Industrial Hygiene Assessment Leads to Cost Avoidance and Positive Workplace Culture
About
As a part of the Allegion family of brands, Republic Doors and Frames has a long history as one of the nation's leading manufacturers of commercial steel doors and frames. Strategically located halfway between Memphis and Nashville, Republic's manufacturing and offices occupy 240,000 square feet on 33 acres in McKenzie, Tennessee. Republic Doors and Frames are designed for institutional, commercial, and industrial markets for new and retrofit construction needs. The main facility includes the majority of the Republic team from customer care to operations and engineering.
While Republic operates a regional manufacturing center in Dallas, Texas, and various regional service centers, the Republic main plant in McKenzie has the capability of supplying a complete portfolio of doors and frames. Republic's doors and frames are marketed in all 50 states and in several foreign countries through a network of stocking distributors and company owned service centers.
The Challenge
Republic’s primary production processes create waste products such as noise exposure, welding particulates, dust, metals, silica-quartz, and wastewater treatment hazards. As a pioneer in protecting people where they live and work and with a commitment to environmental responsibility, Republic requested assistance with an Industrial Hygiene assessment to include noise and air sampling.
MEP's Role
TMEP, part of the MEP National Network™, was able to provide access to a certified industrial hygienist to conduct the assessments. During an eight-hour on-site visit, the resource conducted a three-part evaluation. The evaluation included a noise level survey with personal sampling (dosimetry) and air monitoring inside defined areas and confined spaces. Additionally, Republic was provided a final report that described the process and tools used during the assessment and included conclusions and recommendations based on current applicable Tennessee Occupational Safety and Health Administration Permissible Exposure Limits and American Conference of Governmental Industrial Hygienists Threshold Limit Values. Based on results, recommendations were made on which internal employees should receive hazard communication (HAZCOM) training, access to a hearing conservation program, enhanced PPE, or additional controls. The report also identified processes that could be improved by implementing engineering design controls.
RESULTS
- $4,234,800 in cost savings
- Improved safety through additional training
- Commitment to employee safety creates positive workplace culture