c6_hazard iden, eva & control

8/21/2019 c6_hazard Iden, Eva & Control

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HAZARD

IDENTIFICATION &

EVALUATION

CONTROL


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BASIC TERMINOLOGYHAZARD

Anything that may have the potential to result in injury or harm to the health ofa person

OR

Unsafe condition or practice that could cause an injury or illness to an employee

specific for manufacturing

It takes a hazardand someone exposedto the hazard to produce an accident.

RISK

The probability of that injury or harm to occur

Hazard+ ExposureAccident


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Safety task

Hazard identification

Scenario identification

Accident

probability

Accident

consequences

Risk determination

Acceptable ?Modify work/part

arrangement

Accomplish the safety task

Y

N

Assign the risk code

Take appropriate actionbased on risk controls

hierarchy

IDENTIFY

EVALUATION

CONTROL

PROCESS FLOW


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Among the hazard identification techniques available are;

i. Physical inspection

ii. Checklist

iii. Organisational charts

iv. Flow charts

v. Hazard & operability study (HAZOP)

vi. Fault tree analysis

vii. Job safety analysis (JSA)

viii. Management oversight & risk tree (MORT)

ix. DOW index

x. Risk assessment

IDENTIFICATION

To identify hazards so that can be eliminated / controlled.

OBJECTIVE

METHODS


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For all methods, the main consideration are

What can go wrong & how ?

Consequences ?

Target : - Low probability & Minimal consequences

It must be clear that;

It is unlikely that one particular method will be sufficient to address all of

the problems

Certain methods are more useful in some industries Risk identification

should be an ongoing exercise, because risks mutates. Risk identification should be cost effective

Accurate record keeping is important

In this course, we will concentrate at Risk AssessmentBeside this, well-known risk management techniques to be discussed are;

HAZOP


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HAZARD AND OPERABILITY STUDIES (HAZOP)

Identify hazards due to fixed equipment & procedures.

Is a huge effort.

Provides a controlled mechanism to consider the things that can go wrong.

Customized for each company.

Improves process performance, quality, etc.

Time, people and effort

Information management problem

Advantages: Meets regulatory requirements

Plant operates better

Less down time

Product quality improved

Disadvantages:


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Procedure of HAZOP1. Divide flow sheet into sections, eg: production floor, storage area etc.

2. Choose a study area, eg: line, section, department, system (pump, vessel) &

operating instruction.

3. Describe its design intent/aim.

4. Select a process parameter.

5. Apply a SOP.

6. Determine causes.

7. Evaluate consequences/problems.

8. Recommend action: what? who? when?

9. Record info.

10. Repeat 5 to 9 for a new guide word.

11. Repeat 4 to 10 for a new process parameter.

12. Repeat 2 to 11 for a new study node.

13. Repeat 1 to 12 for a new flow sheet section.


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RISK ASSESSMENT Based on self-regulation system

Very user friendly and can be used by everyone in any organisation. Suitable for

manufacturing industries by prioritizing action plans

Main purpose; To determine whether the planned or the existing control measures, such as

systems of work and safeguards, are adequate or need to be improved.

Advantages: Ownership ;gives employers greater discretion to develop their own S&H

Opportunity to promote safety awareness

Require a lot of time, people and effort

Some assessors have become complacent about danger at work

Disadvantages:


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For successful implementation;

Discuss the purpose & plan with everyone concerned

Identify risk assessment training needs

Identify a list of work activities, & gather information about them

Identify all the hazards relating to each activity, or simply answer the

question could the work activity hold any danger to S&H

Make an informed estimate of the size of the risk associated with each

hazard. This generally means making a common sense judgement on hazard

scale, how much harm, and how many people could be affected

Decide whether the planned or existing S&H (if any) are adequate to keepthe hazard under control

Record the significant findings of the assessment


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TYPES OF HAZARDS

Psycho-social Physical Chemical Mechanical Biological

Stress

Plant layout

Ergonomic

improvement

Weak mgmt

Organisational

culture clash

Lack of job

satisfaction

Inadequate

leadership

Ergonomics

Visualcondition

Thermal

Noise

Vibration

Confined

space

Ventilation

Air

pressure

Electricity.

