Riverdale, IL October/November 2013 - … - Take5 Program.pdf · Riverdale, IL October/November 2013 HIRA (Hazard Identification Risk Assessment) Take 5 Process Betty Hosteny. Hazard

A l Mitt lArcelorMittalRiverdale, IL

October/November 2013

HIRA (Hazard Identification Risk Assessment)

Take 5 Process

Betty Hosteny

Hazard Identification and Risk Assessment (HIRA)and Risk Assessment (HIRA)

The HIRA is most important step in your own h lth d f t th j bhealth and safety on the job

Hazard Identification and Risk Assessment (HIRA)and Risk Assessment (HIRA)

YOU:

Identify the hazards

Figure out the level of risk

Ensure risks are controlled

Do the job safelyDo the job safely

Why do we need this?y

Accidents!

people getting hurt

Incident rate – bad and getting worse

Higher cost means less money to hire people and to make

improvements

Why do we need this?

• Job hazard analyses (JHAs) and work instructions

Why do we need this?

y ( )need to be improved

• New hires need additional guidance – need toNew hires need additional guidance need to transfer knowledge from experienced workers to newer workers

• Have the workers on the front line identify the hazards and controls

• Helps prioritize the hazards/risks that need attention

Take5 Tool

A very simple 5-step process to stop and

think about the hazards of a task and

make sure we’re ready to do it safely

Take 5…Take 5…

• Replaces hazard assessment checklist done now by maintenance

• HIRAC-light at Indiana Harbor and Burns Harbor

• Still do the work authorization forms with contractors

Applies to ALL work • Routine Operations

• Normal, planned, production activities that typically happen every dayevery day

• Non-routine Operations • Non daily activities that are planned such as maintenance• Non-daily activities that are planned such as maintenance,

outage work, breakdown, shut-down, start-up

• After Emergency situations• After Emergency situations• Un-planned incidents/accidents e.g. breakout at caster or

cobble at hot strip mill

Done by

Either our own workers, contractors or sub-contractors

Take 5 applies to ALL workThi

All i t j b

This means…

• All maintenance jobs

• Routine operations – each day for each position (this p y p (is when most of our accidents happen)

• Any job that has unusual or changed conditionsAny job that has unusual or changed conditions

After 30 days management will assess the frequencyAfter 30 days, management will assess the frequency of use for Operations jobs

Key Concepts

A h d i t id t• A hazard is not an accident or injury - it’s the potential for harm (see back of Take 5)(see back of Take 5)

• The assessment of risk – need to look at both the likelihood of an accident/incident happening and the severity of any consequences

Take5 Step 1: Stop and Think, with your co workers in thewith your co-workers in the work area

• Do I have the required skills and knowledge to do the job?• Such as mechanical or electrical skills, ,

training, experience

• Do I understand the steps required to do the job?required to do the job?• Do I know what’s involved and how the

job should go?

• Do I have the right tools for the• Do I have the right tools for the job? Are they in good condition?• Correct rating for the job? Inspected?• Correct rating for the job? Inspected?

Take5 Step 1: Stop and Thi kThink

D I h th t PPE?• Do I have the correct PPE?• Right type of gloves, safety

glasses/goggles, gas monitor, aluminized gear, harness, etc.g , ,

• Have I walked the job and checked the work area?

Trip/slip hazards weather vehicle• Trip/slip hazards, weather, vehicle movements, pedestrians, etc.

• Have I got a clear plan in mind?I th b tt / f t d thi ?• Is there a better/safer way to do this? What can go wrong, and how do I protect myself?

Take5 Step 2: Look for the HazardsHazards• Have I completed the hazard pchecklist?• (back page of Take 5)

Does a JHA or SWI exist and• Does a JHA or SWI exist and have I reviewed it against the hazard checklist?• If YES, then compare the hazards on each• If you’ve missed something, fill it in • Ensure the proper controls in place for each

hazard before you start the jobhazard before you start the job• Give the Take5 to your supervisor

Take5 Step 2: Look for the HazardsHazards

Does a JHA or SWI exist and have I reviewed it against the hazard checklist?

If NO, then continue with Take5

Take5 Step 2: Look for the Ha ardsHazards• Will I be operating equipment p g q pwith the guards removed?• Such as trouble-shooting

• Am I or others in the area atAm I or others in the area at risk from operation of mobile equipment?• Does this task require mobile equipment

or is anyone else in the area usingor is anyone else in the area using mobile equipment?

• Can we see each other? Overhead crane?

• Will I be handling heavy loads or manual lifting?• Is there a smarter way to lift this load?

Take5 Step 2: Look for the HazardsHazards

• Will I be isolating energy g gywithout a procedure?• Always follow isolation procedures

• Will I be working at height or• Will I be working at height or in a confined space?• Do I need fall protection? Do I know

the confined space procedure?

• Are there pinch points? Can I get caught in or between?• Can I crush a finger? Foot? Could my• Can I crush a finger? Foot? Could my

whole body get stuck?

