Module 2: Hazard Assessment & PPE Selection for Eye and Face Protection

Effective eye and face protection begins with a comprehensive hazard assessment – identifying the specific threats your workers face – and ends with precise PPE selection that matches each hazard’s intensity and nature. In this module, we’ll walk through:

1. Assembling Your Assessment Team and Tools
2. Systematic Hazard Walk-Through
3. Quantifying Impact and Splash Hazards
4. Optical Radiation Assessment
5. Selecting the Right PPE – impact ratings, chemical splash resistance, and optical density
6. Documenting Your Selection Process
7. Common Mistakes & Best Practices

By the end, you’ll have a replicable process and clear criteria to choose safety glasses, goggles, face shields, welding helmets, or chemical hoods – ensuring every worker’s eyes and face stay protected.

2.1 Building Your Assessment Team & Gathering Tools

Why a Team? No single person sees every risk. Form an Eye & Face Protection Committee (EFPC) comprising:

• Safety Leader/EHS Specialist: Guides regulatory compliance
• Industrial Hygienist or Engineer: Assesses impacts, sprays, and UV/IR levels
• Operations Supervisor: Knows workflows and common exceptions
• Maintenance Technician: Understands equipment ejection points and fluid pressures
• Worker Representative: Offers frontline insight into everyday practices

Essential Tools & Instruments:

• Projectile Test Kit: Calibrated BB-gun apparatus or Dorfman Impact Tester per ANSI Z87.1 to simulate high-velocity fragments.
• Spray Nozzle & Pressure Gauge: To reproduce worst-case chemical or coolant splash pressures.
• UV/IR Radiometer: Measure welding arc emissions or infrared heater output; ensure appropriate lens shade.
• Ophthalmic Examination Kit: Basic fluorescein strips and loupe to spot micro-injuries in pilot assessments.
• Camera & Note App: Photograph hazard zones and PPE mismatches; record observations on your digital checklist.

2.2 Systematic Hazard Walk-Through

Conduct clear, step-by-step walkthroughs of every work area:

1. List All Tasks: Assembly, grinding, cutting, welding, chemical transfers, painting, cleaning, and confined‐space entries.
2. Identify Sources of Impact: Grinder spark ejectors, punching and stamping press ejection ports, pneumatic nail guns, overhead conveyors that drop bolts or rivets.
3. Assess Splash Risks: Chemical tank fills, high-pressure washdowns, hydraulic line ruptures (often >3,000 psi), and molten‐metal splash in foundries.
4. Map Optical Hazards: Welding booths, laser stations, UV‐curing ovens, infrared heat lamps.
5. Note Environmental Conditions: Glasses fog in high-humidity paint booths, lens haze with solvent exposure, or distortion under extreme heat.

Example: In a steel plant, our team discovered that conveyor belt misfeeds often caused cut steel shards to bounce underfoot – trajectories aimed directly at knee and eye level. Standard safety glasses with side shields offered insufficient wrap-around protection; only a full-coverage goggle or face shield meeting Z87+ high-impact criteria would do.

2.3 Quantifying Impact & Splash Hazards

Impact Testing (ANSI Z87.1)

• Low-Velocity Impact: Simulate flying sand or small debris at 150 ft/s.
• High-Velocity Impact: Use a .25-inch steel ball at 610 ft/s to represent worst-case high-speed shrapnel.
• Procedure: Position PPE in the impact tester; if no penetration or cracking, the lens passes. Document results and note any “secondary fragment” violations (e.g., lens spalling).

Splash Testing (ANSI Z87.1 Chemical Splash)

• Pressure Spray Test: Direct streams of water or appropriate chemical at 2.4 gallons/minute from 5-inch distance for 5 seconds.
• Coverage Requirements: Goggles and face shields should prevent any liquid ingress around the seal or under the brow. Visualize with colored dye to highlight leak paths.

Tip: For corrosive chemicals (acids/alkalis), test with a surrogate dye – inspect seals and replace gaskets or upgrade to chemical-specific hoods as needed.

