33rd Environmental, Health and Safety Conference
Ray Ostrowski
AFS EHS Division Chair
INTRODUCTION
- AFS EHS Committee Overview
- Recognition of AFS EHS Division Members in Attendance
Conference Co-Chairs
Dan Plant
Metal Technologies Inc., Auburn, IN
Daniel Engling
Keramida, Inc., Indianapolis, IN
Jeff Longsworth
Barnes & Thornburg, Washington, DC
- Summary of recent changes to EPA’s industrial stormwater discharge requirements and the legal challenges to the new MSGP.
Scot Aler
US Pipe and Foundry Company, LLC, Bessemer, AL
Jeff Hannapel
The Policy Group, Rockville, MD
Tony Pitts
EJ, East Jordan, MI
Jenny Pappalardo (invited)
Charlotte Pipe and Foundry Company, Charlotte, NC
- State Specific Requirements
- Operations and Pollutants of Concern
- How to be Proactive?
David Georgeson & Derek Webster
McWane Ductile Utah, Provo, UT
Kimberly Hinebaugh
John Deere Waterloo Works, Waterloo, IA
McWane Ductile Utah’s energy audit identified an outdated compressed air system that was using approximately 27% of plantwide energy use. The system received two upgrades: 1) The outdated rotary screw compressors were replaced with new, more efficient centrifugal compressors. The new compressors automatically adjusted output to meet demand. 2) The main compressed air line was replumbed to eliminate the former loop system, making it easier to isolate sections. Energy consumption was reduced by approximately 2500 megawatts per year, which was approximately equal to eliminating 2600 tons of carbon dioxide emissions per year. The cost savings were estimated at $190,000 per year, with an RI of 2 years.
The judges were impressed with John Deere’s determination to work past numerous hurdles and to find a cement manufacturer close enough to accept their spent foundry sand on a cost-neutral basis as compared to their prior local disposal method. John Deere Foundry staff showed persistence and determination in working out storage issues, quality control processing, and transport issues to make a viable arrangement to reuse the spend foundry sand rather than continue to send it to their local quarry, which was running out of space.
Moderator:
Jeet Radia
McWane Inc., Birmingham, AL
Panelists:
Keith Johnston
Southern Environmental Law Center, Birmingham, AL
Mitchell Reid
The Nature Conservancy, Arlington County, VA
- Environmental group goals and priorities
- Dealing with “knowns” and “unknowns”
- Conflict resolution modes – litigation vs. collaboration
- Opportunities for partnerships
Jeff Longsworth
Barnes & Thornburg, Washington, DC
- Update on PFAS regulatory, legislative and policy developments and the potential impacts on the metalcasting industry
Tommy Lotz
Alliance Technology Group, Birmingham, AL
- Understanding PM10 testing and analytical artifacts
- Things to look for in a Method 5/202/25A stack test report
- Using test duration to your advantage
Vic LaFay & Pat LaFey
Common Sense Applications LLC
- Recent publications
- Evaluation technique
- Supporting data from multiple sources
- Foundry real-life “floor applications”
Craig Schmeisser
Mad River Strategies LLC, New Bremen, OH
- Database layout and parameters
- Characterization of collected data
- Latest benchmarking information
Moderator:
John Batchelor
American Cast Iron Pipe Company, Birmingham, AL
Panelists:
Kevin Trychta
Benton Foundry Inc., Benton, PA
Dan Plant
Metal Technologies Inc., Auburn, IN
Jenny Pappalardo
Charlotte Pipe & Foundry Co., Charlotte, NC
Jeff Hannapel
The Policy Group, Rockville, MD
- Summary of the latest climate change developments from Washington and how metalcasting facilities can prepare for it
George W. Crimmins
Schroek, Herold Law, P.A., Warren, NJ
- Environmental justice laws are everywhere.
- States with environmental justice laws (pending/passed)
- New Jersey environmental justice law
- NJDEP rulemaking and initiatives
- Potential impacts to permitting and businesses
Air Quality
Jeet Radia
McWane, Inc., Birmingham, AL
Water & Waste
Bryant Esch
Waupaca Foundry, Inc., Waupaca, WI
Health & Safety
Brent Charlton
Metal Technologies of Indiana, Auburn, IN
Brent Charlton
Metal Technologies of Indiana, Auburn, IN
- Using social media to get your message out to your workforce and beyond.
Tom Slavin
Slavin OSH Group LLC, Chicago, IL
- What is a voluntary standard; is it really voluntary?
- OSHA’s use of standards for regulation and enforcement
- How standards are developed and why you should be involved
- AFS Division Individual Awards
- 2021 AFS Metalcasting Safe Year Awards
- Green Foundry Awards
- Innovation & Insight Awards
- 2020 Millionaires Safety Award
Dan Plant
Metal Technologies Inc., Auburn, IN
Bryant Esch
Waupaca Foundry, Inc., Waupaca, WI
The metalcasting industry is experiencing increasing demand from its customer base to provide accurate information to assist in satisfying the requirements of elective and regulatory programs to better understand the sourcing and composition of cast products, and potential impacts (if any) to the end user. From the metalcasting facility perspective, this presentation will provide a review of the various programs that may generate such requests, what types of formats these requests may be received by your facility, and case study examples of how such requests may be satisfied.
