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TRANSCRIPT
WELCOME to
Human Performance Tool Training Presented by:
Paul Merritt Principal Engineer
EHS & Continuous Improvement
To Minimize the Frequency and Severity of Events
Events
Purpose of HuP
What Is Human Performance (HuP)
Birth In The Aviation Field Used At Nuclear Utilities For Several Years With
Significant Impact Institute of Nuclear Power Operators (INPO)
The Initiative Has Safety, Quality, & Equipment Impacts
All Westinghouse Fuel Sites Have Implemented
Human Performance
Quality of Execution
Ease of Doing Business
Lean Enterprise Six Sigma Human Performance
Behavioral Differentiation
HuP Core Module/ Precision Leadership
SMP Human Performance Plan
Precision Leadership
HuP Fundamentals
HuP Observations
SMP HuP Excellence
HuP Learning Lab
Event Investigations
Observations
HuP Tool R
oll-Out
Com
munications
Benchm
arking
Event Clocks
Adjust Grow Learn
Hazard R
ecognition
Slide No: 7
The Fundamentals Our SMP Process Owners
Lisa Fox Organization
Paul Merritt & Laurie Kubala Continuous Improvement
Brian Jones Coaching and tool use to prevent events
Brian Jones Enhancing the ability of our people
Jim Cook Operations Focus
Mike Morris Maintenance and outage planning
Jeff Cerny
Maintaining, improving, monitoring and evaluating equipment performance and condition
SMP Human Performance
The Journey Continues
Food for Thought…
Human Performance
….our industry is, and forever will be, one major accident away from being permanently shut down!
Jim Rhodes former CEO INPO
Principles of Human Performance Management Humans are fallible . . . Error is predictable. . . Organization influences behavior. Behaviors are reinforced. Events are avoidable.
Source: INPO, Excellence in Human Performance. 1997.
Event: any undesired occurrence that has an adverse effect on safety, quality, or production.
What is an Event?
Event
What is the difference between an Error and an Event?
To Minimize the Frequency and Severity of Events
Events
Purpose of HuP
New Paradigm
Re + Md → ØE
Limited short-term memory Personality conflicts Mental shortcuts (biases) Lack of alternative indications Inaccurate risk perception (Pollyanna) Unexpected equipment conditions Mindset (“tuned” to see) Hidden system response Complacency / Overconfidence Workarounds Assumptions (inaccurate mental picture) Confusing displays or controls Habit patterns Changes / Departures from routine Stress (limits attention) Distractions / Interruptions
Human Nature Work Environment Illness / Fatigue Lack of or unclear standards “Unsafe” attitude for critical task Unclear goals, roles, & responsibilities Indistinct problem-solving skills Interpretation requirements Lack of proficiency / Inexperience Irrecoverable acts Imprecise communication habits Repetitive actions, monotonous New technique not used before Simultaneous, multiple tasks Lack of knowledge (mental model) High Workload (memory requirements) Unfamiliarity w/ task / First time Time pressure (in a hurry)
Individual Capabilities Task Demands
Error Precursors short list
MANAGERIAL METHODS
TRAINING
WORK SCHEDULE WORK ORGANIZATION OR
SUPERVISORY METHODS
WRITTEN COMMUNICATIONS
CHANGE IMPLEMENTATION
VERBAL COMMUNICATIONS
DESIGN
WORK PRACTICES
ENVIRONMENTAL FACTORS
EVENTS
Defense -in-
Depth
Site Event Flags Vs. Area Learning Clocks
Site Event Flags Area Learning Clocks • Notification that an event has occurred at the site with significant consequences
• Trip Criteria is defined by site management
• Goal is Zero Events
• Forces Reactive Mode
• Notification that an event has occurred in an area with significant consequences, or low to no consequences
• Clock trips = learning opportunities that allow us to apply defenses to prevent recurrence. Some level of trips is desired.
• Proactive mode
• Reducing errors will drive toward elimination site events
Area Learning Clocks Implement area-specific criteria
Minimum criteria is expected (e.g., near-hit)
As a team, develop meaningful criteria specific to your area
Lower level than events Learn and adjust to lower severity
issues in order to avoid high level events.
INPO Toolbox- Individuals Seven tools selected -
SMP Peer Checking Procedure Use and
Adherence Pre & Post Job Briefs Personal Safety
Assessment (2 Min Rule) Questioning Attitude Self Checking (STAR) Time-Out
4PQST
Pre Job Brief
Pre-job Brief
Heightens awareness before a task Summarize critical steps Anticipate error traps- precursors Foresee consequences Evaluate defenses Review operating experience OFTEN CONSIDERED THE MOST
POWERFUL HuP TOOL!
