Hazard Analysis Process - AIHA Home

Hazard Analysis Process

Management Systems Presented by:

Paul Esposito, CIH, CSPSTAR Consultants. IncStarconsultants.net

Presented to:

AIHCEMay 2004

Paul Esposito, CIH CSPPaul Esposito, CIH CSP STAR Consultants, Inc.STAR Consultants, Inc.

What are Management Systems?What are Management Systems?

How does Webster define a system?

ProcessProcess“A series of actions, changes, or functions that “A series of actions, changes, or functions that

bring about an end or result. To put through bring about an end or result. To put through the steps of a prescribed procedure.”the steps of a prescribed procedure.”

SystemSystem“A group of interacting, interrelated or “A group of interacting, interrelated or

interdependent elements forming or regarded interdependent elements forming or regarded as forming a collective entity.”as forming a collective entity.”

NOT A “PROGRAM”NOT A “PROGRAM”


Change the Way We Do BusinessChange the Way We Do Business

You've carefully thought out all the angles. You've carefully thought out all the angles.

You've done it a thousand times.You've done it a thousand times.

It comes naturally to you.It comes naturally to you.

You know what you're doing, its what you've You know what you're doing, its what you've been trained to do your whole life.been trained to do your whole life.

Nothing could possibly go wrong, right ?Nothing could possibly go wrong, right ?


Think AgainThink Again


Goal???Goal???

Prevention vs. ReactivePrevention vs. ReactiveReduce RiskReduce RiskAgree on Safe Work ProceduresAgree on Safe Work ProceduresEnsure Workers Understand Safety Work Ensure Workers Understand Safety Work ProceduresProceduresEnsure Supervisor Enforce Safe Work Ensure Supervisor Enforce Safe Work Procedures Procedures


Hazard AnalysisHazard AnalysisVPPVPP

Criteria: Criteria: Analyze planned and new facilities, Analyze planned and new facilities, processes, materials, and equipment; and perform processes, materials, and equipment; and perform routine hazard analysis of jobs, processes, and/or routine hazard analysis of jobs, processes, and/or varied phases of work as needed.varied phases of work as needed.

OHSMSOHSMSCriteria:Criteria: Identification, risk assessment and risk Identification, risk assessment and risk control processes should be suitable and sufficient control processes should be suitable and sufficient and and should should allow the organization to identify, allow the organization to identify, evaluate and control its OH&S risks on an evaluate and control its OH&S risks on an ongoing basis.ongoing basis.


HAZARD ANALYSIS PROCESS

Hazard Analysis Process

Hazard Analysis ProcessGoals & ObjectivesGoals & Objectives

Perform Hazard Analysis

Perform Hazard Analysis

Process AssessmentProcess Assessment

Follow-upFollow-up

Review Job Task Review Job Task

Corrective ActionsCorrective Actions

Identify “Priority” Schedule for Hazard

Analysis

Identify “Priority” Schedule for Hazard

Analysis

Training and Communication Training and

Communication

“High” Hazard Tasks“High” Hazard Tasks

Record-keepingRecord-keeping

Training Training Establish Hazard Analysis Team

Establish Hazard Analysis Team

Injury/Illness History

Injury/Illness History

1 Define Steps 1 Define Steps

Safe Working Procedures

Safe Working Procedures

Interview Interview 2. Identify Hazards rds 2. Identify Haza

Standard Operating Procedures

Standard Operating Procedures

Job QualificationsJob Qualifications


Problem #1 Problem #1 Which Hazard Analysis Tool?Which Hazard Analysis Tool?

Job Safety (Hazard) AnalysisJob Safety (Hazard) AnalysisFailure Modes and Effects Analysis (FMEA)Failure Modes and Effects Analysis (FMEA)HazHaz--OPOPEtc???Etc???


Analysis Includes???Analysis Includes???

