ANNUAL ALLIANCE REPORT
The Occupational Safety and Health Administration (OSHA) and the
American Foundry Society (AFS)
April 23, 2009

1. Alliance Background
   
   Date Signed
   
   March 22, 2004
   
   Dates Renewed
   
   April 28, 2006; April 11, 2008
   
   Evaluation Period
   
   March 22, 2008 - March 21, 2009
   
   Overview
   
   Through the OSHA and AFS Alliance, OSHA and AFS are working together to encourage AFS members and others, including small businesses in the metalcasting industry, to increase employee access to safety and health information and training resources on workplace issues, to include personal protective equipment, heat stress, and reducing and preventing exposure to silica.
   
   Implementation Team Members
    

   OSHA:
   Bill Coulehan, Region V, Calumet City, Illinois Area Office Russell Jones, Office of Small Business Assistance (OSBA), Directorate of Cooperative and State Programs (DCSP) Tony Mapes, Office of Outreach Services and Alliances (OOSA), DCSP Lisa Ramber,* OOSA, DCSP
   AFS:
   Jim Barry, On-site Consultation Program, Wisconsin/10-Q Committee Bob Forrester, 10-Q Committee Fred Kohloff, Director, Environmental, Safety, and Health Gary Mosher, 10-Q Committee Kay Rowntree, 10-Q Committee Stephanie Salmon, AFS Washington, DC representative Bob Scholz, 10-Q Committee Jack Schuldt, 10-Q Committee Tom Slavin, 10-Q Committee Jeff Willman, 10-Q Committee * Lisa Ramber is no longer with OSHA as of August 2009.

2. Implementation Team Meetings
    
   • April 8, 2008 Implementation Team Meeting
   • August 4, 2008 Implementation Team Meeting
   • January 9, 2009 Implementation Team Meeting
   In addition to these formal meetings, the Alliance coordinators from the groups maintained regular contact throughout the reporting period to monitor the Alliance's progress and results.
    
3. Results
    
   1. Events and Products
      
      Training and Education Goal
       
      • Work with OSHA to provide expertise to develop workplace safety and health curricula on the foundry workplace issues including, PPE, heat stress, and silica.
        
        AFS "Foundry Best Practices Seminar"
        
        Through the OSHA and AFS Alliance, AFS developed a draft agenda for a "Foundry Best Practices Seminar" for OSHA staff, with input from Luis Garcia, Safety and Occupational Specialist, Region V, Chicago North, Illinois Area Office, USDOL-OSHA. The seminar will provide attendees with an overview of the safety and health hazards that are present in foundries, and measures that might be taken to eliminate or reduce the severity of the hazard. In addition, information will be presented on the metalcasting industry's processes and methods from patternmaking to quality control. During the reporting period, Luis attended AFS' "Introduction to Metalcasting Course," July 15-17, 2009 in Schaumburg, Illinois. The course was used as a foundation to develop the draft agenda for the "Foundry Best Practices Seminar."
        
        Outreach and Education Goals
         
      • Work with OSHA to provide expertise in developing information on the recognition and prevention of workplace hazards, and to provide expertise in developing ways of communicating such information (e.g. print and electronic media, electronic assistance tools, and OSHA's and AFS's Web sites) to employers and employees in the industry.
        
        Products
        
        AFS Heat Stress White Paper, "Establishing a Foundry Heat Stress Management Program"
        
        Through the OSHA and AFS Alliance, AFS developed the Heat Stress White Paper, "Establishing a Foundry Heat Stress Management Program." The White paper addresses heat-related illnesses and can be used by employers in the foundry industry to help implement a heat stress management program.
        
        Control of Silica Exposure in Foundries Manual
        
        Through the OSHA and AFS Alliance, AFS developed the "Control of Silica Exposure in Foundries" manual. The manual provides foundries with information that can help control the potential hazards of respirable crystalline silica. It focuses on the elements of an air contaminant exposure control program; management commitment; worker involvement; hazard assessment and communication; exposure monitoring; operational and maintenance procedures for the process and its ventilation; housekeeping; respiratory protection and medical monitoring.
        
