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New Fatigue Reports Awaken Employers to Injury Risks

The National Safety Council (NSC) estimates that roughly 13 percent of workplace injuries are attributable to sleep problems, causing an economic impact of $400 billion. NSC information suggests that employers with 1,000 employees could incur losses of more than $1 million per year in missed workdays, lower productivity and increased healthcare due to employee fatigue.

But rather than merely provide a bunch of statistics and projections that could put you to sleep, the NSC is providing possible solutions to combat the risk in its new report Managing Fatigue: Developing an Effective Fatigue Risk Management System

According to the report, a workplace culture that rewards or tolerates fatigue can indirectly lead to on-the-job injuries. In some high-performance cultures, employees may view fatigue as a sign of weakness or laziness. They may be committed to getting the work done despite long hours, even believing that fatigue doesn’t affect them.

“In our 24/7 world, too many employees are running on empty,” said Emily Whitcomb, NSC senior program manager for fatigue initiatives.

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“Employees are an organization’s greatest asset, and addressing fatigue in workplaces will help eliminate preventable deaths and injuries.”

Strong fatigue risk management systems blend employee education and training with improvements to workplace environments, culture change, and data-driven programs. But implementing a fatigue risk management system is not an easy sell — to the C-suite and possibly also to employees. The report suggests:

It is important that the fatigue management process be transparent and that appropriate information is shared throughout the effort to obtain buy-in from all levels of the organization. Providing open forums that allow employees to share how fatigue affects them is one way to get engagement from the outset.

The NSC lists key components in creating a fatigue risk management system:

  1. Education and training. This raises awareness of risks, create motivation to prioritize rest, and provide information on how to manage fatigue and get proper rest.
  2. Policies and practices. Clarify roles and expectations and institute policies and practices for hours of work and rest based on science that recognizes the physiological need for sleep and circadian rhythms.
  3. Shared responsibility. Employers and employees should cooperate when it comes to understanding the sleep needs of the employee, while the organization should expect output from a well-rested worker.   
  4. Fatigue mitigation. A workplace with positive environmental controls promotes better overall working conditions and should be less physically stressful in ways that contribute to on-the-job fatigue.
  5. Data-driven programs and continuous improvement. With the system in place, seek employee feedback, facilitate monitoring mechanisms, check the data and apply lessons learned. Understand why the system was or was not successful and modify from there.  

Complementary to Managing Fatigue, the Campbell Institute – the center for environmental health and safety (EHS) excellence at the NSC – released results from a pilot study conducted among renowned safety organizations to assess worker fatigue and effective countermeasures. In Understanding Fatigue Risk: Assessment and Countermeasuresthe Institute identifies a persistent gap between how employers and employees view fatigue and argue for changing a culture to enhance safety.

According to the study, about one-third of workers surveyed reported sleeping between one to five hours per weekday, and not the expert-recommended seven to nine hours.

“This indicates that a large proportion of workers at these sites are chronically sleep deprived, which when coupled with longer work days and work weeks than scheduled means that the risk of a fatigue-related injury is significantly increased,” the report said.

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Additional information about workplace fatigue is available at nsc.org/fatigue.

Fatigue in National News

The timing of these reports should be welcome news for employers. Earlier this month, the National Transportation Safety Board (NTSB) unveiled its 2019-2020 Most Wanted List of Transportation Safety Improvements. One of the 10 items included the need to “Reduce Fatigue-Related Accidents.”

The NTSB’s Open Safety Recommendations describes fatigue as “a pervasive problem in transportation that degrades a person’s ability to stay awake, alert, and attentive to the demands of safely controlling a vehicle, vessel, aircraft, or train.” There are currently 27 open recommendations for railroad, aviation, highway and marine operators in an effort to curb fatigue-related accidents.

“We do not simply come up with these recommendations based on a whim,” NTSB chairman Robert Sumwalt said during the list’s unveiling in Washington, D.C. “It’s a data-driven approach based on the results of our investigation and the tragic and senseless deaths we investigate.

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NTSB’s Most Wanted Improvements Reflect Major Transportation Disasters of 2018

The National Transportation Safety Board (NTSB) unveiled its 2019-2020 Most Wanted List of Transportation Safety Improvements today. The 10-item list is associated with 267 open NTSB safety recommendations that mark critical changes needed in the next two years to reduce transportation accidents, injuries and fatalities, and longstanding safety issues that threaten businesses, professionals and the traveling public.

