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HAZARD
IDENTIFICATION &
EVALUATION
CONTROL
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BASIC TERMINOLOGYHAZARD
Anything that may have the potential to result in injury or harm to the health ofa person
OR
Unsafe condition or practice that could cause an injury or illness to an employee
specific for manufacturing
It takes a hazardand someone exposedto the hazard to produce an accident.
RISK
The probability of that injury or harm to occur
Hazard+ ExposureAccident
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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 actionbased on risk controls
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 AssessmentBeside 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 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.
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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 keepthe 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
Visualcondition
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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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 sampleof safety inspection checklist
http://elearn.kuktem.edu.my/study/uploads/Safety_Inspection_Checklist.dochttp://elearn.kuktem.edu.my/study/uploads/Safety_Inspection_Checklist.dochttp://elearn.kuktem.edu.my/study/uploads/Safety_Inspection_Checklist.dochttp://elearn.kuktem.edu.my/study/uploads/Safety_Inspection_Checklist.dochttp://elearn.kuktem.edu.my/study/uploads/Safety_Inspection_Checklist.doc -
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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
(SOPs)
Should refer to the related guidance for specific hazard to ensure within regulation
requirements.
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SEVERITY= HAZARDx RISKx PERSONS AT RISK
FACTOR HAZARD RISK PERSON AT RISK
RANK 1 2 3 1 2 3 1 2 3 4 5
WEIGHT
Minimalrisk
Moderate
risk
Se
riousrisk
Im
probable
oc
currence
Po
ssible
oc
currence
Common
oc
currence
Lo
westno.
pe
ople
af
fected
Lo
wno.
pe
ople
af
fected
Mediumno.
pe
ople
af
fected
Highno.
pe
ople
af
fected
Highestno.
pe
ople
af
fected
DETAILS
Anxiety,stress,
min
orinjuries
Bro
kenbones,
burns,scalds
Disease,lossof
lim
bsordeath
Roofcollapse
Unlicensed
forkliftdriver-
acc
ident
Oilyfloorfall
dow
n
1~5
6~10
11~20
21~49
Morethan50
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 measuredand 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 problemshould 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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Failstoinspect
No recognitionplanInadequate training plan
No accountability policy No inspection policy
No discipline procedures
OutdatedhazcomprogramNo orientation process
Unguardedmachine H
orsepla
y
FailstotrainTomuchwork
Defective PPE
Failstor
eportinju
ry
Inadequate training
Createa
hazard
Fails to enforce
Untrainedworker
Brokentools
Ignoreahaz
ard
Lack of time
Inadequatelabeling
No recognition
Cuts
Burns
Lackofvision
Strains
Nomissionsta
tement
Chemicalspill
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 andconditions 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 thehazards -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 oneSUBTITUTION
* 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 hazardsx. 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 trainingWhen is it important to train employees?
How do we know safety education and training has been effective?
If it isnt in writingit didnt 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.
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Thank you