        OSHA Safety and Health Topics Pages
        
        Representatives from AFS serve on the editorial boards of the following OSHA Safety and Health Topics pages and eTool, providing OSHA with their expertise and technical review:
         
        • Control of Hazardous Energy (Lockout/Tagout)
          • Jack Schuldt, President, Safety Specialties, Inc., Mulberry,
            Florida
        • Heat Stress
          • Bob Scholz, Project Manager, RMT Inc., Brookfield, Wisconsin
        • Lead
          • Gary Mosher, CIH, Mosher Environmental and Occupational Health Consulting, Inc., Arlington Heights, Illinois
        • Powered Industrial Trucks
          • Bob Forrester, Neptune Technology Group, Tallahassee, Florida
        • Respiratory Protection
          • Kay Rowntree, CIH, Industrial Hygiene Services, LLC, Waterford, Wisconsin
        • Silica, Crystalline
          • Gary Mosher, CIH, Mosher Environmental and Occupational Health Consulting, Inc., Arlington Heights, Illinois
        • Ventilation
          • Gary Mosher, CIH, Mosher Environmental and Occupational Health Consulting, Inc., Arlington Heights, Illinois
          • Bob Scholz, Project Manager, RMT Inc., Brookfield, Wisconsin
        • Powered Industrial Trucks eTool
          • Tom Daughetee, Morrison Brothers Foundry, Dubuque, Iowa
          • Bob Forrester, Neptune Technology Group, Tallahassee, Florida
          • Glenn Huneycutt, Charlotte Pipe and Foundry, Charlotte, North Carolina
        OSHA and AFS Alliance Web page
        
        OSHA is continuing to update the OSHA and AFS Alliance Web page that is posted on the OSHA Web site. It includes the OSHA and AFS Alliance agreement, renewal agreement, news releases, products and resources, activities and events and milestones and successes of the OSHA and AFS Alliance.
        
        AFS and OSHA Alliance Web page
        
        AFS is continuing to update the sections on its Web site, which contains information on the OSHA and AFS Alliance. The sections include links to the OSHA and AFS Alliance Web page, Alliance-developed products, and available compliance assistance resources on the OSHA Web site.
        
        Publications and Newsletters
        
        Information on the activities of the OSHA and AFS Alliance have appeared in a number of print and online publications. For more information on the articles, see the "Alliance Program Reach" table.
         
      • Speak, exhibit, and/or appear at OSHA and AFS conferences, local meetings, and other events such as the annual Environmental Health and Safety (EHS) conference and the Washington Conference.
        
        Events
        
        20th AFS Environmental Health and Safety Conference, August 24-27, 2008, St. Louis, Missouri
        
        Joe Czaicki, Industrial Hygienist, Region VII, St. Louis, Missouri Area Office, USDOL-OSHA, staffed an OSHA and AFS Alliance exhibit booth during the conference to distribute compliance assistance publications, and answer attendees' questions.
        
        Cast Expo 2008, May 17-20, 2008, Atlanta, Georgia
        
        Marilyn Velez, Compliance Assistance Specialist , Region IV, Atlanta-West, Georgia Area Office, USDOL-OSHA; Anita Fountain, Compliance Safety and Health Officer, Region IV, Atlanta-West, Georgia Area Office, USDOL-OSHA; and Patricia Morris, Compliance Safety and Health Officer, Region IV, Atlanta-West, Georgia Area Office, USDOL-OSHA, staffed an OSHA and AFS Alliance exhibit booth during the conference to distribute compliance assistance publications, and answer attendees' questions.
        
        AFS Government Affairs Conference, April 9-11, 2008, Washington, DC
        
        On April 11, 2008, Edwin G. Foulke Jr., then-Assistant Secretary, USDOL-OSHA made a presentation on OSHA's outreach efforts and compliance assistance resources to 100 conference attendees. Following the presentation, Mr. Foulke signed the OSHA and AFS Alliance renewal agreement. In addition, Richard Fairfax, Director, Directorate of Enforcement Programs, USDOL-OSHA; and Jim Maddux, then-Acting Director, Office of Biological Hazards, Directorate of Standards and Guidance, USDOL-OSHA, made presentations during a panel discussion entitled "OSHA Enforcement and New PPE Rule" to 100 conference attendees.
         
      • Share information among OSHA personnel, including Compliance Safety and Health Officers, and industry safety and health professionals regarding AFS's best practices or effective approaches and publicize results through outreach by AFS and through OSHA- or AFS-developed materials, training programs, workshops, seminars, and lectures.
        