…Pre Job Brief
What A planned interactive discussion that
occurs just prior to the task and involves ALL personnel related to the specific task
…Pre Job Brief
When When performers determine a PJB is
beneficial When required by procedure
…Pre Job Brief
How Have we done this job before ? What are the critical steps ? What mistakes might be made? What’s the worst thing that could
happen ? What kind of defenses should be
used?
…Pre Job Brief
…Pre Job Brief At Risk Practices
Failure to consider SCOPE Discussing generalities Failure to plan for PJB Failure to hold PJB in an area
conducive to holding proper meetings Failure to incorporate lessons learned
from previous Post Job Briefs Failure to identify contingency actions
or back out plan if the worst thing does happen
Failure to identify a lead for the job
Post Job Brief
Don’t perform only if something has gone wrong
Should be Quick but effective review Validates the process used for the job or task Opportunity to refine the process Opportunity for supervisor to reinforce
appropriate behaviors
Findings of the post job brief are detailed below;
What Went Well? What Went Wrong? What Should be Done Differently? • Equipment drawings and parts lists were immediately available. • No Injuries • Asset is currently operational. • On time in full delivery. • Craftspeople and engineers dedication to completing the project was outstanding. • Turnover from third shift was outstanding. • Mechanical job scope was increased because the upgrade was going so well.
• Pipefitter support was scarce. • Maintenance supervision needed to be more visible. • Craftspeople pulled randomly with no coordination with project team. • Area cleanup prior to job start and after job completion was not thorough. • A dedicated millwright crew could not be assigned due to other conflicting plant needs. • Air and electrical service to power tools was scarce and inconvenient. • The lack of an overall job lead led to a lack of communication and coordination. • Crafts thrown at job with no coordination between crafts or specific plan only an idea of what needed done. • Movement of parts being repaired and painted was not followed well.
• Establish and enforce a plan for pulling dedicated project workers.. • Coordinate work between crafts so crafts don’t get in each others way. • Identify outstanding problems and PM’s and complete everything at once and go in with awareness of all known problems. • Make sure outside vendor has a plan prior to startup to eliminate wasted time figuring out what they need to do.. • Establish a Project Lead for each repair. • Define the interface between Equipment Engineers and the Maintenance Department. • Create standard work practices. • Include dock in pre job brief in future to let them know the importance of receiving UPS red items expeditiously.
CPM 19 Electrical and Mechanical Upgrade
Save to O Drive!!!!!!
Human Performance / Post Job Brief
Questions To Ask In A Post Job Brief
Was the task accomplished with the expected results? Were the Procedures accurate? Is this the way the job
should be performed in the future? What errors occurred during the task / job? Was the Supervisor made aware of conditions that, if
uncorrected, could lead to human error the next time the task / job is performed?
Were there any lessons learned from this job that should be recorded, retained, or immediately passed on to others?
Where will we retain this information for future use?
SMP Human Performance Tools Pre- / Post-Job Briefs & Time Out - Review
Pre-Job Brief 1. Have we done this job before? 2. What are the critical steps? 3. What mistakes might be
made? 4. What is the worst thing that
could happen? 5. What defenses should be
used?
It is a thought process! These 5 questions should
always be asked!
Post-Job Brief Was the task accomplished
with expected results? Were the procedures
accurate? What errors occurred? Lessons learned?
Time Out Stop Get help Never proceed if uncertain
Time Out !!!!!!!!!!!
Time Out Tool
When the situation / task / environment is not safe or clear ----- TIME OUT
…Time Out
What A brief stoppage of the task
…Time Out
When Has a lot to do with Questioning
Attitude Warning Flags Something different than
expected
…Time Out
How STOP Inform Supervisor Never proceed if you are
uncertain
…Time Out
At Risk Practices Not asking for help Management not reinforcing properly
the behavior - You did good “BUT”
…Time Out – Wooden Spoon
Time Out……
Severity Pyramid
600
1
30 10 Significant
events
Major Accident
Nonconsequential Errors
Near Misses
Source: Frank Bird, Jr., Practical Loss Control Leadership, Det Norske Veritas (formerly International Loss Control Institute), 1969.