Jeff Hannapel
The Policy Group, Rockville, MD
Stephanie Salmon
AFS Washington Office, Washington D.C.
AFS Washington Office will provide key updates on EHS legislative, regulatory, and policy developments impacting the metalcasting industry. The Biden administration promised to increase OSHA’s budget, grow the number of inspectors and generally ramp up enforcement. In particular, we will focus on the new rulemaking efforts under development that will impact foundries, as well as enforcement initiatives and recent fines.
Moderator:
Brent Charlton
Metal Technologies of Indiana, Auburn, IN
Panelists:
Rebecca Ferrell
TRC, Brookfield, WI
Eric Pylkas
Insight IH Consulting, Hartland, WI
Daniel Engling
Keramida, Inc., Indianapolis, IN
Discussion will be focused on the current status of applying real-time sampling methods in this application, including capability to:
- Identify root causes of worker exposure
- Assess process-related emission sources
- Diagnose ventilation system defects
Facilitators:
Mike Lenahan
Kurtz Bros. Inc., Independence, OH
Jenny Pappalardo
Charlotte Pipe & Foundry Co., Charlotte, NC
Actors:
AFS All Stars
How to successfully manage visits from regulatory Personnel.
Enjoy networking time with exhibitors with hors d ’oeuvres, & refreshments for all.
Bill Wahoff
Steptoe & Johnson LLC, Columbus, OH
On September 9, 2021, the President announced he directed the Department of Labor’s Occupational Safety and Health Administration (OSHA) to develop a rule requiring companies of 100 or more employees to require their workers be vaccinated or supply a negative COVID-19 test result each week before returning to in-person work. The measure will be authorized under the Emergency Temporary Standard Code which authorizes the agency to regulate hazardous threats to public health. The new rule is part of a six-part plan to combat the coronavirus and will affect approximately two thirds of America’s workforce when it goes into effect. Our speaker, Bill Wahoff, Steptoe & Johnson, will discuss what steps metalcasters need to be taking to be in compliance and understand when a COVID-19 infection can be a recordable illness on an employer's 300 Injury and Illness Log.
Clifford Frey
3M Personal Safety Division, Saint Paul, MN
- Why fit test hearing protection?
- How does fit testing hearing protection work?
- Live demonstration of 3M’s EarFit system
Paul Lynes
Finger Lynes Engineering, Nashville, TN
Pete Buczek
WGS Global Services LLC, Flint, MI
- Leading or lagging - What’s the difference
- Why use leading metrics
- Managing by metrics - How leading metrics can drive improvement
Kay Rowntree
Industrial Hygiene Sciences LLC, Waterford, WI
- Types of processes
- Characterization of hazards
- Potential emissions and exposures during pre-printing, printing, post-printing, and maintenance
- Worker protection measures
Moderator:
Daniel Engling
Keramida, Inc., Indianapolis, IN
Panelists:
Brent Charlton
Metal Technologies Auburn LLC, Auburn, IN
Tom Slavin
Slavin OSH Group LLC, Chicago, IL
Bob Scholz
TRC , Brookfield, WI
- How foundries cope with heat
- ASTM Standard development and content
- What the ASTM standard means for you
Brent Charlton
Metal Technologies Auburn LLC, Auburn, IN
- Learning is vital to an organization’s performance
- Much can be learned from those at the “sharp end of the stick”
- Why is there often a difference between “work as imagined” and “work as done?”
Mickey Hannum
McWane Inc., Birmingham, AL
One company’s approach to protecting team members from COVID-19 while continuing to operate all locations. This presentation will provide an overview of McWane’s approach to handling the many challenges the pandemic presented to manufacturing operations.
- Initial challenge of understanding the issue
- COVID-19 Team and guideline development
- Risk assessments and specific procedures
- Continuous changes with CDC
- Vaccinations
- What did we learn?
Earl Miller and Brian McGuire
Accurate Castings Inc., Hiler Industries, La Porte, IN
Examples using the method, “Four Sight,” a Creative Problem-Solving Method Framework applicable to any problem solving, including ventilation improvements Clarify context and set guardrails.
- Clarify context and set guardrails
- Ideate and brainstorm potential concepts
- Develop and refine concepts, including prototyping
- Implement concepts, measure and pivot
Ted Schorn
Enkei America Inc., Columbus, IN
Seven key safety beliefs that drive foundry safety performance.
Moderator:
Mickey Hannum
McWane Inc., Birmingham, AL
Panelists:
Glenn Huneycutt
Charlotte Pipe & Foundry Co., Charlotte, NC
Bob Forrester
Neptune Technology Group Inc., Tallassee, AL
Josh Gunning
M&H Valve, Anniston, AL