Radiation

Gases

Liquid

Solid

Vapours

Dusts

Fumes Pesticide

Mists

Smoke

Machinery

Equipment

Tools

Transport

Insects

Fungi

Yeast

Bacteria

Viruses


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How to develop an effective safety and health checklist.

Determine applicable state safety & health rules for the workplace.

Review rules and use those you feel apply to your workplace.

Develop applicable checklist questions that are not addressed in the rules.

i-Physical inspections

Identify;

Who's involved in the inspection process?

What is weakness inherent in the inspection process?

What process can be used to overcome this weakness?

Identifying high risk job activities/ procedures/ controls and exposures to the hazards.

See sampleof safety inspection checklist
http://elearn.kuktem.edu.my/study/uploads/Safety_Inspection_Checklist.dochttp://elearn.kuktem.edu.my/study/uploads/Safety_Inspection_Checklist.dochttp://elearn.kuktem.edu.my/study/uploads/Safety_Inspection_Checklist.dochttp://elearn.kuktem.edu.my/study/uploads/Safety_Inspection_Checklist.dochttp://elearn.kuktem.edu.my/study/uploads/Safety_Inspection_Checklist.doc


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iv-Employees reporting hazards

To overcome immediate safety problems.

Eg.: Unauthorized worker driving forklift, using compressed air as drier

How can employer most effectively recognize employees for reporting hazards?

Watch your language.

Keep it simple.

Format;

Background/Introduction

Findings

Recommendations

Conclusion/Summary

Writing Effective Inspection Reports


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EVALUATION A process where judgements are made about the hazards that might be arise from unsafe

conditions (USC) and unsafe act (USA)-based on Risk assessment technique

The process of hazard analysis consists of;

i. Break a job or task into specific steps

ii. Analyze each step for specific USA and USC

iii. Develop preventive measures in each step to eliminate or reduce the hazards

iv. Integrate preventive measures into training and standard operating procedures

(SOPs)

Should refer to the related guidance for specific hazard to ensure within regulation

requirements.


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SEVERITY= HAZARDx RISKx PERSONS AT RISK

FACTOR HAZARD RISK PERSON AT RISK

RANK 1 2 3 1 2 3 1 2 3 4 5

WEIGHT

Minimalrisk

Moderate

risk

Se

riousrisk

Im

probable

oc

currence

Po

ssible

oc

currence

Common

oc

currence

Lo

westno.

pe

ople

af

fected

Lo

wno.

pe

ople

af

fected

Mediumno.

pe

ople

af

fected

Highno.

pe

ople

af

fected

Highestno.

pe

ople

af

fected

DETAILS

Anxiety,stress,

min

orinjuries

Bro

kenbones,

burns,scalds

Disease,lossof

lim

bsordeath

Roofcollapse

Unlicensed

forkliftdriver-

acc

ident

Oilyfloorfall

dow

n

1~5

6~10

11~20

21~49

Morethan50

MEASURING SEVERITY


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SEVERITY CODING

CATEGORY ACTION CODE

Minor/ minor No action is required to deal with trivial risks, and

no documentary records need be kept.

-

Acceptable No further preventive action is necessary, but

consideration should be given to more cost-effective

solutions. Monitoring is required.

GREEN

Moderate Efforts should be made to reduce the risks, but the

costs of prevention should be carefully measuredand limited. Risk reduction should be implemented

within 3~6 months , depending on the no. of people

exposed to the hazards.