2.4 Optical Radiation Assessment

In welding, UV/IR, and laser environments, eye protection pivots on shade number and filter quality:

• Welding Shades:
  • Shade 10–12: For light gas‐metal arc welding (GMAW).
  • Shade 12–14: For heavy stick (SMAW) or plasma cutting.
• Laser Safety:
  • Match goggles to laser wavelength and power (OD rating). Use manufacturer’s tables.
• UV/IR Heaters & UV Curing:
  • Use lens filters blocking UVA, UVB, and UVC down to 200 nm – ensuring both lens and side shields meet filter class requirements.

Measurement: Use a radiometer placed where the operator’s eye would be to confirm irradiance stays below the Maximum Permissible Exposure (MPE) for each wavelength.

2.5 Selecting the Right PPE

With your hazard data in hand, choose from:

Selection Criteria:

1. Impact vs. Splash vs. Radiation: Always layer protection: safety glasses + face shield when both impact and splash hazards exist.
2. Field of View & Comfort: Ensure lens size and headgear accommodate peripheral vision and fit over prescription eyewear if needed.
3. Anti-Fog & Anti-Scratch Coatings: In high‐humidity or heated zones, prioritize fog‐resistant treatments; in abrasive environments, choose scratch‐resistant coatings.
4. Integration with Other PPE: Welding hoods over hard hats, face shields with respirators, or goggles under earmuffs – check compatibility.

2.6 Documenting Your Selection Process

Regulations require a written PPE selection procedure that includes:

• Hazard Summary: Tasks, frequencies, and quantified risks.
• PPE Matrix: Mapping each hazard pocket to specific PPE type(s) and standards (e.g., Z87.1+).
• Test Results: Impact and splash test data, radiometer logs.
• Fit & Training Requirements: Seal checks for goggles, helmet donning protocols, training frequency.
• Review Cycle: Annual reassessment or upon process changes.

Store these documents in your safety management system – version-controlled and accessible to supervisors and auditors.

2.7 Common Mistakes & Best Practices

Module 2 Summary

By building an interdisciplinary assessment team, systematically quantifying impact, splash, and optical hazards, and mapping each risk to the precise PPE – complete with test data and documented logic – you establish a defensible, user-friendly eye and face protection program.

In Module 3, we’ll align your process with regulatory requirements – OSHA, ANSI Z87.1, CSA Z94.3, and provincial codes – and dissect real-world injury case studies to extract lessons that keep your program robust and compliant. Onward to Module 3!

Module 3: Regulatory Deep Dive & Key Incident Studies

A rock-solid eye and face protection program aligns with – and often exceeds – standards on both sides of the border. Here, we compare critical requirements under U.S. OSHA, ANSI Z87.1, Canadian CSA Z94.3, and provincial codes, then learn from high-cost injury case studies.

3.1 Regulatory Comparison

Tip: Adopt the strictest standard across your operations for simplicity.

3.2 U.S. Incident Case Studies

1. Grinding Debris Strike (2019, Ohio):
   • What Happened: A chip flew beneath standard safety glasses and struck an operator’s eye.
   • Finding: No Z87+ eyewear for overhead sparks.
   • Cost: $85K fine; mandated upgrade to goggles + face shields.
2. Chemical Splash Blindness (2020, Texas):
   • What Happened: A technician mixing caustic soda splashed solution; prescription glasses provided no seal.
   • Finding: No splash goggles or hoods.
   • Cost: $120K citation; required full-face chemical hoods and splash-barrier training.
3. Welding UV Injury (2021, Michigan):
   • What Happened: Apprentice disabled auto-darkening, suffered photokeratitis.
   • Finding: No enforced welding helmet use policy.
   • Cost: $95K penalty; introduced mandatory helmet checks and discipline for non-use.