If YES to any of these,If YES to any of these, complete JHA

Take5 Step 3: Assess the Ri kRisk

We need to think about all these hazards and ask “what’s the Rare Unlikely Possible Likely Almost

Risk Matrixhazards and ask what s the actual risk of this job?”That is, how likely are the hazards to hurt me or someone

Rare Unlikely Possible Likely Almost certain

Minor non‐recordable employee injuries

Low Low Moderate Moderate Moderate

else, and, how bad would the injury be?That’s the risk assessment –

p y j

OSHA recordable injury without lost work time

Low Moderate Moderate Significant Significant

Moderate Moderate Moderate Significant Significant High

evaluating how likely and how severe an injury might be.

employee injury, adapted work

Moderate Moderate Significant Significant High

Serious injury resulting in lost work time

Moderate Significant Significant High High

Use the table on the back of the Take5

Fatality(s) Significant Significant High High High

Take5 Step 3: Assess the Ri kRisk


LIKELIHOOD

Minor non-recordable employee injuries


y) injuries


Low Moderate Moderate Significant Significant

(sev

erity

Moderate employee injury, adapted work

Moderate Moderate Significant Significant High

QU

ENC

E


Moderate Significant Significant High High


CO

NSE


A simplified overview of the risk assessment processrisk assessment process

Severity of Likelihood of Severity ofinjury X

Likelihood of Injury = Risk

5 Fatality 5 Almost Certain 25 Highest

4 Serious Injury

4 Likely 16

3 Moderate Injury

3 Possible 9

2 OSHA 2 Unlikely 4Recordable

y 4

1 Non‐Recordable

1 Rare 1 Very LowRecordable

If risk is low or moderate, continue with Step 4continue with Step 4





Low Moderate Moderate


Moderate Moderate


Moderate

Fatality(s)y( )

Take5 Step 4: Make the ChChanges•Have I controlled all the hazards so I will be safe?

•Does this feel right?Does this feel right?

If yes, then go ahead with job

If no, then talk with your supervisor about what else

needs to be done to control theneeds to be done to control the hazards.

Done!

If risk is significant or high,complete the JHAcomplete the JHA




Significant Significant


Significant Significant High


Significant Significant High High


Complete JHA when:• Risk is significant or high, OR• ‘Yes’ to any question in Step 2

Remember Step 2:Look for the Hazards

• Will I be operating equipment with the guards removed?• Such as trouble-shooting

• Am I or others in the area at risk from operation of mobile equipment?• Does this task require mobile equipment

or is anyone else in the area using mobile equipment? Can we see each other?

• Will I be handling heavy loads or manual lifting?• Is there a smarter way to lift this load?

Take5 Step 2: Look for the H dHazards• Will I be isolating energy g gywithout a procedure?• Always follow isolation procedures

• Will I be working at height or in• Will I be working at height or in a confined space?• Do I need fall protection? Do I know the

confined space procedure?p p

• Are there pinch points? Can I get caught in or between?

Can I crush a finger? Foot? Could my• Can I crush a finger? Foot? Could my whole body get stuck?

If ‘YES’ t f th l t JHAIf ‘YES’ to any of these, complete JHA

Take5 Step 4: Make the ChChanges

Now that you’ve identified all the hazards andNow that you ve identified all the hazards and assessed the actual risk, ask yourself:

Have I controlled all the hazards so that I will be safe? Does this feel right?

If ‘No’ to either question, see your supervisor for direction

Consider hierarchy of controlscontrols

• Elimination or Substitution• Eliminate hazard – e g design the• Eliminate hazard – e.g. design the

equipment or process to remove the hazard, or substitute materials to lessen the hazard (e.g. replace asbestos insulation with syntheticasbestos insulation with synthetic fibers)

• Engineering ControlsEnclose the hazard• Enclose the hazard

• Isolate the hazard with interlocks, machine guards, railings, shields, etc.

• Remove or redirect the hazard with ventilation or a muffler for example

Controlling the Risk

• Administrative controls• SWIs permits JHAsSWIs, permits, JHAs• Set exposure time limits• Monitor highly dangerous jobs• Alarms signs and warnings• Alarms, signs and warnings• Buddy system• Training, inspections

• Personal protective equipment (last resort)

Completing the Take5

Turn into supervisor for creating/improving:Safe Work Instructions• Safe Work Instructions

• JHAs• Updating HIRACs – prioritizes capital budgetUpdating HIRACs prioritizes capital budget

Job Hazard Analysis (JHA)

• Risk is significant or high, OR• ‘Yes’ (red!) to any question in Step 2Yes (red!) to any question in Step 2


• Risk is significant or high, OR• ‘Yes’ (red!) to any question in Step 2( ) y q p

Examine the task/job to:Examine the task/job to: Break the job into separate, defined steps Identify the potential hazards for each step that could

occur with that job stepoccur with that job step Risk assess / analyze the hazards utilizing the risk matrix

to determine the severity and the likelihoodLi t t th t l d t iti t th List out the control measures used to mitigate those hazards


Step 1: list the job steps, from set up to clean up

Job steps Hazard and risk descriptions Likelihood Severity Control measurers

1. Choose an item.

Choose an item.

