On March 16-18, 2025, 9 ERC students and 3 faculty went on a trip to visit River View Coal, LLC in Waverly, KY and the GE Appliances Park in Louisville, KY. At River View the group learned about the safety features and gear, then went on an underground tour and a surface tour of the mine, and spoke with leadership, clinicians, and staff to ask questions and learn more about worker safety. At the GE Appliances tour, the group had the opportunity to tour the dishwasher production, learn about Every Voice Program, and learn about Employee Health and Safety at GE Appliances. Below are more details about the trip written by the students in attendance. The in-depth knowledge gained in classroom preparation of all the ERC students was palpable. Students engaged site leaders with questions that demonstrated not only knowledge of occupational health and safety (OHS) topics, but of critical thinking and applying OHS program concepts.

ERC students and faculty at the River View Coal Mine

River View Coal, LLC

Written by: Chien-Yu Hsu & Hannah Frame

On Monday, March 17, 2025, the UC ERC students visited the River View Coal Mine located in Waverly, Kentucky. River View Coal Mine has underground mining operations, which require a number of safety technologies to keep workers safe both in ordinary workdays and in case of emergency. When in the mine, each worker wears a hard hat with a tracker on the back. The trackers display a flashing blue light to demonstrate that they are on and are connected to a number of hubs throughout the mine. This allows individuals on the surface to detect the exact location of workers inside the mine. Workers also had proximity trackers, which are designed to shut off moving machinery if an individual gets too close to avoid crushing risks. There are several carbon monoxide monitors that are able to detect combustible and fire conditions before smoke begins, allowing workers ample time to exit. Each worker is also equipped with a rescuer which can provide immediate access to oxygen in case of emergency. In addition to safety at the company, River View Coal Mine also engages in community advocacy and education through the Friends of Coal organization. This group is comprised of industry leaders who work to facilitate discussion and decision-making processes among varying stakeholders including suppliers, citizens, financial institutions, consulting firms, and the local community. Demonstrating the value of continuing coal production is vital to the company’s success, and showcasing the reliability of coal operations is an ongoing part of the group’s outreach with local community members. The UC ERC students are grateful for the opportunity to visit the River View Coal Mine and appreciate the valuable insights that we were able to gain through our tour and conversations with the safety team at the mine.

Hard hat and proximity monitoring devices at River View Coal Mine

River View Coal Mine Surface Tour

Written by: Kofi Osei-Acheampong

In addition to learning what occurs underground, the students toured and learned about the above ground activities. River View Coal LLC surface activity is closely tied to effective waste disposal practices. After coal is extracted, they are washed to removed impurities, generating a slurry composed of water, fine coal particles, and chemical residues which are impounded and stored into tailing pounds. Improper handling and storage of the mining waste can lead to serious environmental hazards and safety risks for workers and surrounding communities releasing toxic materials into waterways or triggering flooding events, like the infamous Martin County sludge spill in Kentucky in 2000. In addition, there are large volumes of overburden, earth and rocks removed to access coal seams, which are stored in a waste pile. These piles are engineered for stability to prevent collapse, but they can pose fatal risks to workers and damage the ecosystems if prolonged slope grading, compaction, and drainage system are not put in place to reduce erosion and risk of landslides.

To safeguard against such incidents, the mining operations must adhere to strict engineering standards and environmental regulations. This should include regular inspections of impoundments, monitoring of water quality, and implementation of emergency response plans. Surface safety is also improved by covering or stabilizing the coal refuse with vegetation or synthetic liners to prevent dust and leachate generation.

In summary, even though River View coal LLC has an effective engineering and regulatory compliance policy on how their mining waste is managed on the surface, responsible disposal protects workers and the communities and must prioritize robust surface waste disposal management systems as part of their overall mining safety.

Regulatory Practices at River View and GE Appliances

Written by: Shawn Howe

Kentucky has a rich heritage in mining and manufacturing. At the forefront of this heritage is the River View Coal, LLC, an underground mining operation located near in Waverly, Union County, Kentucky. The Mine Safety and Health Administration serves as the enforcer of the Federal Mine Safety and Health Act of 1977 (Mine Act), as amended by the MINER Act of 2006. The regulations are designed to protect life and prevent injuries in mining processes in the USA. The rules define compliance standards that govern the operation of coal mines. The regulations contain mandatory health standards, dust sample requirements, medical surveillance screening methods, and provisions for miners, as well as numerous safety standards to protect against the various hazards associated with coal mining processes (eCFR :: 30 CFR Chapter I Subchapter O -- Coal Mine Safety and Health, 2025).