Ergonomic AnalysisErgonomic AnalysisIndustrial Hygiene Qualitative and Industrial Hygiene Qualitative and Quantitative AnalysisQuantitative AnalysisLean ManufacturingLean Manufacturing


Priority SchedulePriority Schedule

Jobs which have a past history of Jobs which have a past history of accidents/injuries/illnessaccidents/injuries/illnessJobs with less frequent accidents, but potential Jobs with less frequent accidents, but potential for serious injury/illnessfor serious injury/illnessNew Jobs or New Equipment or Machinery New Jobs or New Equipment or Machinery installed installed New, nonNew, non--routine, or changed jobs routine, or changed jobs Jobs which have high turnoverJobs which have high turnoverJobs with some potential for accidentsJobs with some potential for accidentsJudgment and experienceJudgment and experienceRoutine JobsRoutine Jobs


Performing Hazard AnalysisPerforming Hazard Analysis

Design a DatabaseDesign a DatabasePickPick--list Hazard Categories (24 from OSHA list Hazard Categories (24 from OSHA Publication 3071)Publication 3071)ID Critical to Safety and HealthID Critical to Safety and HealthStandardize Control OptionsStandardize Control Options


Design a DatabaseDesign a DatabaseMicrosoft AccessMicrosoft AccessInternal NetworkInternal NetworkPicture AcceptablePicture AcceptableEverything a Pick ListEverything a Pick List


PickPick--list Hazard Categorieslist Hazard Categories1. Toxic Chemicals1. Toxic Chemicals2. Flammable Chemicals2. Flammable Chemicals3. Corrosive Chemicals 3. Corrosive Chemicals 4. Environmental4. Environmental5. Explosion (chemical 5. Explosion (chemical reaction)reaction)6. Explosion (over 6. Explosion (over pressurization)pressurization)7. Mechanical/Vibration7. Mechanical/Vibration8. Electrical (shock, short 8. Electrical (shock, short circuit)circuit)9. Electrical (Fire)9. Electrical (Fire)10. Electrical (Static, ESD)10. Electrical (Static, ESD)11. Electrical (Loss of power)11. Electrical (Loss of power)12. Ergonomic (over exertion)12. Ergonomic (over exertion)

13. Ergonomic (human error)13. Ergonomic (human error)14. Vibration14. Vibration15. Fall (slip, trip)15. Fall (slip, trip)16. Fall ( to a different level)16. Fall ( to a different level)17. Excavation (collapse)17. Excavation (collapse)18. Fire, Heat, Thermal, Cold18. Fire, Heat, Thermal, Cold19. Noise19. Noise20. Radiation (Ionizing and 20. Radiation (Ionizing and nonnon--ionizing)ionizing)21. Visibility21. Visibility22. Weather22. Weather23. Caught (in/on/between)23. Caught (in/on/between)24. Struck (by/against)24. Struck (by/against)


ID Critical to Safety and HealthID Critical to Safety and HealthFigure 1. Risk Matrix, Critical to SafetyFigure 1. Risk Matrix, Critical to Safety

FrequencyFrequencyX hrX hr X dayX day LessLess

SeveritySeverity

Death or permanent Death or permanent 66 55 44DisabilityDisability

Temporary disability or Temporary disability or 55 44 33OSHA recordable with lost timeOSHA recordable with lost time

First aid or OSHA recordable First aid or OSHA recordable 44 33 22with no lost timewith no lost time

Code 5Code 5--66 = Severe Risk = CTS = Severe Risk = CTS -- lost time, permanent disability or deathlost time, permanent disability or death-- all all CTS tasks should receive engineering controls prior to assigningCTS tasks should receive engineering controls prior to assigningadministrative or PPE type controls.administrative or PPE type controls.Code 4Code 4 = Moderate Risk = Moderate Risk -- medical recordable, light work, or restricted duty medical recordable, light work, or restricted duty -- engineering controls are preferable, however, PPE or administraengineering controls are preferable, however, PPE or administrative tive controls are typically acceptable.controls are typically acceptable.Code 2Code 2--33 = Lesser Risk = Lesser Risk -- no injury or first aid no injury or first aid -- PPE or administrative PPE or administrative controls are likely to be adequate.controls are likely to be adequate.


Standardize Control OptionsStandardize Control OptionsRecommend Safe Work Practices on JHARecommend Safe Work Practices on JHA

Eliminate the hazardEliminate the hazardSubstitute a less hazardous materialSubstitute a less hazardous materialEngineeringEngineeringMachine guardingMachine guarding

TrainingTrainingHousekeepingHousekeepingErgonomics Ergonomics -- rotation from repetitive tasksrotation from repetitive tasksAdministrative controlsAdministrative controlsPPE

Only these if CTS

If CTS, Approval Required

PPE


Integrate Into Work ProceduresIntegrate Into Work ProceduresExisting Work Instructions for Existing Work Instructions for Manufacturing on ISO Controlled Manufacturing on ISO Controlled documentdocumentHyperlink JSAHyperlink JSAInsert all CTSInsert all CTSFuture? Future?

