aw101 osha 1 c6_hazard iden, eva & control
DESCRIPTION
AW101 OSHA 1TRANSCRIPT
HAZARD HAZARD IDENTIFICATIOIDENTIFICATIO
N & N & EVALUATION EVALUATION
CONTROLCONTROL
2
BASIC TERMINOLOGYHAZARD
Anything that may have the potential to result in injury or harm to the health of a person
ORUnsafe condition or practice that could cause an injury or illness to an
employee – specific for manufacturing
It takes a hazard and someone exposed to the hazard to produce an accident.
RISKThe probability of that injury or harm to occur
Hazard + Exposure AccidentHazard + Exposure Accident
3
Safety task
Hazard identification
Scenario identification
Accidentprobability
Accidentconsequences
Risk determination
Acceptable ?Modify work/part
arrangement
Accomplish the safety task
Y
N
Assign the risk code
Take appropriate action – based on risk control’s hierarchy
IDENTIFYIDENTIFY
EVALUATIONEVALUATION
CONTROLCONTROL
PROCESS FLOW
4
Among the hazard identification techniques available are;i. Physical inspectionii. Checklistiii. Organisational chartsiv. Flow chartsv. Hazard & operability study (HAZOP)vi. Fault tree analysisvii. Job safety analysis (JSA)viii. Management oversight & risk tree (MORT)ix. DOW indexx. Risk assessment
IDENTIFICATION
To identify hazards so that can be eliminated / controlled.OBJECTIVE
METHODS
5
For all methods, the main consideration are•What can go wrong & how ?•Consequences ?•Target : - Low probability & Minimal consequences
It must be clear that;• It is unlikely that one particular method will be sufficient to address all of
the problems• Certain methods are more useful in some industries Risk identification
should be an ongoing exercise, because risks mutates.• Risk identification should be cost effective• Accurate record keeping is important
In this course, we will concentrate at Risk AssessmentBeside this, well-known risk management techniques to be discussed are;
• HAZOP
6
HAZARD AND OPERABILITY STUDIES (HAZOP) Identify hazards due to fixed equipment & procedures. Is a huge effort. Provides a controlled mechanism to consider the things that can go wrong. Customized for each company. Improves process performance, quality, etc.
Time, people and effort Information management problem
Advantages: Meets regulatory requirements Plant operates better Less down time Product quality improved
Disadvantages:
7
Procedure of HAZOP1. Divide flow sheet into sections, eg: production floor, storage area etc.2. Choose a study area, eg: line, section, department, system (pump, vessel) &
operating instruction.3. Describe its design intent/aim.4. Select a process parameter.5. Apply a SOP.6. Determine causes.7. Evaluate consequences/problems.8. Recommend action: what? who? when?9. Record info.10. Repeat 5 to 9 for a new guide word.11. Repeat 4 to 10 for a new process parameter.12. Repeat 2 to 11 for a new study node.13. Repeat 1 to 12 for a new flow sheet section.
8
RISK ASSESSMENT Based on self-regulation system Very user friendly and can be used by everyone in any organisation. Suitable for
manufacturing industries by prioritizing action plans Main purpose;
• To determine whether the planned or the existing control measures, such as systems of work and safeguards, are adequate or need to be improved.