3.3 Canadian Incident Case Studies

1. Powder Gun Projectile (2019, Ontario):
   • What Happened: A rivet from a powder-actuated tool rebounded off a wall into a worker’s eye.
   • Finding: No side-shield or sealed goggles required in high-velocity zones.
   • Cost: $100K WSIB claim; mandated sealed impact goggles plus training.
2. Laser Engraving Blindness (2020, B.C.):
   • What Happened: Shop used general-purpose sunglasses, no laser-specific goggles; severe retinal burn.
   • Finding: Lack of wavelength-specific OD-rated PPE.
   • Cost: $150K penalty; purchased CSA-compliant laser goggles and interlock systems.
3. Paint Booth Solvent Splash (2022, Alberta):
   • What Happened: High-pressure solvent spray punctured goggle seals, causing corneal burns.
   • Finding: No face shields over goggles in splash risk areas.
   • Cost: $80K fine; instituted mandatory combined goggles + shields.

3.4 Key Takeaways

• Impact & Splash Testing Are Mandatory: Z87+ ratings and splash tests must match worst-case scenarios.
• Fit & Seal Matter: Side shields alone won’t stop side ejecta; sealed goggles or shields are required.
• Optical Radiation Requires Lens OD Matching: Verify welding shades and laser OD with radiometers.
• Document & Audit Relentlessly: Keep hazard assessments, test reports, and training logs current – review annually.

In Module 4, we’ll transform this technical foundation into engaging, 2,000-word toolbox monologues – making sure every worker remembers why and how to protect their eyes and face. Let’s continue.

Module 4: Engaging Safety Talks for Eye & Face Protection

Below are three fully scripted, conversational Safety Talks – each designed for a 10–15-minute toolbox session (roughly 2,000 words) – to bring eye and face protection vividly to life in your workforce. Deliver them as written or adapt with local anecdotes.

Safety Talk #1: “When Sparks Fly” – Protecting Against Impact Hazards

“Good [morning/afternoon], everyone. Imagine you’re at the grinder station: one wrong angle, and a tiny metal shard the size of a pencil tip can rocket off at over 200 meters per second – fast enough to crack bone or shatter cornea. Last month, at a plant in Ohio, a guard failed to deflect a chip; it struck a journeyman below his eye shield, sending him to the ER and costing the company $85,000 in fines.

Key Messages:

1. Always Use Z87+ Rated Eye Protection: Safety glasses with side shields aren’t enough for overhead sparks – goggles or a combined glasses-plus-face-shield system is mandatory.
2. Maintain & Inspect Guards: Broken or misaligned machine shields force shards into unpredictable paths – inspect guards daily before use.
3. Proper Fit & Adjustment: Loose shields let debris in from the sides – adjust headgear so that the seal hugs your brow and cheeks.

Interactive Exercise: We’ll pair up and inspect grinder guards on two machines. Then each of you will don Z87+ goggles and demonstrate the three-point fit check for side protection. Finally, we’ll fire a low-velocity test round (using the impact tester) to show how proper PPE stops a projectile in its tracks.

By investing minutes now in inspection and fit, we prevent seconds of trauma – and weeks of recovery later.”

Safety Talk #2: “Splash Zone” – Guarding Against Chemical & Fluid Hazards

“Hey team, let’s talk about another silent threat: chemical and coolant splashes. In a Toronto lab, a technician leaned too close to a pickling tank without a full-face chemical hood; a splash of sulfuric acid hit her unprotected cheek and eye, causing second-degree burns and a WSIB claim over $200,000. That could have been prevented by goggles plus a face shield – or better yet, an air-purged chemical hood.

Key Messages:

1. Assess the Worst-Case Splash Scenario: High-pressure lines can spray at over 3,000 psi – no standard glasses will stop that.
2. Select Sealed Goggles or Hoods: Indirect-vented goggles resist low-pressure splashes; full chemical hoods are essential for immersion risks.
3. Combine with Face Shields: For heavy sprays, layer a polycarbonate face shield over splash goggles to deflect droplets away from lens seals.

Interactive Exercise: We’ll use colored water in the spray rig to simulate worst-case splash. Volunteers will test goggles alone, then goggles-plus-shield, and note where leaks occur. We’ll discuss how seal quality and coverage area make all the difference.

Remember: when you see a splash hazard, don’t settle for basic eyewear – think full coverage.”