Color Code Safety, like Critical to QualityColor Code Safety, like Critical to QualityPictures and VideosPictures and Videos


Words or Phrases to Avoid…Words or Phrases to Avoid…ProperProperNecessaryNecessaryNonNon--specific Personal Protective Equipmentspecific Personal Protective EquipmentEnsureEnsureDo notDo notAvoidAvoidCautionCautionBe carefulBe carefulEtc.Etc.


Training and CommunicationTraining and Communication

Worker and Supervisor SignWorker and Supervisor Sign--offoffNonNon--routine: Pre and Post Job Briefingsroutine: Pre and Post Job BriefingsMetricsMetrics

# completed# completed# changed/updated # changed/updated vsvs # of changes# of changes

Safety Committee Observations Safety Committee Observations –– and and Quiz Scores for Recognition Awards Quiz Scores for Recognition Awards


Change ManagementChange ManagementSite Supervisor required to notify Hazard Site Supervisor required to notify Hazard Analysis Committee when changes are Analysis Committee when changes are happeninghappeningLean Team integrated with HA Members to Lean Team integrated with HA Members to include IH and Ergo Signoffsinclude IH and Ergo SignoffsISO Site, so Hazard Analysis Committee receives ISO Site, so Hazard Analysis Committee receives printout of all changes, comparing them to # of printout of all changes, comparing them to # of revisionsrevisionsAudit 5% of new changesAudit 5% of new changes


Future OpportunitiesFuture Opportunities

Trend Analysis and Corrective Action PlansTrend Analysis and Corrective Action Plans

For example, if a Department has 10 For example, if a Department has 10 JHAsJHAs that that cover all of their tasks, can we analyze the list of cover all of their tasks, can we analyze the list of hazards? hazards?

0102030405060708090

Caught In Overexertion Struck By

Total

CTS


Hazard Analysis Audit ProcessHazard Analysis Audit ProcessDocumentationDocumentation

Hazard Analysis Training Course Content?Hazard Analysis Training Course Content?Job Hazard Analysis documents are available for each job Job Hazard Analysis documents are available for each job function.function.Are there training records of areaAre there training records of area--specific discussions?specific discussions?MetricsMetrics

InterviewsInterviews..Can employees explain the hazards associated with their work Can employees explain the hazards associated with their work station and how to avoid illness and injuries?station and how to avoid illness and injuries?Can employees explain the safety review process when a new Can employees explain the safety review process when a new chemical is introduced into the workplace? chemical is introduced into the workplace? Are employees receiving regular training/awareness Are employees receiving regular training/awareness communication that new facilities, equipment, materials, or communication that new facilities, equipment, materials, or processes are hazardous?processes are hazardous?

Visual ObservationsVisual Observations..Are hazard analysis worksheets affixed to machinery?Are hazard analysis worksheets affixed to machinery?Are high hazard areas well marked and proper barriers in place?Are high hazard areas well marked and proper barriers in place?


ReferencesReferencesOSHA Program Management GuidelinesOSHA Program Management Guidelines

http://www.http://www.oshaosha..govgov//plspls//oshaweboshaweb//owadispowadisp.show_document?p_t.show_document?p_table=FEDERAL_REGISTER&p_id=12909able=FEDERAL_REGISTER&p_id=12909

OSHA Publication 3071: Job Hazard AnalysisOSHA Publication 3071: Job Hazard Analysishttp://www.http://www.oshaosha..govgov//plspls/publications//publications/pubindexpubindex.list.list

OSHA (PEP) Program Evaluation ProfileOSHA (PEP) Program Evaluation Profilehttp://www.http://www.oshaosha--slcslc..govgov/SLTC//SLTC/safetyhealthsafetyhealth/pep.html/pep.html

Managing Worker Safety and HealthManaging Worker Safety and Healthhttp://www.dolir.mo.gov/ls/oshaconsultation/ccp/http://www.dolir.mo.gov/ls/oshaconsultation/ccp/

Presentation Available at Presentation Available at StarconsultantsStarconsultants.net What’s New Conferences.net What’s New Conferences

http://www.dolir.mo.gov/ls/oshaconsultation/ccp/

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