2. Choose an item.

Choose an item.

3. Choose an item.

Choose an item.

4. Choose an Choose anChoose an item.

Choose an item.

5. Choose an item.

Choose an item.

6. Choose an i

Choose an iitem. item.

7. Choose an item.

Choose an item.

Thi i t k i t ti !This is not a work instruction!


Step 2: describe the hazards, to you or others

• Arc flash • Accidental start-up • Biological / radiation

Examples:

p g

• Chemical • Collision (pedestrian/vehicle)

• Crane movement

• Crushing • Dust / debris • Electrical

E i E h t (f / ) F ll ( ki t• Ergonomic • Exhaust (fumes / gas) • Fall (working at height)

• Fatigue • Fire / explosion • Heat, cold, extreme temps

H i t l M lt t l / k N i / ib ti• Heavy equip or tools • Molten metal / sparks • Noise / vibration

• Others working in the area

• Pinch point/rotating components

• Poor housekeeping

• Poor visibility • Rail movement • Rolling machinery

• Slippery/wet working surface

• Stored energy • Uneven working surfaces


Step 3 – Assess the risk

Likelihood the incident/injury will occur:How often the task is done

7 Task is conducted multiple times a day

5 Task is conducted once a day

T k i d t d k3 Task is conducted once a week

1 Task is conducted once a month or less


Step 3 – Assess the risk

Likelihood the incident/injury will occur:How many people are exposed

Exposure

7 Greater than 10 employees are exposed7 p y p

5 6-10 employees are exposed

3 2-5 employees are exposed

1 Only one employee is exposed


Step 3 Assess the riskStep 3 – Assess the risk

If it does occur, how bad will the injury be?

10 Fatality7 Lost work time injury

Severity

5 Adapted work injury3 OSHA recordable injury1 First aid treatment or less injury

Identify controls to reduce risk

• Elimination or Substitution• Eliminate hazard – e.g. design the

equipment or process to remove the hazard, or substitute materials to lessen the hazard (e.g. replace esse t e a a d (e g ep aceasbestos insulation with synthetic fibers)

• Engineering Controlsg g• Enclose the hazard• Isolate the hazard with interlocks,

machine guards, railings, shields, etc.• Remove or redirect the hazard with

ventilation or a muffler for example

Controlling the Risk

• Administrative controls• SWIs permits JHAsSWIs, permits, JHAs• Set exposure time limits• Monitor highly dangerous jobs• Alarms signs and warnings• Alarms, signs and warnings• Buddy system• Training, inspections

• Personal protective equipment (last resort)

Safe Work Instruction (SWI)Describes how to perform a task:• Identifies hazards• How to control those hazards

Use in place of a JHA only if: • the task has been risk assessed• is documented in a HIRAC

M t i l d ll f th t iMust include all of these topics:• The purpose of the instruction

• The people involved in the task

• The hazards associated with the task

• The necessary controls needed to mitigate the hazards

• Any additional PPE requirements above the requirements outlined in SMS-20 PPE Program

• Energy isolation procedures (where applicable)

• List of equipment and tools needed to complete the task

• Detailed procedure of instructions and explanations on how to perform the task

Safe Work Instruction (SWI)



Hazard Identification, Risk Assessment and ControlsAssessment and Controls (HIRAC)

Hazard Identification Risk Assessment and Control (HIRAC) Worksheet

Risk Assessment Team:

Location or Dept.:Date:

Activity/Task Hazard Impact Frequency

No. Employees Exposed

Impact Severity Likelihood

ImpactScore

ImpactRating

ControlTypes

Reliability of Controls

After incident, identify controls

which failedRisk

ScoreRisk

Rating

ControlsRisk Profile

0 0

0 0

0 0

0 0

Hazard Identification, Risk Assessment and ControlsAssessment and Controls (HIRAC)

For management to identify: • What tasks are highest risk in their department;• Figure out where to spend money • After an incident, where did controls fail

Break-out session

Each group should discuss their own job:

• Gunning the furnace (BOF)• Welding repairs to LMF bag house (Caster)• Changing a tunnel furnace roll (HSM)• Bottle car inspection (Utilities)• Or choose your own job

JHA

Discuss and fill out:•Job steps•Hazard and risk descriptions•Likelihood•Severityy•Control measures

Just Take 5

Think about what could go wrongTake your time and be thorough

Don’t start the job unless the hazards are identified and controlledidentified and controlled

Questions?Questions?

Documents

Riverdale, IL October/November 2013 - … - Take5 Program.pdf · Riverdale, IL October/November 2013 HIRA (Hazard Identification Risk Assessment) Take 5 Process Betty Hosteny. Hazard