GEAPS 540: Safety Management of Grain and Processing Facilities
Next course offering: Sept. 2-Oct. 3, 2014
Registration opens: July 7, 2014
Course Description: GEAPS 540 provides participants with fundamental safety techniques to help minimize the most significant worker safety and health risks. In addition to an overview of safety management, the lectures will cover emergency action plans/emergency response, fire and explosions in grain facilities, contractor safety, truck and rail safety and flowing grain dangers. Students will be given examples of management plan outlines and learn how to create safety plans in their own facility.
Course Goals: This course aims to enhance operations management staff's basic safety skills and knowledge so they can create safe and healthy environments in their facilities.
Target Audience: This course is designed primarily for operations management staff and individuals responsible for worker safety and health training for their respective companies or employees.
Mark Daniels, Director of Health and Safety, CHS Inc. | Show Bio
Mark has served as corporate safety director at CHS for more than 30 years. He has also served the grain industry as chairman of the American Feed Industry Association's safety committee, the GEAPS/National Grain & Feed Association's former safety committee and was GEAPS International president in 2008-2009.
Mike Ravenstein, Safety Specialist
Brandon Dills, Safety and Compliance Officer, Co-Mark Inc. | Show Bio
Brandon Dills is a 1989 graduate of Hutchinson Community College and a 1991 graduate of the Kansas State University School of Milling Science. Brandon served in the milling industry for more than eight years and has worked safety and compliance in the grain industry since 1999. He assists grain elevators in complying with rules and regulations associated with OSHA, DOT, EPA, FDA, Homeland Security, and other local, state and federal agencies. He has been active in the GEAPS Great Plains chapter since 2000, served on the national GEAPS/NGFA safety committee and the Host Advisory Council for the 2010 GEAPS Exchange in Wichita, Kan.
Joe Mlynek, President, Safety and Loss Control Consultant, Progressive Safety Services | Show Bio
Joe Mlynek is the president and safety and loss control consultant for Progressive Safety Services. Prior to forming Progressive Safety in 2009, Joe worked as a safety professional in a wide array of industries including: automotive, chemical, railcar repair, retail, metal fabrication and grain handling. Joe has a bachelor's degree in environmental policy and analysis from Bowling Green State University and is a certified occupational health and safety technologist.
Julie Waltz, Safety/Regulatory Consultant,RCI Safety | Show Bio
Julie has been educating people about safety planning and emergency response for over 25 years. She currently works for RCI Safety where her primary responsibility is helping clients with safety, health, environmental quality and regulatory issues. Julie has a Bachelor of Science from Iowa State University where she majored in industrial technology with an emphasis in education, communication and safety. She has served as commissioner and chair of the Iowa Emergency Response Commission for eight years and is past president of the Greater Iowa GEAPS chapter.
Joe Allen, Risk Management/Area Manager, Kansas Farmer Service Association | Show Bio
Joe is a commercial account manager in the insurance department and has worked for KFSA for over six years. Up until 2010, he was with the KFSA risk management department, providing solutions to customer safety and regulatory challenges and supervising six ag services employees. Prior to coming to KFSA, Joe spent five years with the Kansas Department of Agriculture as a pesticide investigator, where he enforced Kansas and EPA pesticide regulations. He also has ten years of experience with water quality issues and irrigation concerns.
Matthew Roberts, Distance Education Consultant and Grain Quality Extension Specialist, Purdue University | Show Bio
Matt manages grain, forage, and beef production for J&M Roberts Farms LLC. He holds a master's degree in agricultural systems management from Purdue University. He serves as a private distance education consultant for Kansas State University and instructs approximately 3-4 courses per year. During his time as a research assistant at Purdue, he completed a thesis on flowing grain dangers and rescue techniques. He continues to work for Purdue as a grain quality extension specialist assisting growers with best grain storage management practices.
Gregory Rowe, Senior Director of Operations, Perdue AgriBusiness | Show Bio
Greg Rowe has over 29 years of experience in the grain handling industry. He has been with Perdue AgriBusiness for the past five years as a senior director of operations with responsibility for the grain handling, soybean processing, and PACMA operations. Prior to his current position, he spent 24 years with Cargill in a variety of facilities and operations positions, including health and safety leader for U.S. grain handling operations. He is a member of the NGFA Safety Health & Environmental Quality Committee.
