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DRH, 05/09/03, Slide 1
Methodology for applying HF analysis
or
A Human Factors Toolkit
Debby Hallett, Ciba Specialty Chemicals
DRH, 05/09/03, Slide 2
Introduction…• Purpose of presentation:
– Share experiences of developing and using the “Human Factors Toolkit”
• Contents:– Ciba Specialty Chemicals & it’s requirements– Overview of methodology– Examples of applying the method– Problems encountered (& overcome)
DRH, 05/09/03, Slide 3
Ciba Specialty Chemicals & it’s requirements
DRH, 05/09/03, Slide 4
Ciba Specialty Chemicals…• Globally:
– 20,000 employees– 64 production sites– 25 countries
• Bradford, UK site:– 1,200 employees– Top tier COMAH site
• Human Factors at Ciba Specialty Chemicals:– Wide range of projects involve HF– 3 year history of specific HF work
DRH, 05/09/03, Slide 5
Ciba Human Factors “History”…• 2000: submitted COMAH Safety Report
– Considered Technical control measures– Improvement plan on Human Factors agreed
• 2000 – 2001: Various individual assessments on lone working, manloading and Human Factors DNV
• 2001: Developed HF assessment technique: Ciba/DNV• 2002: Pilot assessment – Grimsby site Ciba/DNV• 2002: Assessment – Bead, Bradford site Ciba/DNV• 2003: Assessment – Maintenance Ciba• 2003: Assessment – R2000 Control room Ciba/DNV• 2003: Assessment – Project Diamond Ciba
DRH, 05/09/03, Slide 6
Ciba’s objectives:• COMAH (Seveso) compliance…demonstration of:
– Evaluation of potential human error– Effectiveness of human interventions required to maintain
control
• Establish awareness of human factors:– Line Management– Engineering design
• Technology transfer:– Develop internal HF assessment methodology– Apply to all types of activities on site– Suitable for use by non-HF professionals– Complement other risk assessment techniques
DRH, 05/09/03, Slide 7
Overview of Methodology
DRH, 05/09/03, Slide 8
Incorporate relevant results into Safety Report
Major Accident Hazard scenarios identified from
COMAH Safety Report
Task inventory & criticality assessment
Observational data
Identify critical tasks
Error analysisTask analysis (HTA & concurrent)
Qualitatively assess critical tasks and potential errors
Staffing assessment
Alarm & Procedure checklists
Evaluate the safeguards
Identify risk control strategies
Before Assessment
Assessment
After Assessment
Human Factors Method to Support COMAH
DRH, 05/09/03, Slide 9
Examples of applying the method
DRH, 05/09/03, Slide 10
1) Maintenance activities• Manual task:
– Breaking and making gasketted joints
• Toolkit worked well:– Easy to identify task steps, errors & consequences– Easy to generate recommendations
• Example - handover incomplete job to next shift– Error: fail to communicate task status– Consequence:
• Gaskets missing/untightened - leak of hazardous substance– Recommendations:
• Maintenance operatives handover job personally• Use job sheet to record status
DRH, 05/09/03, Slide 11
2) Automated continuous plant• General control room duties difficult to assess
• Selected a manual task, and looked at links to control room activities
– e.g., communications, data entry & decision making
• Example – taking sample of reactor contents– Error: fail to circulation valve on sample cooler– Consequence:
• Unrepresentative sample taken - status of reactor unknown• Potential runaway reaction
– Recommendations:• Ensure all operators understand importance of sampling• Improve labelling of valves• Investigate linking valves to sample point
DRH, 05/09/03, Slide 12
3) Design phase of new plant• Multi-disciplinary team established during design phase• Applied methodology to proposed design:
– Identified how plant will operate– Identified design problems before too late– Identified manning levels– Most importantly…ensured employee involvement
• Example – connect road tanker to off-load point– Error: driver connects to wrong point– Consequence:
• Incompatible substance into storage tank - exothermic reaction– Recommendations:
• Tanker drivers not allowed on site unaccompanied• 2 x paperwork checks• Off-load points locked
DRH, 05/09/03, Slide 13
Problems encountered (& overcome)
DRH, 05/09/03, Slide 14
Key learning points…• Consultants requirements Ciba’s:
– Unused data removed from process– Role of Task Inventory?– Training modified: less academic, more pragmatic
• Select the right assessment team:– Key people = experienced operators– Manager/supervisor also required (reality check)– Must be available for whole assessment
• Time intensive process:– Moved some steps outside assessment timetable– Ensure assessment scope is realistic– Facilitator observe task(s) before assessment– Smarter recording (reduce time to ‘write-up’)
DRH, 05/09/03, Slide 15
Key learning points (cont)…• Costs involved:
– Move to Ciba Specialty Chemicals led assessments– DNV provide support as required
• Staffing assessment:– Diagrams told us what we suspected – not specific enough– Concurrent task analysis = more useful
DRH, 05/09/03, Slide 16
Conclusions…1) Methodology meets Ciba’s requirements:• COMAH Compliance:
– “Reality check” on current practice– Identifies deficiencies/opportunities
• Raised HF awareness within Ciba Specialty Chemicals• Technology Transfer:
– Simple method (but time consuming)– Suitable for wide variety of activities– Compliments other RA techniques
2) Most important parts of process:– Team selection– Setting scope– Concurrent task analysis– Smart recording
DRH, 05/09/03, Slide 17
• Continue assessment programme:– Incorporate into design process– Roll-out to remaining production areas
• Development of best practice document– Continue Technology Transfer to other Ciba Specialty
Chemicals EHS professionals
• Link to other business initiatives e.g. quality
Way forward…