to continue to quote you:

"A few years ago, I inspected the place (Pitts). The place was squeaky clean." From this statement, the reader could infer that you inspected the entire facility and at the time of the initial inspection:

  1. Pitts' safety program and behaviors were fully compliant. "Squeaky clean"
  2. As a consequence of "A", Pitts knew the LOTO rules and how to comply with them and indeed was in compliance with them. "Squeaky clean"
  3. Or you performed a shoddy inspection and did not even bother to check their LOTO program.  (Kind of makes us wonder about that "Squeaky clean.")

There is your Willful, Mr. O'Shay, but I am sure you knew that as well because, "when it involves LOTO.  I've seen too many machine accidents in my time."  But the willful violation is not Pitts', Mr. O'Shay, it is yours. Either you willfully violated the Safety Professional's code of ethics by turning a blind eye the first time (we can only wonder why) or you just are not with the program in your own organization.

In his comments to area professionals some years back, former Assistant Secretary of Labor for Occupational Safety, John Henshaw, said the following: "There are three groups of employers out there right now. The top 10% are doing it right and are interested in working safely.  They have or want to be VPP, they build a safety culture through self audits, up to date maintenance and training, rewarding good safety performance, and remediating their own offenders. I am not going to bother them. Why should I? There is also a middle 80% who want to do the right thing but do not know how. My mission is to do whatever I can to help them build and maintain a positive safety program and attitude. Finally, there is the bottom 10% who refuse to make any effort to work safely. They openly defy attempts to force them to protect their workers and become compliant. My mission is to run them out of business before they can hurt anyone else."

You did not fine Pitts because of a violation of federal law that could and probably would have resulted in death or serious injury. No, you cited them because one person in their organization, who may have been having a bad day personally, "ticked you off."

Finally, I think you should forward your article to the Justice Department. Unless you tape recorded those comments allegedly made by Mr. Sitania, both he and his company have a good case for libel. It also throws into question the merits of the citation and the merits of any past citations you may have issued out of pique.

Very truly yours,

Name and Company Withheld at Author's Request


NICK'S REPLY

Dear Sir:

Thanks to SafetyXChange for giving me a chance to answer this letter not only to defend my personal reputation but to explain to the guy who wrote it and to other SafetyXChange readers how OSHA enforcement works.

First, I want you folks to understand that even though I'm a fictional character, my adventures are all based on actual cases. They come from:

  1. Interviews by my ghost writer with actual OSHA inspectors;
  2. Cited cases; and/or
  3. A combination of both.

This story of the Pitts plant is of the c. variety. U.R.D. Pitts and Lou Sitania are made up names as are some of the other extraneous details of the story, like the Valentine's Day flowers for Mrs. O'Shay. But one thing that's not made up is the part about employers thinking that all they got to do is follow industry standards and not worry about OSHA. Inspectors told my ghost writer about this. The group LOTO example comes from an OSHRC case, Sec. of Labor v. Exelon Generating Corp., OSHRC Docket No. 00-1198, April 6, 2005.

Let's now talk about my previous inspection of the Pitts place. With all due respect, your attacking me for finding Pitts "squeaky clean" is unfair. After all, how do you know that:

  • Pitts was using the same group LOTO back then when I first inspected the place. Maybe they were doing it right and changed the practice later.
  • The scope of the inspection wasn't limited to something non-machine safety related. Remember, sir, that OSHA inspectors don't automatically look at LOTO any time they check out a place. In fact, it might be against the law for me to poke around machines when a programmed inspection addresses, say, eyewash stations or something else unrelated to LOTO.

Let's now talk about the not ticking off an OSHA inspector point. You guys gotta realize that we OSHA inspectors got a lot of leeway. The leeway isn't in pointing outa violation. If me or any other OSHA inspector notices a problem, especially one as serious as LOTO, and don't point it out to the employer, we're not doing our job and deserve to be fired.

The leeway kicks in after we spot the problem. We don't necessarily have to issue a citation just because we see a violation. We can and often do give the employer a chance to fix the problem without a fine. This is especially true if the problem is readily correctable and the employer is cooperative. I thought this might be the case with Pitts. But when the plant director, Mr. Sitania, started spouting off about the OSHA standard's being unrealistic, I could see that I wasn't likely to get the cooperation I wanted.

And, yes, somebody who ticks me off is more likely to get a citation than somebody who demonstrates remorse and cooperation. It's the same with other OSHA inspectors. I admit that it would be better if we didn't let our emotions dictate whether to issue a citation. But we're only human.

So, it's not about me. It's about the process. At the end of the day, I wanted to let the SafetyXChange members know that industry standards aren't a substitute for OSHA. If you're not doing it the OSHA way, you're breaking the law. And if you cop an attitude and debate an OSHA inspector on the merits of the standard, you're increasing your odds of being cited for not following the OSHA standard.

Sincerely yours,

Nick O'Shay

OSHA, CSHO

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