Embed Size (px)
Citation preview
Implementing and Improving Occupational Health and Safety in
Manifacturing
Gianandrea Gino
www.sirt.it
Chemical Engineer – EHS
consultant – Certified
Occupational Hygienist
Intro Definitions
HAZARD: any source of potential damage, harm or adverse health effects on something or someone under certain conditions at work. Basically, a hazard can cause harm or adverse effects (to individuals as health effects or to organizations as property or equipment losses)
RISK: Risk is the chance or probability that a person will be harmed or experience an adverse health effect if exposed to a hazard.
RISK ASSESSMENT: the process where we identify hazards,
analyze or evaluate the risk associated with that hazard, and
determine appropriate ways to eliminate or control the hazard.
Workplace Safety and good Occupational Health are:
I • Economic
II • Mandatory (legal and insurance requirements)
III • Ethically correct
IV • Reasonable and practicable
Accidents at work in a manufacturing site implementing an OHS program
(500 employees - Real case)
0,0
5,0
10,0
15,0
20,0
25,0
30,0
35,0
40,0
45,0
50,0
1993 1994 1995 1996 1997 1998 1999
Number of
accidents
An effective hearing conservation program (100 employees - Real case)
Noise
exposure
Lepd
[dB(A)]
Workers
Ist year
Workers
IInd
year
Workers
III year
Workers
IV year
< 80 26 26 27 30
80-83 15 15 17 14
83-85 1 3 = =
>85 2 = = =
OCCUPATIONAL HEALTH AND SAFETY ? A SOURCE-TARGET MODEL
PPEquip.
PROCEDURES TRAINING
PLANT
SOURCE
TARGET
SAF.TY GUARD
Prevention: all the steps or measures taken or planned at all stages of work in the undertaking to
prevent or reduce occupational risks
MITIGATION HAZARD RISK
f (F ; M) EFFECTS
Emergency plans first aid, fire-fighting & evacuation
MA
GN
ITU
DO
FREQUENCY ( likelihood of occurrence of a hazard)
PREVENTIVE ACTIONS
PROTECTIVE MEASURES
A graphical representation (Bow tie)
Risk Cause/Hazard
Cause/Hazard
Cause/Hazard
Consequence
Consequence
Consequence
C
o
n
t
r
o
l
C
o
n
t
r
o
l
C
o
n
t
r
o
l
C
o
n
t
r
o
l
Manteinance and Housekeeping is safe
SAFE UNSAFE
Safety is (also) made of simple things
Fire alarm
Fire alarm sign
Safety barrier
Safety signs
Danger: EXTREME COLD
Grounding
Fall Protection barrier
Principles and Ranking of best practice (and Legal requirements) =>EEC Directive 89/391
avoiding risk and intrinsically safe configurations
evaluating the risks which cannot be avoided
combating the risks at source
adapting the work to the individual (design of work
places, work equipment, working and production
methods) upgrading to technical progress
replacing the dangerous substances / processes by the non-
dangerous or the less dangerous
developing a coherent overall prevention policy (- technology, -
organization of work, - working conditions, - social relationships)
giving collective protective measures priority over individual
protective measures
appropriate instructions for workers.
What to do? First of all: Risk assessment
We should try to answer the following questions:
What can/has [before/after] happen and why (risk identification => methods) ?
Consequences / Magnitude => evaluation?
Probability of future occurrences (at least qualitative)?
Is there any factor that mitigate the consequence of the risk or that reduce the probability of the risk?
Finally, is the level of risk tolerable or acceptable (legal /internal/ethical standard) and/or does it require further treatment ?
How ? Starting from process, local environment, work-flow, man behavior
Evidence based methods:
check-lists
reviews of historical data and news
internal standards and notes
near-miss evaluation
Risk identification methods can also include:
systematic team approaches where a team of experts follow a systematic process to identify risks by means of a structured set of prompts or questions or inductive reasoning techniques (what-if; HazOp; LOPA, …)
=> ISO 31010 Risk Assessment Techniques
Other useful tools
Safe-work practices
Near miss monitoring and analysis
Training
Workers participation and consultation
Internet resources (http://osha.europa.eu/)
And also remember that often …
is better !
A SQUINTING EYES WATCHING
Hit parade (examples of most common dangers in plants)
Ranking Main Plant Danger / Causes What to check
1
Walking, climbing, running, moving: slip, trips and falls, works in height
Protective barriers, Safe projecting and site-design, Stairs, Maintenance, Safety shoes, Working procedure, Danger Pictograms,
Water drain and ice-floor control
2 Mobile equipments (fork lift, trucks, vehicles, …)
Speed Limits and Gerachic Controls, High visibility garments, Circulation plan and limitation, vertical and horizontal safety
and/or health signs
3 Lifting heavy or disergonomic loads
Mechanical device, formation, procedures, ergonomic design
4
Unsafe work near or with unguarded-machinery and unsafe moving parts
Machine guarding and maintenance, CE safety compliance, periodical auditing and
improvement, safe-maintenance with work-permits & Zero-Energy procedures
16
Hit parade (examples of most common dangers in plants)
Ranking Main Plant Danger / Causes What to check
5
Physical risks from dangerous Substances, gases and steam (hot/COLD burns, high pressure, …), Confined Spaces
Personal protective Equipment, training and procedures, Safety
Signs, Instruments, Work Permits
6
Fire / explosion from flammables / oxidizer gas and liquid or physical explosion due to pressurized cylinders and tanks
Fire prevention, correct plant & equipment siting and
construction, legal and insurance compliance, CE marking
7 Splitters in eyes (grinding, welding, hammering, venting pressurized air and gas, cleaning/wiping)
PPE, procedure, correct work practice
8 (Long term effects) Excessive Noise Professional deafness
Noise levels (Compressors, high pressure pipes, …), PPE, Hearing conservation programs
Hazards classification
4 Main Kinds
(often inter-linked) Physical Hazards
Chemical Hazards
Biological hazards
Psychosocial hazards
FORK LIFTING ?
GOOD PRACTICES
Safety belt
A matrix for risk evaluation and ranking
Evaluation &
Actions
Priority
Non Acceptable Reduce risk to the lowest
level reasonably practicable
(ALARP)
Acceptable (the border-line depends
also from Policy)
EFFECTS
SEVERITY
1
No health
impacts
2
Minor health
impacts
3
Moderate /
Reversible
health impacts
4
Permanent
consequence/
Death
LIK
EH
OO
D
1 Not expected to occur
during facility life 1 2 3 4
2 Could occur once during
facility life 2 4 6 8
3 Could occur several times
during facility life 3 6 9 12
4 Could occur on an annual
basis (or more often) 4 8 12 16
And don’t forget Human Error
(HRA Human Reliability Analysis)
For example we may be in error
in feeling the danger and or the risk (too high / too low)
about the nature of risks and therefore on the corrective actions to take
in implementing the correct answers and/or at the appropriate time
It’s common and daily experience of all of us that we can fail also during very easy actions or forget simple things.
Instead: forget common phrases!
It never happened [So what?]
A mistake ? It's impossible ! [Are you sure?]
That safe-guard is useless: no body works there !
We have always worked in this way:
why should we change right now?
Everyone does it anywhere!