YELLOW

Substantial/

considerable

Work should not be started until the risk has been

reduced. If the risk involves WIP job, the problemshould be remedied within 1~3 months, depending

on the no. of people exposed to the hazards

ORANGE

Intolerable/

impossible

Work should not be started or continued until the

risk level has been reduced. If not possible to

reduce the risk, then the work must remain

prohibited

RED


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CONTROLS Consideration needs for hazard controlling;

Try & eliminate as many hazards as possible; eg: using a safe substance

instead of a potentially dangerous one Combat risks at source

Select preventive measures, such as guards,

Avoid creating new hazards when seeking to control existing hazards

Select PPE only as a last resort, after all other options have been considered

and found to be impracticable Organisation should have official form to record the findings of an assessment,

covering;

Work activity,

The hazards

The risk levels and severity of hazard

The personnel at risk & crucially

The action required


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Failstoinspect

No recognitionplanInadequate training plan

No accountability policy No inspection policy

No discipline procedures

OutdatedhazcomprogramNo orientation process

Unguardedmachine H

orsepla

y

FailstotrainTomuchwork

Defective PPE

Failstor

eportinju

ry

Inadequate training

Createa

hazard

Fails to enforce

Untrainedworker

Brokentools

Ignoreahaz

ard

Lack of time

Inadequatelabeling

No recognition

Cuts

Burns

Lackofvision

Strains

Nomissionsta

tement

Chemicalspill

Root causes

Surface causes

Direct Cause of Injury

Harmful transfer of energy

that produces injury or

illness.

The causes of injuries and accidents

Specific hazardous conditions

or unsafe behaviors that

result in an accident.

Common behaviors andconditions that ultimately

result in an accident.


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HIERARCHY OF RISK CONTROL

ELIMINATION

ISOLATION

PPE

ENGINEERING

CONTROL

ADMINISTRATIVE

CONTROL

Removing the hazard or hazardous work practice from

the workplace

Separating hazard or hazardous work practice from

people not involved in the work (eg : marking off

hazardous areas, installing barrier)

Modification to tools or equipment (eg : guarding to

machinery)

Introducing work practices that reduce the risk ( eg :

limiting amount of time a person is exposed to thehazards -noise, thermal, etc)

Should be considered only when other control

measures are not applicable

Replacing a hazard or hazardous work practice with a

less hazardous oneSUBTITUTION

* Constraint: You may need to use more than one control measure to reduce

risk


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ENGINEERING CONTROL

EXAMPLE

ADMINISTRATIVE CONTROL

PPE


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COMMON HAZARD CONTROLLING PRACTICES

Is the orderly arrangement of tools, equipment, storage facilities and supplies

Housekeeping & 5S

5S

SEIRI

SHITSUKE

SEIKETSU

SEITON

SEISO

(CLEARING-sort & discard)

(ORGANISING-

systematically arrange)

(CLEANING-

spick & span)(MAINTAINING-

standardise)

(SELF

DISCIPLINE)

For 5S, deeper concept housekeeping because includes self-discipline


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Benefits of housekeeping / 5S

i. Reduce operating costs because much less time & effort are required to maintain &clean.

ii. Production increases because once obstacles are removed without interference or

delay, the plant can function smmothly

5S main objectives ;

SAFETY

(Preventing accident)

PRODUCTIVITY(Eliminating wastes) EQUIP. MAINTENANCE(Eliminating breakdown)

QUALITY

(Preventing error)

5S


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iii. Control of production becomes easier because materials and parts of component do not

get lost or mixed

iv. Easier to check operation and process

v. Recovery of unused material and scrap become easier

vi. Production time is saved. There is no time spent in searching for materials, tools, parts,

etc

vii. Better utilization of floor space, clear area allows the operators to move freely and

maintenance men to carry out the works easily

viii.Clear aisles permit quick traffic without accidents

ix. Reduce fire hazardsx. Lower accident rate due to free and orderly movement

xi. Results in higher employee morale. The attitude of employees improve on observing

clean surroundings and comparative freedom from injuries


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Effective education and trainingWhen is it important to train employees?

How do we know safety education and training has been effective?

If it isnt in writingit didnt get done

Training need to be documented

Sample training certification for specific tasks

Trainee certification

Trainer certification

Supervisor validation

Effective Maintenance Processes

i. To make sure equipment and machinery runs safely and smoothly. To make sure equipment gets back into safe service quickly.


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Thank you

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