Investigation of injury data at a detonator facility

Los Alamos National Laboratory (LANL) has been the design agency for nuclear weapon detonators for over 70 years. Detonator development, in support of the U.S. Department of Energy's (DOE) nuclear weapons program, account for most activities performed by the Detonator Production Agency (DET). Management of work-related injuries includes in-field monitoring of injury/illness reports. Employing Lean Manufacturing and Six Sigma business practices (LSS), statistically significant variations (trends) have been identified in DET injury reports. An output metric has been developed that measures DET management progress toward meeting its operational safety objectives and goals. An I-chart format has been chosen to validate the variation of DET Occupational Safety and Health Administration (OSHA) recordable and sub-recordable injury cases because this information is tracked as changes in the number of days between DET recordable and sub-recordable injury cases. Using a timeline, the primary injury types have been tracked. Using a Pareto Chart, the primary injury factors have been prioritized. This paper focuses on the collection of injury data; incorporation of this information into a visual format that DET management uses to make decisions to improving operations. Results from this study include of the following: chemical exposure cases have declined because the Hazard Assessment of each DET operation has been formally reviewed; Slip/Trip/Fall factors have decreased due to Slip Simulator training; and work station evaluations have led to fewer injuries with Lift/Push/Pull factors. Rotation of employees, ergonomically friendly balances, automatic powder dispensers, and other equipment procurements will lower ergonomic injuries.