Course of Study
Lecture 1 – Overview of Safety Management
This lecture explains the logic behind implementing and following safety programs at grain and processing facilities and discusses ways to implement a program. It covers the following topics: why safety matters, primary causes of accidents, benefits of an effective safety program, developing an action plan, creating a safety culture and making a safety program effective. It will also provide students with external resources for help in safety management in the grain industry.
Lecturer: Mark Daniels
Lecture 2 – Lockout and Tagout
This lecture focuses on the development and implementation of lockout/tagout (LOTO) programs related to grain and processing facilities. The lecture covers the definition of LOTO, the difference between lockout and tagout, the purpose of LOTO, and identifies who can perform LOTO. Students will be given a guide to what needs to be included in a LOTO plan, what is needed to control the energy and how to do it, annual inspection requirements of the LOTO and the written procedure and the needed training requirements.
Lecturer: Mike Ravenstein
Lecture 3 – Walking and Working Surfaces
This lecture reviews fall-related prevention strategies for grain handling and processing facilities. It covers several topics including: an introduction to walking and working surfaces and statistics, categories of falls, employer responsibilities and an overview of areas and equipment considered within walking and working surfaces. By the end of this course students will know the factors contributing to slip, trip and fall incidents, the different types and uses of portable ladders, the basics of portable ladder inspection and maintenance, the types of aerial lifts used in grain handling facilities and inspection and authorization rules.
Lecturer: Greg Rowe
Lecture 4 – Confined Spaces in the Grain Industry
This lecture covers on the basics of confined space entry procedures as they relate to the grain industry. Students will be provided with an overview of statistics, definitions, employer responsibilities, rules, training and hazards associated with confined space entry, how to work with first responders and learn the requirements of a permit and reclassification. At the end of the lecture, students will be asked to analyze a case study using what they have learned.
Lecturer: Brandon Dills
Lecture 5 – Emergency Action Plans/Emergency Response
This lecture discusses developing an emergency response plan that will facilitate timely pre-planned response. Topics include: what an emergency action plan (EAP) is, why having an EAP is important and where to begin, who is responsible for developing the plan, what to put in a plan, when a plan should be implemented, types of emergencies to consider and how to coordinate with emergency responders. The lecture will also help students build a plan and assist them in developing their plan.
Lecturer: Mike Ravenstein
Lecture 6 – Fire and Explosions in Grain Facilities
This lecture provides an overview of various hazards, goes over operating parameters, industry experience, and track record and gives risk mitigation strategies to prevent fires and explosions in grain handling facilities. Students will learn what creates a grain dust explosion, what makes the difference between a fire and an explosion, what regulations apply to the grain industry and prevention techniques such as good housekeeping and ignition control.
Lecturer: Brandon Dills
Lecture 7 – Contractor Safety
This lecture teaches students procedures for avoiding contractor issues at grain handling facilities, including documentation, training, auditing and integration with other facility safety policies. Students will learn about developing an effective contractor safety policy, contractor pre-certification and safety training prior to work, contractor documentation and auditing and other training aids related to contractor safety.
Lecturer: Joe Mlynek
Lecture 8 – Truck and Rail Safety
This lecture provides an overview of the hazards of working on or around rail and truck operations and gives hazard prevention techniques that can be employed. Topics include communication and accountability, safe work practices, ergonomic issues, awareness in the work area, fall protection, traffic flow, truck receiving/unloading safety and truck loading safety.
Lecturer: Julie Waltz
Lecture 9 – Ag Chemical Safety
This lecture will address various possible chemical exposures and provide risk management strategies to help protect employees and assets. Students will learn about the types of chemicals allowed at facilities, hazard communication, worker protection standards, Personal Protective Equipment, training/certification, storage (704 diamond, fumigant), record keeping, annual reporting and what first responders should do. The lecture will also provide an outline for a risk-management plan and a fumigation management plan that students will be able to use in the future.
Lecturer: Joe Allen
Lecture 10 – Flowing Grain Dangers
This lecture discusses engulfment and suffocation hazards associated with flowing grain and toxic atmospheres associated with stored grain. It introduces the dangers of flowing grain, identifies the seven types of engulfment and the sites involved and teaches students how to respond to an engulfment. The lecture also provides recommendations to reduce the likelihood of grain entrapment and/or suffocation.
Lecturer: Matt Roberts