Vaughn R. Plummer, Ph.D., BCFE, CEMPresident/Senior Safety Engineer
Construction Safety Management for Large Aluminum Smelter
Functioned as Project Safety and Environmental Manager for a $40M anode bake furnace demo and rebuild for this international organization. Developed project-specific safety and training programs for entire project. Supervised six contractor safety representatives to assist in successfully completing this project with 0 lost time or medical treatment incidents.
Safety Engineering for the World’s Largest Engineering Firm Contracted as the Safety Engineer and “Fall Protection Specialist” for a multi-million dollar project involving the redesign and installation of fall protection systems for client’s customer; a large international aluminum producer.Responsibilities included hazard identification and analysis, directing field surveys, developing safe-standard operating procedures, specifying fall protection equipment to be utilized, and providing application advice to the contract design firm.
Program Development for Large Aluminum Smelter in Iceland Assisted the Safety Department at this smelter after it was purchased by a Major US Aluminum Producer, in the review of all safety and training programs.Participated in safety audits and the development and enhancement of new safety and training programs.Conducted accident investigation training for local plant management personnel.Held discussions with AOSH (Iceland’s OSHA) management regarding suggestions for improvements to government sponsored training for powered industrial truck operators.Experienced opportunity to blend established US principles of safety into a uniquely different culture and working environment.
Greenfield Construction Site for Large Steel Rolling Mill Directed an on-site Safety Management Team, supervising safety for several prime contractors at one of the largest construction sites in North America.Project achieved over two million man-hours without a lost time accident.Additional responsibilities included extensive hazard assessments, as well as selecting equipment and systems to control site fall hazards.(Continue to provide safety consulting and industrial hygiene services to most of these contractors.)
Industrial Hygiene for Large Steel Rolling Mill Conducted the “baseline” data accumulation and analysis to develop an Industrial Hygiene Program for a new “state of the art” steel rolling mill in Southern Indiana, (same plant as identified above).Project included considerations for several hazardous substances, including hydrochloric acid, sulfuric acid, nitric acid, hydrofluoric acid and NOX concentrations, as well as temperature extremes.Also designed and implemented employee and contractor training programs to address potential hazards and exposures.
Safety & Training Programs & ISO 14001International Auto Parts Manufacturer
Instrumental in the development of a Corporate Safety and Training Program for this international parts manufacturer’s first U.S. operation. Was responsible for conducting initial hazard analysis of their facilities, designing an effective safety program and developing training plans to achieve compliance with applicable local, state and federal standard, while enhancing employee safety. Have continued to provide services to this client’s safety staff and executive management, by conducting safety auditing, safety program reviews, ISO 14001 auditing and assisting with OHSAS 18001 implementation.
Construction SafetyLarge Aluminum ManufacturerFunctioned as on-site Safety Engineer, representing a large national client, responsible for safety management of all contractor and subcontractor personnel involved in excavation and related construction of an underground accumulator pit, basement and associated concrete work. Project involved equipment mobilization, excavation and installation to a depth of over 80 feet below grade, inside an existing structure, with significant ground water hazards.
Program DevelopmentInternational Chemical CompanyRetained as a Safety Consultant by this Global Chemical Company to review the safety and training programs of a recently purchased chemical manufacturing facility.Initial responsibilities included review of existing programs to ensure compliance with applicable standards.Also revised these programs, as necessary to attain conformance with the new owner’s industry-specific requirements and reflect their safety philosophy.Additional responsibilities included assisting in the development and presentation of new employee training programs.
Program DevelopmentInternational Real Estate CompanyRetained as a Safety Consultant to one of the largest diversified commercial real estate services companies in the world, to conduct reviews and revisions to their Corporate Safety Programs, for their Building Management Division.Reviews and revisions were directed to ensure applicability of safety programs in relation to the work being performed, compliance with OSHA Standards, and auditability of the of the programs to aid this client in measuring the success of their safety efforts. (On-site safety audits are currently being scheduled to assist this client with formal implementation of these revisions.)
Systems Safety EngineeringNational Coal Mining CompanyServed as Safety and Project Engineer during design, manufacturing and commissioning phases of experimental underground mining equipment.Assisted with planning and design of equipment, as well as personally directed System Safety Engineering on all equipment and related components.Coordinated with the Washington, DC based Engineering Division of MSHA, to communicate design and field operating data in order to gain Agency approval for use of this equipment. Efforts contributed to MSHA approval of equipment, which is still being utilized in the mining industry on a worldwide scale. Also developed applicable safety and training programs for operating personnel.
Civil & Safety EngineeringUnderground Hazardous Waste Storage FacilityResponsible for re-design, implementation and management of all safety and training programs, roof control and ground control engineering systems for this two-hundred acre underground hazardous waste storage facility, located in an abandoned limestone mine.This national priority listed (Superfund) site contained over 1.4 million tons of salt cake fines (Aluminum Dross).Unique hazards included direction of heavy equipment operation and personnel in extremely unstable geological conditions, with water hazards and high ammonia concentrations.Additional responsibilities included the direction of explosives/blasting contractor in removal of over 2,000 yd3 of unstable overburden that was creating falling rock hazards at mine entrances.Duties included supervision of a 28 person, 40-Hour trained crew, performing remediation, facility modification and closure tasks.
OSHA ComplianceSmall Midwestern Municipality Served as client’s Safety Representative in discussions with OSHA following a fatal accident.Developed a safety and compliance program, approved by OSHA Officials, as well as trained this client’s employees. Successfully negotiated on client’s behalf with OSHA to secure a significant reduction in proposed penalties.