In addition to visiting River View Coal Mine, the students visited the General Electric (GE) Appliance Park. GE also operates in accordance with Occupational Safety and Health Administration (OSHA) regulations and local air quality controls defined by the Louisville Air Pollution Control District (APCD) (Louisville-Jefferson County Metro Government, 2025). Both sectors strive for excellence and ensure a continued and compliant future.

References

eCFR :: 30 CFR Chapter I Subchapter O -- Coal Mine Safety and Health. (2025, March). https://www.ecfr.gov/current/title-30/chapter-I/subchapter-O

Louisville-Jefferson County Metro Government. (2025, March). Air Pollution Control District | LouisvilleKY.gov. Retrieved March 28, 2025, from https://louisvilleky.gov/government/air-pollution-control-district

GE Appliances

Written by: Amour Dondi

The trip to GE Appliance Park in Louisville Kentucky, was an eye-opening and enlightening experience. I was amazed with how big the plant was, estimated to be at 900-acres industrial park, making it their largest manufacturing site with 5 facilities making mainly washers, dryers, dishwashers and refrigerators.

The site has excellent Environmental, Health and Safety management. I observed some of the active programs being implemented such as lock-out-tag-out of energized equipment, electrical safety, pedestrian safety (designated walkways for pedestrians), machine guarding in place (I saw various mechanical interlocks, light curtains, emergency to and some machines were 2 control type). Other programs I quickly observed included the noise conservation program (where I saw a booth for annual hearing tests), and earl intervention with availabilities of very advanced medical clinics for early intervention. Speaking to the site plant manager, I was impressed by how passionate, and safety driven he was. I could clearly see the management support in overall occupational health and safety aspects of the business.

Occupational Health Clinic on-site at GE Appliances

Focusing on Ergonomics, the site has been a successful ergonomics program. I was impressed to learn the site has an active stretching program. This is a very important proactive approach in minimizing work-related injuries. Another control in place was job rotation. We were informed that workers get rotated 100% for all shifts in a duration of 2 hours at the respective lines. Various workstation re-designs were reported to have been completed, this is due to regular ergonomic assessments conducted by the Ergo-team on-site. A very good proactive approach that I was very impressed with was their focus on new hires. For example, in 2024 the site received a total of 3,475 new hires, and 98% of those went through a stringent ergonomic assessment within 30 days of employment. This is wonderful practice in helping workers to navigate through their first month of employment safely. In the same year, 13,600 overall ergonomic observations were completed, and coaching was administered to close the action items observed.

Finally, lagging indicators in terms of metrics presented showed a successful reduction in OSHA recordable rates, days away restricted and transferred, ergo first aid success rate, and overall total ergonomic injuries year after year.

Ergonomics and Risk Management of GE Appliances

Written by: Mercy Omoifo-Irefo

GE Appliances is a manufacturing company with five buildings and four plants, working three shifts, 5 or 6 days per week. They are environmentally friendly, recycling 84% of their waste and segregating it. They participate in energy conservation programs and produce 10,000 dishwashers daily. They have occupational health programs, including occupational clinics and medical surveillance programs to prevent occupational injuries. Their top concern is noise hazards, which are the most hazardous exposure in manufacturing. To control this, they have hearing conservation programs for employees and annual screenings to determine workers' exposure levels.

GE conducts ergonomic risk assessments on various jobs, tasks, and workstations, making necessary adjustments to manage ergo risk. They utilize Job Rotation, Ergo Intervention, and Existing Stretching Program to eliminate strains, musculoskeletal injuries, and pains from job tasks. Statistically, 98% of new employees undergo an ergonomic assessment within the first 30 days of employment. In 2024, they carried out 13,600 ergonomic observations/job coaching. They had a success rate of 88% in Ergo First Aid, and their total ergonomic injuries reduced from 16% in 2022 to 10% in 2023 and 21% in 2024. Many ergo injuries remain at first aid level, decreasing costs by an estimated $500-$750k.

They engage in preventative placement as first aid for individuals. One important aspect that made a difference in eliminating accidents and injuries was having their HSE team involved in the design stage with engineers. However, a review of their job rotation is needed to eliminate fatigue, discomfort, and musculoskeletal injuries over time.

GE Appliances Health Surveillance

Written by: Judith Arthur

In Louisville, Kentucky, GE Appliances manufactures various household appliances, including dishwashers, freezers, air conditioners, washing machines, refrigerators, dryers, water filtration systems, and heaters. What sets it apart is its strong safety culture that prioritizes the well-being of its diverse workforce. During our visit to the site on March 18, 2025, a registered nurse and an Environmental Health and Safety (EHS) member, provided a tour of the facility. She provided valuable insights into the company's safety system and introduced us to key personnel in production and manufacturing at Appliance (AP) 3.

