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Lean Construction Institute
Prevention through Design (PtD)
By Michael Mills, Kevin Coen, Dan Lavoie, Gary Cunningham Liberty Mutual Insurance
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Objec&ves ReviewthebenefitsofPreven1onthroughDesign(PtD)
DiscusshowPtDandLeancomplimenteachother.
BecomefamiliarwithhowtoestablishaPtDProcess
Iden1fyandmanagepoten1alrisksofcollabora1vePtDprocesses
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What is Preven&on through Design?
It’saPROCESS
Addressessafetyandhealthneeds
Duringthedesignstage
An1cipatesandpreventsorminimizeshazardsandrisks
Bydesigningouttherisk!
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Benefits of Preven&on through Design
CostSavings• DesignOutRisk• ReduceInjuryCosts
EmployeeAcceptance• InvolvedinProcess• Collabora1ononSolu1ons
ImprovedEfficiencies• EliminateInefficientProcesses• ReduceComponents
PtD = ROI
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Similar to Lean
Focusesonelimina1ngWastewhichleadstoRisk.
Collaborateprocessthatinvolvesfrontlineworkers.
EngageseveryoneinthebuildingprocessfromArchitectstoContractors.
Demonstrateaddi1onalvaluetoOwnersofcollabora1onwithContractors.
CaneliminaterisktoOwner’semployeesaswellasContractoremployees.
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An Overview of the Process
Plan• DevelopaPtDProjectPlan
Assess• ConductRiskAssessment
Design• DevelopDesignExpecta1onsforRiskReduc1on(DERR)
Review• ConductDesignReview
Verify• MonitorConstruc1on/Installa1on/ProcessChangeandVerify
Learn• ReviewProjectandDocumentLessonsLearned
EliminateInjuries
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PLAN
DevelopPtDProjectPlan
• EstablishscopeofthePtDPlan• Iden1fykeystakeholdersanddefineresponsibili1es
• EstablishaDesignReviewTeam• Determineexper1seneededfrominternalandexternalsources
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Plan and Track
Sample Tracking Sheet to Monitor PtD Project Progress
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Design Review Team
• Management:bothuppermanagementandlinesupervision• Employees• Architects,designers,andengineers• Safetyandhealthprofessionals• Contractors• Suppliersofequipment,machineryortools• Othersasneeded,suchasIndustrialHygienist,Purchasing,orLegalCounsel
• InsuranceBroker
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ASSESS
ConductRiskAssessment
• SelectRiskAssessmentmethod• ConductRiskAssessmentofplannedprocessoropera1ons
• Priori1zerisks
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Insurance Broker
• CommercialGeneralLiability:GeneralContractor(GC)• Trigger:BodilyInjury(BI)/PropertyDamage(PD)arisingfromanoccurrence
• CG2243–fullprofessionalliabilityexclusion• CG2279–excludesprofessionalservices(exceptmeansandmethods)
• CG2280–offerslimiteddesignrelatederrors
• Professional:Designer/Engineering• Trigger:Negligence/StandardofCare,doesn’tneedoccurrence• Doesnotcoverconstruc1onmeansandmethods(temporaryjobsitestructures)
• “OtherInsurance”clause
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Risk Assessment Process
Sample Process from ANSI/ASSE Z590.3 – 2011
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Risk Assessment
• AssessExis1ngandFutureBuildings,StructuresorProcesses• Choosetheriskassessmenttool.• Meetwithkeystakeholderstoiden1fytasksandhazards.• Determineiftraininginhowtoperformariskassessmentisneeded.
• Reviewplanstoiden1fytasksandhazards.• Brainstormtoan1cipatesourcesofhighestrisk.• Setpriori1esforriskstotargetforreduc1on.
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Iden&fying Tasks and Corresponding Hazards
• Useasystemsapproach• Examine:
• Plansandspecifica1ons• Workexpecta1onsandwaste• Commonbehaviorsandwaste• Similarbuildingsoropera1ons(includinglosshistory,riskassessmentsandjobhazardanalyses)
• Maintenanceproceduresandwaste• Relevantcodes,standardsandregula1ons
• Interviewcurrentorintendedusers
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Brainstorm Future Hazards
• Buildinganewplant,tankswillbeinstalledtofeedtheproduc1onprocess.
Task:1. Workersneedtoclimbto
thetopofthetanktomeasurefluidinsidefromthetop.
Risks:• FallsfromHeightswhileclimbingandworking/takingreadingsontopoftank.
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Assessing the Risks
• Questions to consider • What aspect of the technology or activity produces waste
and risk? • What action or inaction causes risk? • Where are the potential sources of high severity injuries?
• High/low pressure or temperature, work at elevation, unplanned energy release, hazardous material release, etc.
• Any standard controls for common risks without performing detailed Risk Assessment (e.g. parapet or guardrail at roof perimeter)?
From ANSI/ASSE Z590.3 – 2011 PtD Guidelines for Addressing Occupational Hazards and Risks in Design and Redesign.
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DevelopNewControls
No
DesignFallArrestSystem
andAnchorPoints
Yes
Eliminatethehazardbychangingaprocess
Cantheneedforworkersto
accessthetanktopbeeliminated?
Canthefallhazardbeeliminatedthruworkprocess
change?
Canweengineerorguardagainstthehazard?
Designawaytomeasurelevelsfromtheground.
