133234735 Chapter6 Hazard Identification Risk Assesment and Risk Control Hirarc

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

3

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

4

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. _____________________________________________________________________


Hazards


1. _____________________________________________________________________

2. _____________________________________________________________________

3. _____________________________________________________________________


Hazards


1. _____________________________________________________________________

2. _____________________________________________________________________

3. _____________________________________________________________________

Safe Job Procedure

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________


Job Description: ____________________________________________________________


Hazards


1. _____________________________________________________________________

2. _____________________________________________________________________

3. _____________________________________________________________________


Hazards


1. _____________________________________________________________________

2. _____________________________________________________________________

3. _____________________________________________________________________


Hazards


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

http://elearn.kuktem.edu.my/study/uploads/Safety_Inspection_Checklist.doc

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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.


Job Description: ____________________________________________________________


Hazards


1. _____________________________________________________________________

2. _____________________________________________________________________

3. _____________________________________________________________________


Hazards


1. _____________________________________________________________________

2. _____________________________________________________________________

3. _____________________________________________________________________


Hazards


1. _____________________________________________________________________

2. _____________________________________________________________________

3. _____________________________________________________________________

Safe Job Procedure

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________


Job Description: ____________________________________________________________


Hazards


1. _____________________________________________________________________

2. _____________________________________________________________________

3. _____________________________________________________________________


Hazards


1. _____________________________________________________________________

2. _____________________________________________________________________

3. _____________________________________________________________________


Hazards


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

Documents

133234735 Chapter6 Hazard Identification Risk Assesment and Risk Control Hirarc