MSA Analysis (URUT-1 Operations) Jan - Jul 2014

8/10/2019 MSA Analysis (URUT-1 Operations) Jan - Jul 2014

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MSA ANALYSIS OF URUT-1 (Jan Jul 2014) ) Page 0

URUT-1 REP

OPERATIONS DEPARTM


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URUT-1 REP

OPERATIONS DEPARTM

CATEGORY:

Incident Report

Audit Report

Proposal

Information Feed Back

Others

AUTHOR: ZAN

ISSUED TO: URUTOPS

COPIES: MAM / MSD / UM PROD all / MIA / RSM / AHB / QJ / MIK / SASh

SUBJECT: MSA ANALYSIS FOR URUT-1 (JanJul 2014)

1. EXECUTIVE SUMMARY:

MSA analysis can be used to achieve much more than just keeping focus on compliance and LI

scores of the unit. Urut-1 MSA Analysis report new format will prove to be highly beneficial in

achieving below mentioned objectives.

1.

Focus on action completion (Serious Injury / Fatality Potential Observations).

2. Analyze observations in MSA done by other departments at URUT-1.

3. Segregate and highlight PMS related observationsby URUT-1 SICs.

4. Avoid re-work for Productions LI coordinators to compile data from MIS.

5. Focus on Audit compliance / quality.

This report contains MSA Analysis for URUT-1 from Jan to Jul 2014.


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URUT-1 REP

OPERATIONS DEPARTM

CONTENTS:

1.

EXECUTIVE SUMMARY 01

2.

MSASTATISTICS 03

3.

SERIOUS INJURY /FATALITY POTENTIAL OBSERVATIONS 04

4.

PMSRELATED OBSERVATION 05

5.

IN-PROGRESS PENDING ACTIONS 06


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URUT-1 REP

OPERATIONS DEPARTM

2. MSA STATISTICS:

URUT-1 MSA compliance for operation team from Jan to Jul 2014 remained 1.1%. Total 143 audits

were conducted against a plan of 157 audits. Maximum 2 audits per person are considered in cases

where more than 2 audits were conducted by a person.

Details of individual compliance figures are given below. Production LI coordinator is requested to

go through the figures and discuss to match the MSA compliance figures as individuals have

changed units as well as have been on long leaves due which planned figures have changed.

Planned

Con

ducted

Planned

Con

ducted

Planned

Con

ducted

Planned

Con

ducted

Planned

Con

ducted

Planned

Con

ducted

Planned

Con

ducted

Planned

Con

ducted

Com

pliance

INITIALS 20 19 22 22 21 20 24 21 24 19 24 21 22 21 157 143 91

Akm 2 2 2 2 2 2 2 2 2 2 2 2 2 2 14 14 100

Alf 2 2 2 2 2 2 2 2 2 2 2 2 2 2 14 14 100

AMJ 2 2 2 2 2 2 2 2 2 2 2 2 2 2 14 14 100

ARC 2 2 2 2 2 2 2 2 2 0 2 2 2 2 14 12 86

MAKm 2 2 2 2 2 2 2 2 2 2 2 2 2 2 14 14 100

MFL 0 0 2 2 2 2 2 2 2 2 2 2 2 2 12 12 100

TAM 2 2 2 2 2 2 2 2 2 2 2 2 2 2 14 14 100

TAQ 2 2 2 2 2 2 2 2 2 2 2 2 2 2 14 14 100

TH 0 0 0 0 1 1 2 0 2 2 2 2 2 2 9 7 78

ZAN 2 2 2 2 0 0 2 2 2 2 2 2 2 2 12 12 100

YTDMAY

URUT-1

JAN FEB MAR APR JUN JUL

NOTE:

I.

MFL (Fahim) was on leaves for whole January 2014, due which the planned MSA for MFL considered ZERO for Jan 2014.

II.

TH (Tahir) took independent shift charge from mid-March 2014, hence planned MSA for TH considered from mid-Mar 2014.

III.

ZAN (Zia) was on sick leaves from 02 to 31 March 2014, hence planned MSA for ZAN considered ZERO for Mar 2014.

IV.

BQ and WaY audits have been considered till Jul and Jun 2014 respectively as they moved from URUT-1 in these months.V.

Audit figures for KBM will be included in URUT-1 MSA analysis from Aug 2014 onwards.

50 55 60 65 70 75 80 85 90 95 100

91.1%

URUT-1 MSA Compliance (Year to Date)


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URUT-1 REP

OPERATIONS DEPARTM

The average YTD audit quality score from Jan Jul 2014 for audits conducted by URUT-1

operations team is around 103%. Quality of audits conducted by each individual has generally been

good as shown in following graph (average year to date quality score of each individual of URUT-1

operations team).

3. SERIOUS INJURY / FATALITY POTENTIAL OBSERVATIONS:

Following were the serious injury / fatality potential observations on URUT-1 for month of Jun and

July 2014 divided into different categories. These observations are taken from MSAs done by all

interfaces on URUT-1 plant.

0

25

50

75

100

125

Akm Alf AMJ ARC MAKm MFL TAM TAQ TH ZAN

100 100 100

86100 100 100 100

78

100

AuditCompliance(%)

0

25

50

75

100

125

Akm Alf AMJ ARC MAKm MFL TAM TAQ TH ZAN

98108 108

97 105108 108 107 105

93

AuditQuality(%)


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URUT-1 REP

OPERATIONS DEPARTM

Behavioral Safety related observations:

a) Contractor people sitting right below scaffolding job in progress at AM-1. (Contractor)

b) Scaffolding job in progress without hooking up safety harness at AM-1. (Contractor)

c) AM-1 catalyst basket cutting job: Pipe fitter found operating a pneumatic grinder. (Contractor)

d) CPT boring machine belts were being adjusted while engine was running. (Contractor)

e) CPT boring machine had no guard over rotating cutting disc. (Contractor)

f) AC electrical terminals found open / substandard extension in contractor container. (Contractor)

Unsafe Condition:

g) PT-1 insulation sheets are loose. Falling hazard during wind storms. (FM)

Understanding Issue:

h) Scaffoldings at URUT-1 are not as per standard. Pose falling hazards. (FM / HSE)

4. PMS RELATED OBSERVATIONS:

Following PM&S related observations have been taken by audits conducted by URUT-1 SICs

showing the involvement of team on PM&S front.

a)

Truck reversing without standby persons help in truck parking yard.

b) Sewing operators working without goggles (frequent observations).

c) Truck last dham was being loaded with no mobile platform attached.

Behavioral

Safety

75%

Unsafe condition

12%

Understanding Issue

13%


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URUT-1 REP

OPERATIONS DEPARTM

5. IN-PROGRESS / PENDING ACTIONS:

Following are the actions pending with operations or other departments regarding serious injury /

fatality potential observations at URUT-1.

a)

Long bushes grow around ETP area that poses hazard of snakes. A conflict is present between

Housing and URUT-1 operations to get the job done. --- Action: SRHS / KBM (Target: Sep

30, 2014).

b) R-101 loose insulations have been fixed. However PT-1 loose insulation sheet fixation is still

required. --- Action: SID (Target: Sep 10, 2014)

c) Scaffolding standard are not being followed as per HSE Safety Manual Scaffolding procedure.

Need to finalize with HSE if the observation is valid. If found valid then this needs to be

communicated to FM teams on the plant to either correct these scaffolding access ladder

installations or remove the scaffoldings from areas. --- Action: ZAN / AHB (Target: Aug 25,

2014)

Documents

MSA Analysis (URUT-1 Operations) Jan - Jul 2014