Safety Talk #3: “Seeing Clearly” – Optical Radiation & Laser Safety

“Good [morning/afternoon]. Welding arcs and lasers unleash invisible energy that burns your eyes from inside out. A Saskatchewan apprentice disabled his helmet’s auto-darkening sensor for better vision and suffered ‘welder’s flash’ so severe he missed three weeks of work. In a B.C. shop, a laser operator wearing regular sunglasses endured irreversible retinal damage because his goggles weren’t rated for the laser wavelength.

Key Messages:

1. Match Shade & OD to the Source: For arc welding, use auto-darkening filters with shade 10–14 based on amperage. For lasers, verify wavelength-specific OD ratings – no guesswork.
2. Test with Radiometers: Never rely solely on manufacturer charts – measure UV/IR intensity at the operator’s position and confirm filter compliance.
3. Maintain Helmet & Lens Integrity: Scratches, cracks, or burnt-on spatter degrade filter performance – inspect lenses daily and replace at first sign of damage.

Interactive Exercise: We’ll demo an arc-flash simulator (or share photos) to show flash-burn symptoms. Then, using a UV/IR meter, we’ll measure a live welding cell’s radiation and compare readings against two different helmet filters. You’ll see firsthand why the correct shade – and an undamaged lens – are non-negotiable.

Protecting your vision from radiation hazards isn’t optional – it’s your right and responsibility. Choose the right filter, maintain it rigorously, and never override safety features.”

End of Module 4
These Safety Talks, rich with real stories, hands-on drills, and clear “why & how” guidance, will transform abstract PPE rules into memorable, life-saving habits.

Up next: Module 5 – Frequently Asked Questions on Eye & Face Protection to arm your team with precise, ready-to-use answers for every scenario.

Module 5: Frequently Asked Questions on Eye & Face Protection

Answering common queries clearly smooths program adoption and reduces non-compliance. Here are the 15 top FAQs – each in a conversational style you can share directly with your teams.

1. “When do I need goggles versus safety glasses?”
   Answer: Safety glasses with side shields (Z87+) are fine for general flying debris and light dust. But if you’re in a splash zone (chemicals, oils) or heavy dust/grit, opt for sealed goggles. When both impact and splash hazards exist, layer goggles plus a face shield.
2. “Can I just wear my regular sunglasses?”
   Answer: No – only use PPE certified to Z87.1 or CSA Z94.3 standards. Sunglasses lack impact testing and splash protection, and their tint/shade may not block UV/IR.
3. “How often should I replace scratched lenses?”
   Answer: Immediately. Even tiny scratches scatter light and weaken impact resistance. Inspect daily – replace any lens with visible damage before starting work.
4. “Are face shields alone ever enough?”
   Answer: No – face shields shield against splashes and large fragments but offer no ATF (around-the-face) protection. Always wear safety glasses or goggles underneath shields.
5. “What shade lens do I need for welding at 200 amps?”
   Answer: Typically Shade 12–14. Check your helmet’s chart, but confirm with a UV/IR radiometer at the work station – match shade to measured irradiance, not guess based on amps alone.
6. “Can I clean my PPE with solvents?”
   Answer: Only use manufacturer-approved cleaners. Solvents can degrade gaskets, coatings, and plastics – shortening PPE life and compromising protection.
7. “Do prescription glasses count as PPE?”
   Answer: Only if they’re ANSI/CSA-approved safety spectacles – prescription inserts fit inside certified protective frames. Regular glasses provide no guaranteed impact or splash defense.
8. “How do I know if my goggles seal properly?”
   Answer: Perform a quick seal check: press the goggles against your face, inhale gently, and hold – if they stay suctioned, you have a good seal. Adjust straps or switch models until you get consistent suction.
9. “Can I share goggles or face shields?”
   Answer: It’s not recommended. PPE contoured to one face may not fit another. If sharing is unavoidable, sanitize thoroughly between uses and verify fit each time.
10. “What about laser work – are regular welding lenses OK?”
    Answer: No – lasers require wavelength- and power-specific goggles rated with the correct optical density (OD). Using the wrong lens is like staring at the sun.
11. “Is anti-fog coating really necessary?”
    Answer: In humid or overheated environments, yes – fog obscures vision and tempts users to lift their PPE. Anti-fog coatings or removable inserts keep vision clear and PPE on.
12. “How long can I use the same face shield?”
    Answer: Inspect daily; replace when scratched, cracked, or if the edges show wear. Typically, shields under heavy use last 3–6 months – but environment and maintenance frequency can shorten that.
13. “Do I need training to use this PPE?”
    Answer: Absolutely. All users must understand hazard types, PPE selection, seal checks, maintenance, and replacement. Training initial + annual refresher is mandatory under OSHA/CSA.
14. “What records should we keep?”
    Answer: Document hazard assessments, PPE matrix, training attendance, inspection logs, and damage replacements – retain for at least three years (U.S.) or per provincial requirements (2–5 years).
15. “How do I handle combined hazards – impact, splash, and radiation?”
    Answer: Layer appropriately: start with safety glasses or goggles for impact, add a chemical face shield for splashes, and for optical radiation use a welding helmet or laser goggles over that ensemble if needed – ensuring seals aren’t broken.