The list, which is now available online, was unveiled at the NTSB’s press conference in Washington, D.

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C.:

  • Eliminate Distractions.
  • End Alcohol and Other Drug Alcohol Impairment.
  • Ensure the Safe Shipment of Hazardous Materials
  • Fully Implement Positive Train Control (PTC)
  • Implement a comprehensive strategy to reduce speeding-related crashes
  • Improve the Safety of Part 135 Aircraft Flight Operations
  • Increase Implementation of Collision Avoidance Systems in All New Highway Vehicles
  • Reduce Fatigue-Related Accidents
  • Strengthen Occupant Protection
  • Require Medical Fitness – Screen for and Treat Obstructive Sleep Apnea

“We do not simply come up with these recommendations based on a whim,” NTSB chairman Robert Sumwalt said during his opening remarks. “It’s a data-driven approach based on the results of our investigation and the tragic and senseless deaths we investigate. The NTSB’s most wanted list is written in blood.”

Sumwalt said driving while distracted – from cars to trains – had risen to be one of the most prevalent transportation risks facing American roads, railways, businesses and the general population. Texting-while-driving, he said, can increase the likelihood of a crash between four and 20 times. Sumwalt said the NTSB has called for an outright ban on all mobile devices when operating a vehicle because of the distraction to a driver’s cognitive ability and has urged policymakers to regulate the use of devices like Bluetooth and hands-free phones the same as standard mobile device use.

He also said that nearly 37,000 fatalities were reported on roadways in 2017, the most recent year of data available.

The inclusion of distracted driving dovetails with a study released in January by the Insurance Institute for Highway Safety (IIHS), which highlighted the marked increase in drivers using phones in risky ways. based on an observational survey of drivers in four Northern Virginia communities drivers were 57 percent more likely to be observed manipulating their phones, like when texting or using for purposes other than phone calls.

Based on findings that fatal crash risk is 66 percent higher when manipulating a phone, IIHS researchers estimated that about 800 crash deaths in the United States in 2017 could be attributed to drivers texting or using phones for things other than talking.

PTC also received special focus during the NTSB panel discussion and press conference. Board member Jennifer Homendy said the most recent data is from the third quarter of 2018 and that, “we are closer to installation but there’s a big difference between installation and operational. We’re a ways away from that, unfortunately. The risk is the same 50 years ago as it was a year ago,” she said, referencing the PTC-preventable crash she investigated exactly one year ago in Cayce, South Carolina.

After Congress passed the PTC Enforcement and Implementation Act of 2015 it also authorized the FAST Act, which allocated $199 million in PTC grant funding and specifically prioritized PTC installation projects for Railroad Rehabilitation and Improvement Financing funding. The Association of American Railroads estimates that freight railroads will spend $10.6 billion implementing PTC, with additional hundreds of millions each year to maintain. The American Public Transportation Association has estimated that the commuter and passenger railroads will need to spend nearly $3.6 billion on PTC.

As previously reported, several major transportation providers, such as AMTRAK and the Long Island Railroad have missed critical deadlines for installing PTC.

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“In 1961 President Kennedy set a goal to put a man on the moon by the end of the decade and in July 1969 Neil Armstrong and Buzz Aldrin did that,” Homendy said. “In 1969, NTSB investigated its first PTC-preventable accident. In one decade we put a man on the moon but in five decades we haven’t implemented PTC.”

Six Tips For Risk Managers When Assessing Automation Hazards

From a risk management perspective, one of the benefits of automation is that robots can play a significant role in reducing injuries when deployed to replace or support workers in high-hazard jobs, such as those involving high force and repetition. Yet, without appropriate risk assessments, their benefits can become skewed in other situations.

Unfortunately, many companies still make critical automation decisions without adequately engaging risk management, which can leave workers vulnerable to a new set of unanticipated workplace hazards. By some estimates, manufacturers will deploy 1.2 million new robots in the next decade; the expanding use of robotics may bring numerous new significant safety considerations along with a critical need for effective risk management.

As the trend toward greater automation gains momentum, here are six tips for risk managers to assess automation-related workplace hazards and help their organizations achieve the gains they envisioned with these major investments:

  1. Do not underestimate the value risk management brings to automation. Although automation is not new, companies still have much to learn about its effective deployment and implementation – especially in situations where the aim is increased productivity.
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     Risk managers need to be actively involved in assessing potential risks as automation purchasing decisions are made, as well as in planning and managing implementation, related employee training and post-implementation safety assessments and injury monitoring.

