Metalworking fluids: oil mist and beyond

This article is based upon my own experiences with metalworking fluids and the adverse health effects and medical conditions associated with exposure to metalworking fluids. I have researched and witnessed the benefits that can be achieved when metalworking fluids are properly maintained and managed. My experiences have provided insight into how a shop operates, including comprehension of the equipment used, processes, mist generating points, engineering controls currently being adopted, and procedures that are used to maintain metalworking fluids. I have been able to share my personal experiences with the country's leading experts in the field of metalworking fluids. I have presented my insights on the topic in Washington, D.C., to the Standard Advisory Committee of OSHA, as well as at many other conferences nationwide. I have provided awareness training for a number of union and nonunion workers. Being a part of developing successful metal removal fluid programs, I realize the importance of transferring and sharing information. Many times an organization is not fully aware of certain conditions and how to combat them. My mission and intent is to properly educate those who are exposed to the harm that metalworking fluids can invoke and to inform those involved of the possible methods of reducing long- and short-term risk. One thing that must be kept in mind is the way we view these fluids. Many shops categorize the fluids as a type of "operating expense" when they should actually be seen as a sort of investment. Just as performing a scheduled maintenance on a machine promises the best possible longevity of that machine, the upkeep of metalworking fluid also provides longer "tool life." Monitoring and maintaining the fluids also provides for more effective and efficient productivity. If we fail to consider that proper management of the fluids can cut cost dramatically, then we will miss out on the financial impact they can have on a company. Try looking at the fluids as a liquid tool. Doing so I believe will bring a better understanding of the value of a successful metalworking fluids program. With this new understanding, it can be seen just who must play a role in the management of metalworking fluids. The employees who deal with the daily tasks involving the coolant play a major part. They are on the floor where these metalworking fluids are being used. In many shops, it is assumed that the environmental health & safety departments are responsible for standard operating procedures and management of fluids. The EH&S department should only be responsible for the protection from exposure and the transfer of information regarding policy and procedure to their employees. Not all shops have the resources required to develop and implement the proper standard operating procedure. Therefore, we must understand that what is feasible for one may not be for another. Companies that lack the sufficient resources should not be neglected. It is crucial that awareness of proper standard operating procedure is shared with everyone involved with the fluids in order to provide proper metalworking fluids management. Fluids are as dynamic as the formulations themselves (complex & dynamic). These fluids can quickly become contaminated with foreign materials and chemicals, thereby become aerosolized into mist. With proper education and training, one will be able to control what gets aerosolized.