…HuP Strategic Approach
Re + Md → Ø Re + Md →ØE
Top 10 Error Traps 1. Stress 2. High Work Load 3. Time Pressure 4. Distractions 5. Vague or Poor Work Guidance 6. Poor Communications 7. Overconfidence 8. Infrequent or First Time Task 9. First Working Day After Time Off >4 Days 10. The End of a Shift or Week
…Personal Safety Assessment (two minute rule)
PSA
…Personal Safety Assessment (two minute rule)
What A personal safety assessment
involves deliberate, focused review for potential safety concerns prior to starting a job. Taking two minutes to make this assessment improves your chance of accomplishing the task without an event.
…Personal Safety Assessment (two minute rule)
When We need to include with EVERY task
Immediately following a Pre-Job Brief, just prior to starting work.
…Personal Safety Assessment (two minute rule)
How Look up and down and all around
Ask yourself: What are the hazards? How can I get hurt? What is different?
Take action to understand / mitigate any hazards
Call a Time Out if appropriate
…Personal Safety Assessment (two minute rule)
At Risk Practices
Making assumptions Not asking for help Ignoring warning flags (error precursors)
Personal Safety Assessment
Self-Check STAR (Stop, Think, Act, Review)
STAR
S
T A R
• STAR is an effective Error Prevention Tool that helps us briefly “refocus” on the task when we are doing routine activities
• We don’t need to STAR everything we do
What is it?
When do I use Self Check?
• When performing critical steps where an error could cause bad things to happen. (Refer to page 27 of the HuP Handbook for discussion of Critical Step)
• When performing tasks where inattention or complacency can allow the performer to make an error that can result in an event
• If interruptions occur while performing a task
STAR
STAR
STAR
S top
T A R
STOP! Pause and clear your mind of distractions. Slow your mind down so you can stay focused on the task you are about to perform.
STAR
S top T hink A R
THINK: • Focus your attention on the step to be performed.
• Verify your intended action is appropriate for the equipment/system status. Point to or touch the equipment, system, or component. VERBALIZE!
• Anticipate the expected result of your intended action and how you will know the desired outcome is achieved.
• Consider what actions you will take should an unexpected result occur (contingency plan).
• If uncertain, use a Questioning Attitude and / or Time Out before proceeding with the task.
STAR
S top T hink A ct
R
ACT: • Without losing eye contact, touch the component, label, etc., with checklist , procedure step or drawing.
• Without losing physical contact established earlier, perform the action.
S top T hink A ct
R eview
REVIEW: • Verify you get the intended results.
• If not, exercise contingency actions.
STAR
Avoid these at-risk practices
• Continuing with the action when questions or discrepancies occur
• Failing to eliminate distractions, such as continuing to talk on the telephone or converse with another person during a manipulation or critical action
• Trying to perform more than one action at a time
• Not calling a Time Out when it is needed
STAR
Where Have you used STAR????
…Self-Checking (STAR)
…Questioning Attitude
…Questioning Attitude
…Questioning Attitude
…Questioning Attitude
What A questioning attitude creates awareness of uncertainty, hazards and significance of action before proceeding. (RISK)
…Questioning Attitude
When When conditions change When procedures cannot be followed as written ALL OF THE TIME
…Questioning Attitude
How Consider What Ifs Be open and receptive If question not resolved call time out
…Questioning Attitude
At Risk Practices Making assumptions Thinking the task is routine Believe nothing bad can happen
Questioning Attitude….???
…Peer Checking
…Peer Checking
What Peer Checking is an error prevention
tool involving a verbal agreement between two individuals PRIOR TO a specific action or task to prevent an error.
…Peer Checking
When When required by procedure When there is a history or unfavorable
operating experience When you’re not sure
…Peer Checking
How Peer Check is = TWO STARS
…Peer Checking
At Risk Practices One person being led by another
without separation of thought Too Proud Too Shy Too Sure
…Procedure Use and Adherence
…Procedure Use and Adherence Dupont Video
…Procedure Use and Adherence
What Following the intent and direction
provided in the procedures
…Procedure Use and Adherence
When Procedures must be used for all
physical work and activities that involve manipulation, monitoring or analysis of plant equipment and processes.
How Review procedures frequently to stay
familiar with the details If desired results are not achieved,
STOP – and contact your supervisor
…Procedure Use and Adherence
At Risk Practices Not rigorously following procedures Using an out of date procedure Performing task without considering
critical steps
…Procedure Use and Adherence
The Power Of One!!