Bret McCormick
Region 2 Director
Stewart’s Electric Motor Works, Inc.
Orlando, Florida

Near Miss? Near Hit? Close Call?  

No one ever wants to hear these phrases. These unplanned incidents have the potential of causing serious damage or injury. A good number of these narrow escapes come from a lack of defining proper processes and procedures. Too many people think “no harm, no foul.” Unfortunately, this does not address the root issue. Someone could have been seriously hurt. Not addressing the underlying problem will undoubtedly allow it to happen again.

It’s important to develop a near-miss reporting system. This system should be based on a culture of safety that identifies problems, reduces the risk factor and controls the exposure to danger. In our service center, we had an ongoing issue of rotors not being adequately secured for moving from one department to another. The general process included placing it on a pallet and throwing a 2X4 on each side to keep it in place. After the second time, a big rotor started rolling down the aisle. We knew immediately that we had a problem, so we came up with a form that did not place blame on the offending person. The form asks these three basic questions:

• What happened?
• What could have happened?
• What do you think we can do to prevent this?

We ask for the location of the incident, along with the date and time it occurred, but the report does not go into the employee’s file. During our safety meetings, we have a short discussion about the three questions and ask the rest of the crew if they have any ideas for improvement. It is important to make the report as easy as possible.

Since we started this program, we have discovered damaged eyebolts, broken safety snaps and damaged slings by making people more aware of the dangers around them. Engaging the managers, supervisors, and all employees has made our shop a safer place for everyone. 

The near-miss report is included in the new hire paperwork package as a part of our onboarding process.   

So, what did we do about the rolling rotors? A simple problem requires a simple solution. We made cradles out of pressure-treated wood and mounted them to pallets so that every rotor has a place to rest. Since we started this program, we have discovered damaged eyebolts, broken safety snaps and damaged slings by making people more aware of the dangers around them. Engaging the managers, supervisors, and all employees has made our shop a safer place for everyone.

Categories: Technical topics, Safety

Tags: Safety

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