Advantages: Ownership ;gives employers greater discretion to develop their own S&H Opportunity to promote safety awareness
Require a lot of time, people and effort Some assessors have become complacent about danger at work
Disadvantages:
9
For successful implementation;• Discuss the purpose & plan with everyone concerned• Identify risk assessment training needs• Identify a list of work activities, & gather information about them• Identify all the hazards relating to each activity, or simply answer the
question “could the work activity hold any danger to S&H• Make an informed estimate of the size of the risk associated with each
hazard. This generally means making a common sense judgement on hazard scale, how much harm, and how many people could be affected
• Decide whether the planned or existing S&H (if any) are adequate to keep the hazard under control
• Record the significant findings of the assessment
10
TYPES OF HAZARDSPsycho-social
Physical Chemical
Mechanical
Biological
• Stress• Plant
layout• Ergonomic
improvement
• Weak mgmt• Organisatio
nal culture clash
• Lack of job satisfaction
• Inadequate leadership
• Ergonomics• Visual
condition
• Thermal• Noise• Vibration• Confined
space• Ventilati
on• Air
pressure• Electricit
y. • Radiatio
n
• Gases• Liquid• Solid• Vapour
s• Dusts• Fumes• Pesticid
e• Mists• Smoke
• Machinery
• Equipment
• Tools• Transport
• Insects• Fungi• Yeast• Bacteri
a • Viruses
11
HAZARD IDENTIFICATION PROCESSESThrough;i. Inspectionsii.Questionnaires & hazard surveyiii.Trend analysis/ illness records / operability studyiv.Employees reporting hazards
SAMPLE JOB HAZARD ANALYSIS WORKSHEET
Job Description: ____________________________________________________________
Step 1 Description: _________________________________________________________
Hazards
Preventive Measure(s) Required
1. _____________________________________________________________________
2. _____________________________________________________________________
3. _____________________________________________________________________
Step 2 Description: _________________________________________________________
Hazards
Preventive Measure(s) Required
1. _____________________________________________________________________
2. _____________________________________________________________________
3. _____________________________________________________________________
Step 3 Description: _________________________________________________________
Hazards
Preventive Measure(s) Required
1. _____________________________________________________________________
2. _____________________________________________________________________
3. _____________________________________________________________________
Safe Job Procedure
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
SAMPLE JOB HAZARD ANALYSIS WORKSHEET
Job Description: ____________________________________________________________
Step 1 Description: _________________________________________________________
Hazards
Preventive Measure(s) Required
1. _____________________________________________________________________
2. _____________________________________________________________________
3. _____________________________________________________________________
Step 2 Description: _________________________________________________________
Hazards
Preventive Measure(s) Required
1. _____________________________________________________________________
2. _____________________________________________________________________
3. _____________________________________________________________________
Step 3 Description: _________________________________________________________
Hazards
Preventive Measure(s) Required
1. _____________________________________________________________________
2. _____________________________________________________________________
3. _____________________________________________________________________
Safe Job Procedure
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
12
How to develop an effective safety and health checklist.• Determine applicable state safety & health rules for the workplace.• Review rules and use those you feel apply to your workplace.• Develop applicable checklist questions that are not addressed in the rules.
i-Physical inspections
Identify;• Who's involved in the inspection process?• What is weakness inherent in the inspection process?• What process can be used to overcome this weakness?
Identifying high risk job activities/ procedures/ controls and exposures to the hazards.
See sample of safety inspection checklist
13
Observations, informal and formal, are quite important in daily workplace safety. Employees and managers can spot hazardous conditions and unsafe or inappropriate
behaviors while they conduct their other tasks.
ii-Questionnaires & hazard survey
iii-Trend analysis / illness records and operational study
Using available medical reports, job performance analysis, attendance records and etc.
SAMPLE JOB HAZARD ANALYSIS WORKSHEET
Job Description: ____________________________________________________________
Step 1 Description: _________________________________________________________
Hazards
Preventive Measure(s) Required
1. _____________________________________________________________________
2. _____________________________________________________________________
3. _____________________________________________________________________
Step 2 Description: _________________________________________________________
Hazards
Preventive Measure(s) Required
1. _____________________________________________________________________
2. _____________________________________________________________________
3. _____________________________________________________________________
Step 3 Description: _________________________________________________________
Hazards
Preventive Measure(s) Required
1. _____________________________________________________________________
2. _____________________________________________________________________
3. _____________________________________________________________________
Safe Job Procedure
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
SAMPLE JOB HAZARD ANALYSIS WORKSHEET
Job Description: ____________________________________________________________
Step 1 Description: _________________________________________________________
Hazards
Preventive Measure(s) Required
1. _____________________________________________________________________
2. _____________________________________________________________________
3. _____________________________________________________________________
Step 2 Description: _________________________________________________________
Hazards
Preventive Measure(s) Required
1. _____________________________________________________________________
2. _____________________________________________________________________
3. _____________________________________________________________________
Step 3 Description: _________________________________________________________
Hazards
Preventive Measure(s) Required
1. _____________________________________________________________________
2. _____________________________________________________________________
3. _____________________________________________________________________
Safe Job Procedure
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
14
iv-Employees reporting hazards To overcome immediate safety problems. Eg.: Unauthorized worker driving forklift, using compressed air as drier How can employer most effectively recognize employees for reporting hazards?