        Event
        
        AFS' "Introduction to Metalcasting Course," July 15-17, 2008, Schaumburg, Illinois
        
        Through the OSHA and AFS Alliance, AFS invited one OSHA staff person to attend AFS' "Introduction to Metalcasting Course," July 15-17, 2008 in Schaumburg, Illinois. As a result of AFS' invitation, Luis Garcia, Safety and Occupational Health Specialist, Region V, Chicago North, Illinois Area Office, USDOL-OSHA, attended the course. The course provides attendees with an overview of the metalcasting industry's processes and methods from patternmaking to quality control.
        
        Products
        
        AFS Heat Stress White Paper, "Establishing a Foundry Heat Stress Management Program"
        
        AFS promoted the Heat Stress White Paper, "Establishing a Foundry Heat Stress Management Program," which is a product of the OSHA and AFS Alliance, by placing a link to it on the AFS and OSHA Alliance Web page. In addition, a link to the paper was added to the OSHA and AFS Alliance Web page and the Alliance Program Participants Developed Products Web page on the Agency's Web site.
        
        Control of Silica Exposure in Foundries Manual
        
        AFS promoted the "Control of Silica Exposure in Foundries Manual," which is a product of the OSHA and AFS Alliance, by placing a link to it on the AFS and OSHA Alliance Web page. In addition, a link to the manual was added to the OSHA and AFS Alliance Web page and the Alliance Program Participants Developed Products Web page on the Agency's Web site. In addition, AFS distributed printed copies of the manual to their members and to the following OSHA Regional Offices:
         
        • Region II
        • Region III
        • Region V
        • Region VII
      • Promote and encourage AFS chapters or worksites' participation in OSHA's cooperative programs such as compliance assistance, the Voluntary Protection Programs, and the On-site Consultation Program and its Safety and Health Achievement Recognition Program.
        
        The OSHA and AFS Alliance Implementation Team has not started work on programs or projects to address this goal.
         
      • Work with other Alliance participants on specific issues and projects regarding PPE, ventilation, and silica issues that are addressed and developed through the Alliance Program.
        
        Events
        
        2008 North American Occupational Safety and Health (NAOSH) Week, May 4-10, 2008, Washington, DC
        
        AFS joined with more than 50 other Alliance Program participants to support 2008 NAOSH Week. NAOSH Week, sponsored by the American Society of Safety Engineers, an Alliance Program participant, focuses on increasing the understanding of the positive benefits of investing in occupational safety, health and environmental programs among employers, employees and the public; raising awareness of the role and contribution of safety, health and environmental professionals; and reducing workplace injuries and illness by encouraging new safety and health activities at all companies and organizations. In addition, AFS supported NAOSH Week by placing a link to the 2008 NAOSH Week Web page on ASSE's Web site on the AFS and OSHA Alliance Web page.
         
      • Encourage AFS chapters' or worksites' to build relationships with OSHA's Regional and Area Offices to address health and safety issues, including PPE, heat stress, and silica.
        The OSHA and AFS Alliance Implementation Team has not started work on programs or projects to address this goal.
        
        National Dialogue on Workplace Safety and Health Goal
         
      • Develop and disseminate case studies illustrating the business value of safety and health and publicize their results.
        
        Products
        
        OSHA and AFS Case Study, "Ventilation Upgrade Reduces Silica Exposure at Grede Foundries, Inc. Facility in Reedsburg, Wisconsin"
        
        The OSHA and AFS Alliance Implementation Team developed a case study entitled, "Ventilation Upgrade Reduces Silica Exposure at Grede Foundries, Inc. Facility in Reedsburg, Wisconsin." The case study focuses on control measures that Grede Foundries implemented to reduce employees' exposure to silica at its plant in Reedsburg, Wisconsin. As a result of these control measures, silica exposures were reduced by more than 50 percent to levels that are well below the OSHA permissible exposure limit for silica.
   2. Executive Summary
      
