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Listen "What if "Good Enough" Could Cost You Everything? - Real Talk on DHAs with Diane Cave"
Episode Synopsis
In this episode of the OnAire Podcast, we’re joined by Diane Cave, a powerhouse in the combustible dust world with 20+ years of experience helping facilities uncover and address hidden hazards.
If you're a plant manager, engineer, or EH&S leader, this episode is your no-fluff, real-world guide to doing Dust Hazard Analyses (DHAs) right—and what happens when you don’t.
TL;DR: A vague Dust Hazard Analysis isn’t harmless—it’s dangerous. In this episode, Diane Cave explains how language, leadership, and liability intersect in combustible dust safety. You’ll leave with tools to ask better questions, write stronger reports, and create a culture where safety isn’t a checkbox—it’s a commitment.
🎙️ What You’ll Learn:
✅ Why DHAs fail (and how to make yours actionable)
✅ The danger of “soft language” in safety reporting
✅ How insurers and regulators are driving DHA enforcement
✅ The right way to think about compressed air and blowdowns
✅ How safety culture shows up in the dust (literally)
✅ When your cleaning plan is actually failing
✅ Why clarity in a DHA isn’t just kind—it's critical
Diane also shares her infamous “dust lottery” analogy—and why some facilities are unknowingly buying tickets.
"Every time you say 'should consider,' you're giving someone permission to ignore a hazard." – Diane Cave
🙋♂️ Who This Is For: This episode is made for manufacturing professionals who are:
🧠 Overwhelmed by combustible dust compliance
📋 Unsure what a DHA actually needs to say
🔎 Tired of vague language and unclear next steps
💬 Ready to improve internal safety communication
📉 Trying to reduce risk, downtime, and insurance headaches
❓ Frequently Asked Questions (FAQ)
Q: What is a DHA (Dust Hazard Analysis) and do I need one?
DHA is a formal, systematic review of your facility's combustible dust risks and safety practices. If your process generates dust, you likely need one to comply with NFPA 652 and NFPA 660.
Q: Who enforces DHAs?
While OSHA and AHJs may spot-check, insurance providers and corporate risk departments are often the driving force behind DHA requirements.
Q: What’s the risk of not doing a DHA?
Beyond non-compliance, you risk property damage, production loss, employee injury, or worse. Inaction = liability.
Q: How do I know if my DHA is any good?
If it’s filled with “may,” “might,” or “should consider” language—it's not directing action. A solid DHA gives clear, prioritized, and enforceable recommendations.
Q: Can I write my own DHA?
It’s not recommended. Third-party experts, like Diane’s team at Element 6, bring technical insight, field experience, and unbiased clarity.
🔗 Resources & Contact:
Learn more about Diane Cave and Element 6: / diane-cave-p-eng-616b405
Explore SonicAire’s engineered dust control systems: https://www.sonicaire.com
👍 Like this episode?
Hit like, subscribe, and share with your team.
🎧 Available wherever you get your podcasts.
If you're a plant manager, engineer, or EH&S leader, this episode is your no-fluff, real-world guide to doing Dust Hazard Analyses (DHAs) right—and what happens when you don’t.
TL;DR: A vague Dust Hazard Analysis isn’t harmless—it’s dangerous. In this episode, Diane Cave explains how language, leadership, and liability intersect in combustible dust safety. You’ll leave with tools to ask better questions, write stronger reports, and create a culture where safety isn’t a checkbox—it’s a commitment.
🎙️ What You’ll Learn:
✅ Why DHAs fail (and how to make yours actionable)
✅ The danger of “soft language” in safety reporting
✅ How insurers and regulators are driving DHA enforcement
✅ The right way to think about compressed air and blowdowns
✅ How safety culture shows up in the dust (literally)
✅ When your cleaning plan is actually failing
✅ Why clarity in a DHA isn’t just kind—it's critical
Diane also shares her infamous “dust lottery” analogy—and why some facilities are unknowingly buying tickets.
"Every time you say 'should consider,' you're giving someone permission to ignore a hazard." – Diane Cave
🙋♂️ Who This Is For: This episode is made for manufacturing professionals who are:
🧠 Overwhelmed by combustible dust compliance
📋 Unsure what a DHA actually needs to say
🔎 Tired of vague language and unclear next steps
💬 Ready to improve internal safety communication
📉 Trying to reduce risk, downtime, and insurance headaches
❓ Frequently Asked Questions (FAQ)
Q: What is a DHA (Dust Hazard Analysis) and do I need one?
DHA is a formal, systematic review of your facility's combustible dust risks and safety practices. If your process generates dust, you likely need one to comply with NFPA 652 and NFPA 660.
Q: Who enforces DHAs?
While OSHA and AHJs may spot-check, insurance providers and corporate risk departments are often the driving force behind DHA requirements.
Q: What’s the risk of not doing a DHA?
Beyond non-compliance, you risk property damage, production loss, employee injury, or worse. Inaction = liability.
Q: How do I know if my DHA is any good?
If it’s filled with “may,” “might,” or “should consider” language—it's not directing action. A solid DHA gives clear, prioritized, and enforceable recommendations.
Q: Can I write my own DHA?
It’s not recommended. Third-party experts, like Diane’s team at Element 6, bring technical insight, field experience, and unbiased clarity.
🔗 Resources & Contact:
Learn more about Diane Cave and Element 6: / diane-cave-p-eng-616b405
Explore SonicAire’s engineered dust control systems: https://www.sonicaire.com
👍 Like this episode?
Hit like, subscribe, and share with your team.
🎧 Available wherever you get your podcasts.
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