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  1. Initiate a dynamic dialogue. When the aim of investing in robotics and automation is specifically for productivity improvement, the starting point should be for risk and operations managers and safety/ergonomics experts to open a dialogue with workers in units designated for automation; they are much more flexible than robots and can offer insights on improving the workplace, reducing injuries and driving efficiency – either without significant investment or by focusing deployment of automation where it is likely to have the greatest impact.
  1. Focus on human factors with increased automation. As plants become more fully automated, the interface between the equipment and employees becomes increasingly significant. Historically, there has been an increased emphasis on automation, but an insufficient focus on the human interface. With more industries retooling plants and upgrading operations, the premium will be on the intelligent design of the next generation of facilities. It calls for the use of advanced tools, such as HumanCAD 3D, to analyze the impact of new equipment on human operators, production, and maintenance, as well as assessments from ergonomics and risk management professionals.
  1. Understand automation is not a panacea. Even the latest robotics may not address every issue, such as assembly tasks that require very fine motor skills, hand-eye coordination and higher-level thinking (such as complex assemblies, part orientation, inspection and precision fits). The automation of some tasks ultimately could require higher rates of repetition in the upper extremities of workers. In this case, ergonomic workstation design, scheduled breaks and worker feedback will be keys to prevent injuries and achieve gains in quality and productivity.
  1. Do not overlook worker demographics. Although automation may help all workers raise their productivity levels, implementation should account for the needs of an aging workforce. Businesses with multiple manufacturing facilities may have to refine workstations, signage, and lighting in areas with higher concentrations of older workers to achieve consistent productivity gains across all operations.
  1. Monitor potential worker safety issues with new product designs. Some forward-looking organizations are pushing for the application of design rules and human factors analysis to evaluate the “Design for Assembly and Ergonomics” (DFMAE) process. In these situations, product designers and advanced manufacturing equipment engineers collaborate with ergonomists to evaluate new product designs and the manufacturing equipment that goes with it. Until such approaches become widespread, it makes sense to check how new product designs might affect assembly workers.
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    Even slight adjustments in product design, manufacturing equipment or workstations can make the job easier and less stressful for employees without expensive robotics.

Investments in highly sophisticated equipment require thorough evaluation of all potential risks involving the interface between the equipment and employee. In some cases, operating equipment may expose workers to a range of injuries, such as repetitive motion issues. And high-speed mobile equipment can pose an outright danger on a factory floor without the delineation of designated “safety zones.” As key members of their organization’s automation team, risk managers play a critical role in anticipating and assessing exposures, developing remedies and facilitating success to ensure robots are working in collaboration with employees and not creating new, unanticipated risks.

2017 Workplace Fatality Statistics Released

According to the Bureau of Labor Statistics’ (BLS) Census of Fatal Occupational Injuries in 2017, a total of 5,147 fatal work injuries were recorded in the United States. And while this data marks 43 fewer casualties than in 2016, employers should note that it is still an increase of more than 300 in both 2014 and 2015.

The continued high rate was fueled by the frequency of transportation incidents (2,077) and 887 fatal falls, which marked their highest level in the 26-year history of the census.

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Another key finding involved overdoses of drugs and alcohol while at work.

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Unintentional overdoses due to nonmedical substances while at work increased 25% from 217 in 2016 to 272 in 2017. The BLS noted that this was the fifth straight year in which unintentional workplace overdose deaths have increased by at least 25%.

The National Safety Council (NSC) released a statement in reaction to the BLS data, saying that it was “disheartened to see a small rise in unintentional, preventable worker fatalities.” The NSC’s statement continued:

“Once again, the data clearly show we are not doing enough to mitigate the risks of these everyday killers. At work, leadership should set the tone and engage all employees in safety, identifying hazards and measuring safety performance using leading indicators to ensure continuous improvement.”

Additionally, the BLS found:

  • Contact with objects and equipment incidents were down 9 percent (695 in 2017 from 761 in 2016) with caught in running equipment or machinery deaths down 26 percent (76 in 2017 from 103 in 2016).
  • Fatal occupational injuries involving confined spaces rose 15 percent to 166 in 2017 from 144 in 2016.
  • Crane-related workplace fatalities fell to their lowest level ever recorded in by the census, 33 deaths in 2017.

Clearly, the fatality rate of some occupations remains alarmingly high. Below are the 10 most dangerous jobs in America for 2017, according to the BLS and the fatal work injury rate (per 100,000 workers).

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