Module 5 Summary
These FAQs bridge policy and practice – clarifying when and how to choose, wear, and maintain eye and face PPE across diverse hazards. Equipped with these answers, your teams can make informed, confident decisions.

Next, in Module 6, we’ll uncover the six most common pitfalls that can undermine your eye and face protection program – and how to prevent each one. Let’s move on!

Module 6: Six Pitfalls to Avoid in Eye & Face Protection Programs

Even the most comprehensive eye and face protection initiatives can be tripped up by recurring missteps. Below are the six most common pitfalls – each illustrated by real incidents – and concrete strategies to ensure your program remains bulletproof.

Pitfall #1: One-Size-Fits-All PPE

What Happens:
Organizations purchase a single style of safety glasses or face shield for all tasks, ignoring the diverse nature of hazards – from high-velocity fragments to corrosive splashes.

Real-World Example:
A plastics injectory plant provided only basic safety glasses. When hot polymer shot back during a nozzle clog, an operator suffered facial burns because the glasses lacked a face shield or splash‐rated lens. The company paid $65,000 in medical costs and fines.

How to Avoid:

• Task-Specific PPE Matrix: Develop a matrix linking each hazard (impact, splash, radiation) to specific PPE types and ratings.
• PPE Variety: Stock multiple styles – Z87+ glasses, indirect-vent goggles, face shields, welding helmets, and chemical hoods – to fit every scenario.
• Worker Trials: Pilot new styles with end users to confirm fit, comfort, and compatibility with other gear.

Pitfall #2: Neglected Fit and Seal Checks

What Happens:
Users don goggles or shields without verifying seals or adjustments. Even the best PPE fails if gaps allow debris or liquids to bypass the barrier.

Real-World Example:
At a food processing line, high-pressure washdowns sent water streams under improperly adjusted goggles, leading to corneal abrasions for two maintenance technicians. The subsequent retroactive training and PPE replacement cost $50,000.

How to Avoid:

• Daily Seal Checks: Mandate simple inhalation/exhalation checks for goggles and verification of headgear tightness for shields.
• Supervisor Spot Audits: Include seal checks in quarterly safety walks; coach workers on proper adjustments.
• Fit Guides: Post quick-reference fit posters at PPE stations.

Pitfall #3: Ignoring Optical Radiation Hazards

What Happens:
Facilities focus on impact and splash but overlook UV/IR and laser hazards – leading to photokeratitis (“arc eye”), cataracts, or retinal burns.

Real-World Example:
A maintenance crew serviced UV-curing conveyor lights without proper filter lenses. Within hours, three technicians reported painful eye irritation. Replacement of lenses and medical treatment cost the company $80,000.

How to Avoid:

• Radiation Surveys: Use radiometers to measure UV/IR levels at operator positions.
• Correct Shade & OD Selection: Select welding helmets and laser goggles using measured irradiance and manufacturer OD tables.
• Continuous Monitoring: Re-measure after equipment changes or new processes.

Pitfall #4: Inadequate Maintenance and Cleaning

What Happens:
PPE, especially goggles and shields, accumulates scratches, coatings, or residue that reduce clarity and impact resistance, yet workers continue using damaged gear.

