Investigation of injury/illness data at a nuclear facility

Chemical and metallurgical operations involving plutonium and hazardous materials in support of the U.S. Department of Energy's nuclear weapons program account for most activities performed at the Los Alamos National Laboratory Plutonium Facility (TA-55). Chemical exposures, abrasions (scrapes), contusions (bruises), lacerations (cuts), strains and sprains, and especially ergonomic injuries dominate TA-55 job-incurred injuries and illnesses. The TA-55 Health and Safety Program manages these work-related cases. A key element of the program is in-field monitoring of injury/illness reports. Employing Lean Manufacturing and Six Sigma business practices (LSS), statistically significant variations (trends) have been identified in TA-55 injury/illness reports. An output metrics has been developed that measures TA-55 management progress towards meeting its operational safety objectives and goals. Using a Pareto Chart, the primary injury types have been determined. With a failure modes and effects analysis (FMEA), decisions have been made over which injury types require management support. This paper focuses on the collection of injury/illness data; incorporation of this information into a visual format that TA-55 management uses to make decisions; and some of the decisions TA-55 management has made to improved operations. Conclusions from this study included the following: TA-55 management expectation that workers seek medical attention before an injury or illness becomes serious has been effectively implemented; ergonomic evaluations and improved ergonomics training for all new TA-55 residents and glovebox workers has resulted in a significant reduction in ergonomic injuries, especially those related to glovebox operations; TA-55 management should continue to focus its effort on minimizing lacerations in a Radiological Control Area and ergonomic injuries; and no flawed defenses or safety hazards were revealed in this analysis.