Changethedesignofthetanktops.ElevaDonRiskiseliminated.
No
No
Designguardrailsfor
thetanktop
Yes
Yes
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Redesign to Eliminate Risk
• Redesignoftanks/processtointegratemeasurementsystemswithgaugesatgroundlevelsothatworkerscantakemeasurementswithoutneedtoaccesstopoftanks.• Process/equipmentchangeeliminatestheneedforthepartofthetaskthathasrisk.
• Climbingandtopoftankmeasurementnolongerdonesinceworkersdon’tneedtobeateleva1ontoperformtask.
Workersmustperiodicallyclimbto
accesstopoftankstotakemeasurementsfromtopof
tanks.Collaborate with the customer to work on both risk and waste!
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DESIGN
DevelopDesignExpecta1onsforRiskReduc1on(DERR)
• UsetheHierarchyofControlstoselectthemosteffectriskreduc1onstrategies.
• DevelopDesignExpecta1onstoaddresspriori1esfromtheRiskAssessment.
• ProvidetoArchitects/Designersforinclusioninprojectdesignplanning.
• CommunicateguidanceonPtDprocessexpecta1ons.
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DERR – What Can Be Done to Reduce Risk
• Createsaguidefordesigners,architects,engineers:
• Whatyouwanttosee(ornotsee)incurrentandfuturedesignstoreducerisk.
• Considerthelifecycleofwhatisbeingdesigned:
• Construc1on,use,maintenanceanddisposal.
• UsetheHierarchyofControlstoselectmosteffec1vesolu1ons.
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Example DERR’s
• Designcomponentsthatcanbepre-fabricatedoff-siteoronthegroundtoavoidassemblingorerec1ngatheightsandtoreduceworkerexposuretofallsfromheights.1
DesigntoReduceRiskDuringConstruc1on
• Walkwaysurfacesshallbeslipresistantunderexpectedenvironmentalcondi1onsanduse.2• Designchemicalprocessestobeconductedinclosedsystems,wherefeasible.3
DesigntoReduceRiskforAllUsers
• Wherefeasible,systemsshallbedesignedtoavoidconfinedspaceentry.3• Designthestructuresothatmaintenancecanbeperformedatgroundlevelorsafelyfromthestructure,forexample,posi1oningair-condi1oningunitsandlijplantatgroundlevel.1
DesigntoReduceRiskforMaintenance
1 Safe Design of Structures: Code of Practice July 2012 Safe Work Australia 2 ASTM: F1637 − 13 - Standard Practice for Safe Walking Surfaces 3 ANSI/ASSE Z590.3 – 2011 - Prevention through Design Guidelines
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REVIEW
ConductDesignReview
• ReviewDrawings/Plans/ProcessDesignsforimprovementopportuni1es.
• VerifyplanadherencetoDERR.• Communicatevariances.• Developalterna1vecontrolplanswithvendors.
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Roof Fall Risk Elimination
• A design review revealed no guardrails or safe access to the roof.
• No guardrail designed around the Green Roof.
• Workers access the roof through a window to perform maintenance.
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Prevention through Design
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VERIFY
MonitorConstruc1on/Installa1onProcessChangeandVerify
• MonitorandverifyImplementa1onofexpecta1ons.
• Addressneedsthatariseforchange.• Ensureeffec1vecommunica1onwithvendors.
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Monitor Construc&on • Drain Pipe location was
identified as a risk factor during the Design Review and location was redesigned to eliminate the trip/fall hazard.
• Design changes were not communicated.
• During the monitoring of construction the issue was found and corrected.
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LEARN
ReviewProjectandDocumentLessonsLearned
• ReviewtheoverallPtDprocessforimprovements.
• UpdatetheDERR’sforuseonFutureProjects.
• DiscussLessonsLearnedandwhatcanbedonetoeliminateorreducemissedopportuni1esonfutureprojects.
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Lessons Learned • LessonLearned-postconstruc1onchangescanbecostly.
• DesignReviewTeamlearnedthevaultcoverswereslipperyatonefinishedentrance.
• Matsplacedonthemtocutdownonslipfallexposureblockedrequiredven1ng.
• Workingwiththeu1lityandDesignReviewTeam,thesizeofthecoverswasreduced,thevaultrelocatedandthemetalcoverstreatedwithaslipresistantmaterial.
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Renova&on
• YoumayhaveasmallerDesignReviewTeam.• Encourageemployeesimpactedbytherenova1ontopar1cipate.• Takeadvantageoftheknowledgeandexperienceoffrontlineworkers.
• Takethislessonslearnedfromcurrentsitestoyourrenova1ons.• Usetheopportunitytocorrectissuesthatproducerisk.
Servicing lighting can be costly and high risk.
Design to reduce risk during maintenance.
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Evaluate All Risk
• Have your Design Review Team look at all aspects of the design both contractor and owner employee exposures.
• It could save lives, dollars and prevent a liability incident.
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Roadmap to Risk Reduc&on
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Summary
• PtDcanprovideROIwithcostsavings,improvedefficiencyandreducedinjures.
• Startearlyinthedesignphaseforbestresults.• Focusonthehighestrisks.• UsetheHierarchyofControlsformosteffec1vesolu1ons.• Defineandcommunicateexpecta1onsfordesignsthatwillreducerisk.
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Ques&ons and Comments