Real-World Example:
In a bottling plant, scratched polycarbonate face shields distorted vision and led to a misaligned cut on a conveyor guard – an operator’s face was struck by a metal flange. Repair costs and a fine totaled $55,000.

How to Avoid:

• Cleaning Protocols: Specify approved detergents and cleaning intervals; remove cartridges/visors before washing.
• Inspection Checklists: Include lens checks, gasket integrity, and strap condition in weekly inspections.
• Replacement Triggers: Replace PPE on first sign of wear, as part of routine maintenance.

Pitfall #5: Poor Integration with Other PPE

What Happens:
Eye and face protection clashes with respirators, hard hats, or hearing protection – causing discomfort, reduced compliance, or compromised seals.

Real-World Example:
A refinery required full-face chemical hoods but didn’t account for the hard-hat brim. Workers forced the hood forward, breaking the chemical seal and suffering mild chemical irritation. The retrofit cost $40,000.

How to Avoid:

• Compatibility Trials: Test combinations (goggles + respirator, helmet + face shield + earmuffs) in realistic conditions.
• Integrated PPE Systems: Invest in modular systems designed for multi-PPE use.
• User Feedback: Solicit frontline input before rolling out new PPE combos.

Pitfall #6: Treating PPE as a “Set-and-Forget” Measure

What Happens:
After initial training and distribution, organizations assume PPE use remains perfect – neglecting refresher training, audits, and program evolution.

Real-World Example:
A warehousing operation trained staff on splash goggles and face shields but never revisited the policy. Two years later, they found 30% of operators weren’t using face shields during forklift washdowns – leading to eye irritations and a $30,000 compliance notice.

How to Avoid:

• Regular Refresher Training: Schedule annual “PPE Refresh Days” with hands-on demos and quizzes.
• Spot-Check Audits: Conduct unannounced PPE compliance checks monthly.

Program Metrics: Track PPE use rates, inspection findings, and incident trends – review in quarterly safety meetings.

Module 7: Online Resources & Tools for Eye & Face Protection

Leverage authoritative sources, practical tools, and funding opportunities to keep your program cutting edge and well-resourced.

Regulatory & Standards References

Testing & Selection Tools

• Dorfman Impact Testers: For in-house impact verification of new PPE batches.
• Chemical Splash Rigs: Portable spray systems for verifying guard performance on site.
• UV/IR Radiometers: Ensure welding helmets and shields meet necessary optical density.
• Fit-Check Posters & Apps: Quick-reference materials at PPE stations.

Supplier Catalogs

Grant & Funding Opportunities

Module 8: Drafting Your Eye & Face Protection Policy

A written policy cements your eye and face protection program – ensuring consistent hazard assessment, PPE selection, training, maintenance, and continuous improvement. Below is a comprehensive template, with suggested language and guidance for each section. Adapt it to fit your organization’s structure, operations, and jurisdictional requirements.

1. Policy Purpose & Scope

Policy Statement:

Scope:

• Applies to all employees, contractors, and visitors in areas where eye or facial hazards exist.
• Covers hazards including high‐velocity projectiles, chemical splashes, optical radiation, and biohazards.
• Includes all work activities: machining, grinding, welding, chemical handling, blasting, laser operations, and confined‐space entry.

2. Definitions

3. Roles & Responsibilities

4. Hazard Assessment & PPE Matrix

1. Hazard Assessment Procedures:
   • Frequency: Conduct initial comprehensive walkthroughs, then reassess annually or upon process change.
   • Method: Use impact testers, splash rigs, radiometers, and worker interviews (Modules 2 & 3).
   • Documentation: Complete the Hazard Assessment Form (Appendix A) detailing tasks, hazards, test data, and environmental factors.
2. PPE Selection Matrix:
   • Structure: A table with columns for Task, Hazard Type, PPE Type, Standard (e.g., Z87.1), Rating (impact/splash/Shade/OD), and Notes (e.g., fit considerations).
   • Approval: EFPC to review and sign off on the matrix annually.
   • Accessibility: Post digital matrix on the intranet and printed versions at PPE stations.