Watch your language.Keep it simple. Format;
•Background/Introduction •Findings•Recommendations•Conclusion/Summary
Writing Effective Inspection Reports
15
EVALUATION A process where judgements are made about the hazards that might be arise from unsafe
conditions (USC) and unsafe act (USA)-based on Risk assessment technique
The process of hazard analysis consists of;i. Break a job or task into specific stepsii. Analyze each step for specific USA and USC iii. Develop preventive measures in each step to eliminate or reduce the hazardsiv. Integrate preventive measures into training and standard operating procedures
(SOP’s)
Should refer to the related guidance for specific hazard to ensure within regulation requirements.
16
SEVERITY = HAZARD x RISK x PERSONS AT RISK
FACTOR
HAZARD RISK PERSON AT RISK
RANK 1 2 3 1 2 3 1 2 3 4 5
WEIGHT
Min
imal ris
k
Mod
era
te ris
k
Serio
us ris
k
Imp
rob
ab
le o
ccu
rren
ce
Possib
le o
ccu
rren
ce
Com
mon
occu
rren
ce
Low
est n
o. p
eop
le a
ffecte
d
Low
no. p
eop
le a
ffecte
d
Med
ium
no. p
eop
le
aff
ecte
d
Hig
h n
o. p
eop
le a
ffecte
d
Hig
hest n
o. p
eop
le
aff
ecte
d
DETAILS
An
xie
ty, s
tress, m
inor in
jurie
s
Bro
ken
bon
es, b
urn
s, s
cald
s
Dis
ease, lo
ss o
f limb
s o
r death
Roof c
olla
pse
Un
licen
sed
fork
lift driv
er-
accid
en
t
Oily
floor – fa
ll dow
n
1~
5
6~
10
11~
20
21~
49
More
than
50
MEASURING SEVERITY
17
SEVERITY CODINGCATEGOR
YACTION CODE
Minor/ minor
No action is required to deal with trivial risks, and no documentary records need be kept.
-
Acceptable
No further preventive action is necessary, but consideration should be given to more cost-effective solutions. Monitoring is required.
GREENGREEN
Moderate Efforts should be made to reduce the risks, but the costs of prevention should be carefully measured and limited. Risk reduction should be implemented within 3~6 months , depending on the no. of people exposed to the hazards.
YELLOYELLOWW
Substantial/ considerable
Work should not be started until the risk has been reduced. If the risk involves WIP job, the problem should be remedied within 1~3 months, depending on the no. of people exposed to the hazards
ORANGORANGEE
Intolerable/ impossible
Work should not be started or continued until the risk level has been reduced. If not possible to reduce the risk, then the work must remain prohibited
REDRED
18
CONTROLS Consideration needs for hazard controlling;
• Try & eliminate as many hazards as possible; eg: using a safe substance instead of a potentially dangerous one
• Combat risks at source• Select preventive measures, such as guards, • Avoid creating new hazards when seeking to control existing hazards• Select PPE only as a last resort, after all other options have been considered
and found to be impracticable Organisation should have official form to record the findings of an assessment,
covering;• Work activity,• The hazards• The risk levels and severity of hazard• The personnel at risk & crucially• The action required
19
No recognition planInadequate training plan
No accountability policy No inspection policy
No discipline procedures
No orientation process
Inadequate training
Fails to enforceLack of time
No recognition
CutsBurns
La
ck
of
vis
ion
Strains
No
mis
sio
n s
tate
me
nt
Root causes
Surface causes
Direct Cause of InjuryHarmful transfer of energy that produces injury or illness.