      As a result of the Alliance's successes in its first five years, OSHA and AFS signed a Alliance renewal agreement on April 11, 2008. OSHA and AFS will continue to work together to increase employer and employee access to safety and health information and training resources on workplace issues, including personal protective equipment, heat stress, and exposure to silica. The positive and collaborative relationship has led to the development of the many programs and projects that the OSHA and AFS Alliance Implementation Team are currently working on or has produced. For example, through the OSHA and AFS Alliance, AFS developed the Heat Stress White Paper, "Establishing a Foundry Heat Stress Management Program." The White paper addresses heat-related illnesses and methods that could be used by employers in the foundry industry to help implement a heat stress management program. In addition, AFS worked with OSHA to develop a case study entitled, "Ventilation Upgrade Reduces Silica Exposure at Grede Foundries, Inc. Facility in Reedsburg, Wisconsin." The case study details the measures that Grede Foundries put into place to reduce employees' exposure to silica. As a result of their actions, employees' exposure to silica were reduced to levels below the OSHA permissible exposure level for silica.
      
      As part of their outreach efforts, AFS joined with 50 other Alliance Program participants to support 2008 NAOSH Week, May 4-10, 2008. In addition, AFS representatives are sharing their expertise and technical review by serving on the editorial boards of the following OSHA Safety and Health Topics pages and eTool:
       
      • Control of Hazardous Energy (Lockout/Tagout)
      • Heat Stress
      • Lead
      • Powered Industrial Trucks
      • Respiratory Protection
      • Silica, Crystalline
      • Ventilation
      • Powered Industrial Truck eTool
   3. Alliance Program Reach
       

      Type of Activity (Conference, Training, Print and Electronic Distribution, etc.)	Number of Individuals Reached or Trained
      OSHA and AFS Alliance Web page on the OSHA Web site	3,163
      AFS and OSHA Alliance Web page on the AFS Web site	Data not available
      OSHA Control of Hazardous Energy (Lockout/Tagout) Safety and Health Topics Page	61,801
      OSHA Heat Stress Safety and Health Topics Page	54,650
      OSHA Lead Safety and Health Topics Page	38,997
      OSHA Powered Industrial Trucks Safety and Health Topics Page	73,997
      OSHA Respiratory Protection Safety and Health Topics Page	37,568
      OSHA Silica, Crystalline Safety and Health Topics Page	30,463
      OSHA Ventilation Safety and Health Topics Page	27,450
      OSHA Powered Industrial Trucks eTool	301
      April 14, 2008 - "OSHA and the American Foundry Society renew Alliance," OSHA News Release	69 New Services
      April 15, 2008 - "OSHA and the American Foundry Society Renew Alliance," Compliance Home	Data not available
      April 15, 2008 - "OSHA, AFS Target Silica Exposure Prevention," Occupational Health Safety - Texas	Data not available
      April 17, 2008 - "OSHA and the American Foundry Society Renew Alliance," Safety Online	Data not available
      May 30, 2009 - "New OSHA and Alliance Program Participants Products," ASSE Government Affairs Update	5,500
      July 2008 - "OSHA Alliances," OSHA Up To Date	Data not available
      April 11, 2008 - AFS Government Affairs Conference, April 9-11, 2008, Washington, DC Speakers: Edwin G. Foulke Jr., then Assistant Secretary, USDOL-OSHA, made a presentation on OSHA's outreach efforts and compliance assistance resources.	100
      April 11, 2008 - AFS Government Affairs Conference, April 9-11, 2008, Washington, DC Speakers: Richard Fairfax, Director, Directorate of Enforcement Programs, USDOL-OSHA; and Jim Maddux, then Acting Director, Office of Biological Hazards, Directorate of Standards and Guidance, USDOL-OSHA, made presentations during a panel discussion entitled "OSHA Enforcement and New PPE Rule."	100
      TOTAL	334,159

4. Upcoming Milestones
   
   In the upcoming year, the OSHA and AFS Alliance Implementation Team will continue to work together to develop safety and health information and training resources for AFS members and small businesses in the metalcasting industry. For example, during the next reporting period, the Implementation Team will develop and finalize a foundry hearing protection fact sheet, and a foundry hazards Web page on the AFS Web site.
   
   As part of the Alliance's outreach efforts, AFS will conduct a Foundry Best Practices Seminar, April 21-22, 2009 in Waukesha, Wisconsin for Region V OSHA staff. In addition, AFS representatives will be joining with other Alliance Program participants to support 2009 North American Occupational Safety and Health Week, May 3-9, 2009.
   
   Report prepared by: Tony Mapes, Safety and Occupational Health Specialist, Office of Outreach Services and Alliances, April 22, 2009