5. Training & Competency

1. Initial Training:
   • Curriculum: Hazard awareness, PPE selection rationale, fit and seal checks, cleaning and storage, limitations.
   • Duration: Minimum 2 hours, including hands-on PPE fitting and testing.
   • Assessment: Practical demonstration of seal checks and PPE donning.
2. Refresher Training:
   • Frequency: Annually for all employees; immediately when policy or PPE matrix changes.
   • Format: 1 hour classroom plus toolbox talks using Module 4 scripts.
3. Recordkeeping:
   • Records: Attendance, quiz scores, practical assessments.
   • Retention: Three years (U.S.) or per jurisdiction (2–5 years).
   • Access: Maintain in LMS or document control system for audits.

6. PPE Maintenance, Cleaning & Replacement

1. Daily Inspection:
   • Checklist: Lens scratches, gasket integrity, strap elasticity, headgear fit.
   • Action: Remove and tag any defective PPE; replace immediately.
2. Cleaning Protocol:
   • Frequency: After each shift or use in splash environments.
   • Method: Use mild detergent and water; avoid solvents unless approved by manufacturer.
   • Drying & Storage: Air-dry in clean area; store in designated cabinets or sealed bags.
3. Scheduled Replacement:
   • Lenses/Visors: Replace upon first sign of scratching or after six months – whichever comes first.
   • Gaskets & Seals: Replace annually or as recommended by manufacturer.
   • Disposable PPE: Single-shift use only; discard at end of shift.
4. Inventory Management:
   • Tracking: Log issuance, repairs, replacements in the PPE Inventory System.
   • Stock Levels: Maintain a 20% buffer stock for all critical PPE items.

7. Program Audits & Inspections

1. Spot-Check Audits:
   • Frequency: Monthly unannounced inspections by supervisors/EFPC members.
   • Focus: Proper PPE use, fit-check compliance, condition of PPE, and adherence to the matrix.
2. Formal Annual Audit:
   • Scope: Review hazard assessments, PPE matrix, training records, maintenance logs, incident trends, and KPI performance.
   • Participants: EFPC, safety director, and worker representatives (JHSC in Canada).
   • Reporting: Publish a Program Audit Report with findings, corrective actions, and responsible owners.
3. Key Performance Indicators (KPIs):
   • Compliance Rate: % of tasks performed with correct PPE.
   • Inspection Findings: Defects per 100 PPE units inspected.
   • Training Completion: % of workforce current on training.
   • Incident Trend: Eye/face injuries per 100,000 work hours.

8. Incident Reporting & Corrective Actions

1. Immediate Reporting:
   • All eye/face injuries or near-misses must be reported to supervisors within 1 hour.
   • Complete an Incident Report Form (Appendix B) detailing circumstances, PPE used, and initial observations.
2. Investigation & Root-Cause Analysis:
   • Conduct a structured RCA within 24 hours, examining hazard assessment gaps, PPE failure, human factors, and environmental conditions.
   • Involve EFPC, frontline workers, and maintenance staff.
3. Corrective Actions:
   • Assign documented actions to specific owners with deadlines (e.g., update matrix, retrain staff, replace PPE model).
   • Track closure in the Corrective Actions Log.
4. Communication:
   • Share lessons learned through toolbox talks, email bulletins, and intranet posts.
   • Update policy or procedures as necessary.

9. Continuous Improvement

1. Quarterly Review Meetings:
   • EFPC reviews KPIs, audit reports, and incident data; adjusts hazard assessments and PPE matrix accordingly.
2. Employee Feedback Mechanisms:
   • Conduct periodic surveys on PPE comfort, usability, and perceived protection.
   • Host “PPE Rounds” where workers demo new eyewear models and provide input.
3. Policy Review Cycle:
   • Formal policy revision every 12 months – or sooner after major incidents, regulatory updates, or significant process changes.
4. Innovation & Pilots:

Trial new PPE technologies (anti-fog coatings, laser‐filtering films, lightweight materials) on a small scale before full rollout.