The causes of injuries and accidents
Specific hazardous conditions or unsafe behaviors that result in an accident.
Common behaviors and conditions that ultimately result in an accident.
20
HIERARCHY OF RISK CONTROL
ELIMINATIONELIMINATION
ISOLATIONISOLATION
PPEPPE
ENGINEERING CONTROL
ENGINEERING CONTROL
ADMINISTRATIVE CONTROL
ADMINISTRATIVE CONTROL
Removing the hazard or hazardous work practice from the workplace
Separating hazard or hazardous work practice from people not involved in the work (eg : marking off hazardous areas, installing barrier)
Modification to tools or equipment (eg : guarding to machinery)
Introducing work practices that reduce the risk ( eg : limiting amount of time a person is exposed to the hazards -noise, thermal, etc)
Should be considered only when other control measures are not applicable
Replacing a hazard or hazardous work practice with a less hazardous one SUBTITUTIONSUBTITUTION
* Constraint : You may need to use more than one control measure to reduce risk
21
ENGINEERING CONTROLENGINEERING CONTROLEXAMPLE
ADMINISTRATIVE CONTROLADMINISTRATIVE CONTROL
PPEPPE
22
COMMON HAZARD CONTROLLING PRACTICES
Is the orderly arrangement of tools, equipment, storage facilities and supplies Housekeeping & 5S
5S
SEIRISEIRISEIRISEIRI
SHITSUKESHITSUKESHITSUKESHITSUKE
SEIKETSUSEIKETSUSEIKETSUSEIKETSU
SEITONSEITONSEITONSEITON
SEISOSEISOSEISOSEISO
(CLEARING-sort & discard)
(ORGANISING- systematically arrange)
(CLEANING- spick & span)
(MAINTAINING- standardise)
(SELF DISCIPLINE)
For 5S, deeper concept housekeeping because includes self-discipline
23
Benefits of housekeeping / 5Si. Reduce operating costs because much less time & effort are required to maintain &
clean.ii. Production increases because once obstacles are removed without interference or
delay, the plant can function smmothly
‘5S’ main objectives ;
SAFETY(Preventing accident)
SAFETY(Preventing accident)
PRODUCTIVITY(Eliminating wastes)
PRODUCTIVITY(Eliminating wastes)
EQUIP. MAINTENANCE(Eliminating breakdown)EQUIP. MAINTENANCE
(Eliminating breakdown)
QUALITY(Preventing error)
QUALITY(Preventing error)
5S5S5S5S
24
iii. Control of production becomes easier because materials and parts of component do not get lost or mixed
iv. Easier to check operation and processv. Recovery of unused material and scrap become easiervi. Production time is saved. There is no time spent in searching for materials, tools, parts,
etc…vii. Better utilization of floor space, clear area allows the operators to move freely and
maintenance men to carry out the works easilyviii.Clear aisles permit quick traffic without accidentsix. Reduce fire hazardsx. Lower accident rate due to free and orderly movementxi. Results in higher employee morale. The attitude of employees improve on observing
clean surroundings and comparative freedom from injuries
25
Effective education and training When is it important to train employees? How do we know safety education and training has been effective? If it isn’t in writing…it didn’t get done… Training need to be documented
•Sample training certification for specific tasks•Trainee certification•Trainer certification•Supervisor validation
Effective Maintenance Processesi. To make sure equipment and machinery runs safely and smoothly.• To make sure equipment gets back into safe service quickly.
Thank youThank you