GE enforces comprehensive health surveillance per OSHA’s regulations. New hires undergo pre-employment medical screening, with routine health checks performed on the other staff. Because noise is a primary hazard in manufacturing, workers observed to have changes in audiometry readings are enrolled in a comprehensive hearing conservatory program. Additionally, those requiring respirators undergo respiratory fit testing with periodic evaluations to assess compliance and effectiveness.

The company promotes employee health through preventive methods such as stretching programs and physical and occupational therapy. It also has robust mental health programs to manage work-related mental health challenges. From vaccination to routine screening, health-related information is handled via posters with QR barcodes and web systems. Micro-clinics within each department provide convenient access to screening and treatment for timely diagnosis and treatment of injuries. In addition to meeting with OHS teams, we had an opportunity to speak with site leadership who took time to engage with our students and share their passion for site safety and being an integral part of the community.

Health and safety signs at GE Appliances

While GE Appliances' current processes are commendable, including proactive strategies to identify potential at-risk individuals before injuries occur could improve their health surveillance system.

Evaluation of Health and Safety Programs at GE Appliances

Written by: Victoria Simmons

Our recent visit to GE Appliance, a Haier Company, was an excellent opportunity for us students to learn about the manufacturing process and see the daily aspects of what the workers do. The first safety feature I noticed in the building was the green-paved pathways to keep people safe from walking on the main floor where equipment and things are transported. The entrance had vending machines with Personal Protective Equipment and recycling bins for gloves and safety glasses. There is an area called the “Center of Excellence” where meetings are held to discuss issues that need to be fixed throughout the workday with the team Maintenance, Operation, Quality, Material, EHS & HR to discuss issues that need to be fixed.” GE has its own Occupational Health Clinic. There is a hearing booth – audiometer and hearing conservation program that Industrial Hygienists evaluate the audiograms, and mid-shift will see if the worker is wearing their hearing protection correctly and color blind testing different hues of paints inside the health clinic. DART (Days Away Restricted Trauma), Ergonomic First Aid Success Rate 88% with no additional treatment. Musculoskeletal injuries are the most common, such as carpal tunnel, overreach twist, etc. For prevention, placement workers will be restricted from doing their regular jobs until OSHA says so. There is a medical surveillance process that digitized questionnaires incorporate standards into clinic visits. Next is “LEAN,” which is about creating customer value without resources, Six Sigma measurement critical control problem-solving. Operation & Excellence, Work Good Safety & Quality Tightly connected. Motto: Safety is a “journey”; investigate first aid, injury rate, and below-average leadership. Who leads- EHS & Safety- they help to see the problem, Plant Manager- Leads their idea and makes it work. There are safety representatives in each department and QR codes to report safety concerns vs being distracted on phones. They found that the 2^nd shift has fewer accidents and are less stressed.

LEAN Strategies

Written by: Dickson Rungere

On March 18^th we visited GE Appliances, a Haier company based in Louisville, Kentucky. It manufactures American home appliances such as refrigerators, ranges, dishwashers, microwaves, washers, ovens, HVAC, and other home appliances. GE Appliances applies LEAN to deal with inefficiency. LEAN is a business approach focusing on creating and maximizing customer value with minimum resources and minimizing waste. It is achieved through principles such as identifying value, mapping the value stream, creating flow, and pursuing protection. Common tools applied are 5 “S”s- (sort, set in, shine, standardize and sustain) and Kaizen (continuous improvement). Initially, they determine what customers are willing to pay for, focusing on features and benefits that are truly valuable to them, then visually represent the entire process from raw materials to customer, identifying non-value added activities and potential bottlenecks, doing the tasks themselves to understand the problem, setting up the workstation to be ergonomically compatible, train people to solve problems, EHS meetings, use team leaders and safety representatives to make sure the job is performed efficiently. Moreover, LEAN ensures the elimination of wastes and Interruptions in the process to ensure a smooth and efficient flow of work, wastes from transportation, overproduction, defects, waiting phase, and inventory. About 84% of the waste goes to recycling intending to reach 87% by the end of the year. Lastly, pursuing protection and continuous improvement aiming at the state of zero defects and maximum efficiency. Lean works hand to hand with the EHS department to ensure safety in every approach of maximizing customer value and efficiency.

Thank you!

The UC ERC would like to thank the hosts at River View Coal, LLC and GE Appliances for being so welcoming to our group of students and faculty. It was a great experience to be able to tour the facilities and learn more about the health and safety practices in two different industries and talk directly to those who work at River View and GE Appliances. To learn more about River View, visit the website here. To learn more about GE Appliances, visit the website here