new process and equipment hazard assessment - examples of framework
TRANSCRIPT
Southeastern Wisconsin Safety Conference – UW WhitewaterOctober 27, 2016
Hazard Assessments - Frameworks for New Process and Equipment Move Evaluations
Brian Well, [email protected]
Today’s Overview and Context
Understanding your Hazard Assessment Objective(s) Resources Method of communications• Review some Risk Assessment templates • Apply methodology to scope
Upfront – before assessments begin
Four things to do before you start assessment
1 – Identify and confirm your Objective2 - Confirm your resources (people/time/space)3 - Plan training (who/how/when/where)4 – Plan to widely communicate objectives
Safety and Health Program Management Guideline – core elements
• Management Leadership• Worker Participation• Hazard Identification and Assessment• Hazard Prevention and Control• Education and Training• Program Evaluation and Improvement• Communication and Coordination for Host
Employers, Contractors and Staffing Agencies
Groups of Hazards
Change happens!
Example 1 – EtQ New Workflow Document 02/07/2016 07:36:00 AM
- 1 -
Draft Number: Please Save Reference: Date Created : 02/07/2016 Created By: Brian Well *Area/Equipment: Type: Forming/Press *Plant Site: Whitewater, WI Assessment Team : Brian Well Initial Assessment Date : October 27, 2016Post Assessment Date : schedule at conclusion of initial assesment
Example 1, Grouped Hazard Elements
1.0 General Machine Guarding 2.0 Life Safety3.0 Material Handling4.0 Industrial Hygiene5.0 Chemical Safety6.0 Documentation, Signs and Labels7.0 General Guidelines8.0 Regulatory Review9.0 Electrical Safety
Example 1, Notes and References
Example 2 – manual referencing
Management of Change Checklist Management of Change Checklist
Example 2 Outline
1. Electrical Safety Subpart S - Electrical- 1910.301
2. Mechanical Safety Subpart O-Machinery and Machine Guarding-1910.212
3. Fire Protection Subpart L- Fire Protection- 1910.1554. Industrial Hygiene
5. Process Safety6. Job safety Analysis7. Training8. Ergonomics9. Pre-startup preparation (sub checklist)10. Slip, Trip & Fall Hazards11. Environmental
Notice the punch list for notes – this is a working document
Example 2 - continued
Management of Change AuthorizationInitial Inspection Additional Inspection Final Review
Date: Building: Project Description:
Inspection Committee:1. Project Leader/Sponsor: Print Signature Date2. Area Manager/Equipment User: Print Signature Date3. QA Manager: Print Signature Date4. EH&S Manager or Safety Rep: Print Signature Date5. Vendor:
Print Signature DateComment:
Example 3 – Three Part Equipment Inspection/Assessment
Part 1 - Cover page identifies and references:Type of inspection/assessmentDetails of the work equipment or processParticipantsResults of inspection/assessmentDistribution List
Example 3, continued
• Part 2 – Instructions for the checklist
ScopeUse of the ChecklistQuantitative Risk Assessment
Example 3 - continued
Part 3 - The Checklist (section outline)1. Documentation2. Purpose of Work Equipment Use3. Minimum Requirements (Directive)4. Additional Requirements
Link to document
Example 3, continued• Fourth Piece developed in house to track
changes to completion – Header:
https://youtu.be/Us32wyFi5Hg
Machine Assessm
ent tracking spreadsh
eet
Exposure Probability Severity Risk Score Risk Measures
0.5 0.1 0.5 R < = 21 Assumed Acceptable Risk.
SITE NAME - YEAR 1 0.2 1 21 <R <=70 Possible Risk, requires attention.
2 0.5 2 70 <R <= 200Important risks, improvement is required.
KPI Machine Review3 1 7 200<R<= 400 High risk, immediate improvement.
6 3 15 R > 400 Very high risk, stop work.
10 6 40
10
Asset Tag Number Machine Description
initiated
Responsible owner
Date ready Status Exposure Probability Severity
Risk Score Remarks/proposed improvementsby when plan actual Mar-15 E P S
Ergonomics – Lifting, reaching…You can use the NIOSH Lifting Guide and/or train to specifics.
Choose wisely - Match your methodology to scope
• Large process change? Gather the troops and pre-plan.
• One mechanical machine move or, multiple machines of various risk factors?
• Qualitative vs. Quantitative
Mission/Goal/Objective
UNDERSTAND your organization’s scope - the mission, goal and objective.
Automate the process and manage expectations
Resources, Training & Communication
Do your homework, practice & plan ahead
Utilize cross functional teams to assess risks Train Managers, Supervisors and line employees to conduct risk assessments Broadly publicize all corrective actions
Some potentially helpful Links –• EC directive 89/655/EEC (use of work equipment)
http://eur-lex.europa.eu/legal-content/EN/TXT/?uri=CELEX:52004DC0062• https://osha.europa.eu/en/legislation/directives/3• 29 CFR 1910.132(d) – OSHA assessment requirement for PPE determination• http://www.sunycnse.com/libraries/contractor_documents/ehs-00016_r10_new_equip
ment_process_change_management_procedu.sflb.ashx Procedure example
• http://www.arenasolutions.com/resources/articles/manufacturing-change-process/ - Tips for change process that works
THANK YOU!Brian Well, CSP [email protected]