133234735 chapter6 hazard identification risk assesment and risk control hirarc
TRANSCRIPT
HAZARD
IDENTIFICATION &
EVALUATION
CONTROL
2
BASIC TERMINOLOGY HAZARD Anything that may have the potential to result in injury or harm to the health of
a person
OR
Unsafe 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.
RISK The probability of that injury or harm to occur
Hazard + Exposure Accident
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Safety task
Hazard identification
Scenario identification
Accident probability
Accident consequences
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
IDENTIFY
EVALUATION
CONTROL
PROCESS FLOW
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Among the hazard identification techniques available are;
i. Physical inspection
ii. Checklist
iii. Organisational charts
iv. Flow charts
v. Hazard & operability study (HAZOP)
vi. Fault tree analysis
vii. Job safety analysis (JSA)
viii. Management oversight & risk tree (MORT)
ix. DOW index
x. Risk assessment
IDENTIFICATION
To identify hazards so that can be eliminated / controlled.
OBJECTIVE
METHODS
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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 Assessment Beside this, well-known risk management techniques to be discussed are;
• HAZOP
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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:
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Procedure of HAZOP 1. 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.
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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:
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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
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TYPES OF HAZARDS
Psycho-social Physical Chemical Mechanical Biological
• Stress
• Plant layout
• Ergonomic
improvement
• Weak mgmt
• Organisational
culture clash
• Lack of job
satisfaction
• Inadequate
leadership
• Ergonomics
• Visual
condition
• Thermal
• Noise
• Vibration
• Confined
space
• Ventilation
• Air
pressure
• Electricity.
• Radiation
• Gases
• Liquid
• Solid
• Vapours
• Dusts
• Fumes
• Pesticide
• Mists
• Smoke
• Machinery
• Equipment
• Tools
• Transport
• Insects
• Fungi
• Yeast
• Bacteria
• Viruses
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HAZARD IDENTIFICATION PROCESSES Through; i. Inspections ii.Questionnaires & hazard survey iii.Trend analysis/ illness records / operability study iv.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
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
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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
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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
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
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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
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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 steps ii. Analyze each step for specific USA and USC iii. Develop preventive measures in each step to eliminate or reduce the hazards iv. 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.
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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 risk
Modera
te
risk
Serio
us risk
Impro
bable
occurre
nce
Possib
le
occurre
nce
Com
mon
occurre
nce
Low
est n
o.
people
affe
cte
d
Low
no.
people
affe
cte
d
Mediu
m n
o.
people
affe
cte
d
Hig
h n
o.
people
affe
cte
d
Hig
hest n
o.
people
affe
cte
d
DETAILS
Anxie
ty, stress,
min
or in
jurie
s
Bro
ken b
ones,
burn
s, scald
s
Dise
ase
, loss o
f lim
bs o
r death
Roof c
olla
pse
Unlic
ense
d
fork
lift driv
er-
accid
ent
Oily
floor – fa
ll dow
n
1~5
6~10
11~20
21~49
More
than 5
0
MEASURING SEVERITY
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SEVERITY CODING
CATEGORY ACTION 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.
GREEN
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.
YELLOW
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
ORANGE
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
RED
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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
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Fails to inspect
No recognition planInadequate training plan
No accountability policy No inspection policy
No discipline procedures
Outdated hazcom programNo orientation process
Unguarded machine Horseplay
Fails to trainTo much work
Defective PPE Fails to report injury
Inadequate training
Create a hazard
Fails to enforce
Untrained worker
Broken tools
Ignore a hazard
Lack of time
Inadequate labeling
No recognition
Cuts
Burns
Lack
of v
isio
n
Strains
No
mis
sion
sta
tem
ent
Chemical spill
Root causes
Surface causes
Direct Cause of Injury Harmful 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.
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HIERARCHY OF RISK CONTROL
ELIMINATION
ISOLATION
PPE
ENGINEERING 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 SUBTITUTION
* Constraint : You may need to use more than one control measure to reduce risk
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ENGINEERING CONTROL
EXAMPLE
ADMINISTRATIVE CONTROL
PPE
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COMMON HAZARD CONTROLLING PRACTICES
Is the orderly arrangement of tools, equipment, storage facilities and supplies
Housekeeping & 5S
5S
SEIRI
SHITSUKE
SEIKETSU
SEITON
SEISO
(CLEARING- sort & discard)
(ORGANISING- systematically arrange)
(CLEANING- spick & span)
(MAINTAINING- standardise)
(SELF DISCIPLINE)
For 5S, deeper concept housekeeping because includes self-discipline
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Benefits of housekeeping / 5S i. 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)
PRODUCTIVITY (Eliminating wastes)
EQUIP. MAINTENANCE (Eliminating breakdown)
QUALITY (Preventing error)
5S
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iii. Control of production becomes easier because materials and parts of component do not
get lost or mixed
iv. Easier to check operation and process
v. Recovery of unused material and scrap become easier
vi. 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 easily
viii.Clear aisles permit quick traffic without accidents
ix. Reduce fire hazards
x. Lower accident rate due to free and orderly movement
xi. Results in higher employee morale. The attitude of employees improve on observing
clean surroundings and comparative freedom from injuries
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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 Processes i. To make sure equipment and machinery runs safely and smoothly. • To make sure equipment gets back into safe service quickly.
Thank you