HAZARD IDENTIFICATION & EVALUATION CONTROL

BASIC TERMINOLOGY
HAZARD
Anything that may have the potential to result in injury or harm to the health of a person OR Unsafe condition or practice that could cause an injury or illness to an employee specific for manufacturing

RISK
The probability of that injury or harm to occur

Hazard + Exposure Accident

It takes a hazard and someone exposed to the hazard to produce an accident.

PROCESS FLOW
Safety task Hazard identification

IDENTIFY
Scenario identification

Accident probability

Accident consequences

Risk determination

EVALUATION

Acceptable ?

Modify work/part arrangement

Y
Assign the risk code Take appropriate action based on risk controls hierarchy

CONTROL

Accomplish the safety task

IDENTIFICATION
OBJECTIVE
To identify hazards so that can be eliminated / controlled.

METHODS
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

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 Assessment Beside this, well-known risk management techniques to be discussed are; HAZOP

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.

Advantages:
Meets regulatory requirements Plant operates better Less down time Product quality improved

Disadvantages:
Time, people and effort Information management problem
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Procedure of HAZOP
1. 2. Divide flow sheet into sections, eg: production floor, storage area etc. 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.

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

Disadvantages:
Require a lot of time, people and effort Some assessors have become complacent about danger at work
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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 keep the hazard under control Record the significant findings of the assessment

TYPES OF HAZARDS
Psycho-social
Stress Plant layout Ergonomic improvement Weak mgmt Organisational culture clash Lack of job satisfaction Inadequate leadership Ergonomics Visual condition

Physical
Thermal Noise Vibration Confined space Ventilation Air pressure Electricity. Radiation

Chemical Mechanical Biological

Gases Liquid Solid Vapours Dusts Fumes Pesticide Mists Smoke Machinery Equipment Tools Transport Insects Fungi Yeast Bacteria Viruses

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HAZARD IDENTIFICATION PROCESSES

Through; i. Inspections ii.Questionnaires & hazard survey iii.Trend analysis/ illness records / operability study iv.Employees reporting hazards

_ __ __ T __ ET __ EE __ __ HE __ _ SH K __ _ KS _ R _ R _ _ O _ O _ __ _ W _ _ _ W _ S _ _ _ I S ___ __ SI __ __ YS __ __ LY __ __ __ AL __ __ __ NA AN __ __ __ _ __ _ D __ _ __ _ DA _ _ __ R _ _ _ R _ _ _ _ A _ ___ __ __ ZA __ __ __ AZ __ __ HA __ __ __ __ _ __ __ __ __ BH __ __ __ d __ __ __ _ OB _ __ J ed _ __ _ iirre __ __ _ JO _ __ _ __ _ u _ E _ _ _ _ _ _ u _ E q _ _ _ L _ _ _ _ _ q e _ L _ P e _ __ s)) R __ _ __ __ __ M __ __ __ __ __ MP __ __ __ __ _ ((s R __ A __ __ _ _ _ __ S _ __ _ e __ __ ___ SA _ _ __ _ _ r _ e _ _ _ _ _ _ _ r _ u _ _ _ _ _ _ _ _ _ u _ _ _ _ _ _ s _ a _ __ __ __ M e _ __ _ __ _ _ as _ _ _ _ _ _ _ _ _ e _ _ _ _ _ _ _ _ _ _ _ M __ _ _ _ _ _ _ __ __ e _ __ __ __ __ tiiv _ _ _ _ _ e _ _ __ _ _ _ _ _ _ v _ _ _ _ _ _ _ _ _ _ _ _ __ __ _ nt en __ __ __ _ _ ev __ __ __ __ __ __ __ __ __ __ _ _ _ __ _ _ rreve __ _ __ __ __ ___ _ _ __ _ _ ___ __ _ P _ _ _ _ _ _ _ : _ P _ _ _ _ _ _ _ _ : n _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ iio _ _ on __ __ _ t __ _ _ _ _ _ _ _ _ _ t _ p _ _ _ _ _ _ _ _ i _ p _ _ _ _ _ _ _ __ __ __ __ __ _ __ __ __ crri __ __ __ __ sc __ __ _ _ __ es _ __ __ :: _ _ _ D __ d _ ___ __ _ _ _ __ _ __ _ ___ De n d __ e _ _ _ _ _ _ b _ _ n _ _ r o e _ _ _ _ i _ _ b i _ _ _ o r _ _ o _ t _ _ _ _ u _ J _ _ ti _ _ _ __ _ ui __ _ __ __ Jo q _ __ Re iip _ _ _ p _ _ r q _ _ _ _ _ _ _ _ r _ c e _ _ _ __ _ _ _ _ _ _ _ s _ _ _ (s __ _ _ _ _ )) R _ _ __ __ sc _ __ __ e _ __ __ _ _ _ _ _ _ _ _ e _ _ _ _ _ D _ s _ _ _ _ _ ( _ _ e D _ _ _ _ 1 _ _ __ __ _ __ __ _ __ __ u __ __ __ as __ __ __ __ urre __ __ p1 s __ ep __ _ __ _ _ _ _ __ e _ ___ ___ __ S _ __ _ ___ _ _ s ___ __ _ ___ __ d eas _ _ __ Stte za _ _ _ _ _ _ M r _ d _ _ _ _ _ _ _ _ M r _ _ _ _ _ _ _ e _ _ _ __ _ _ __ _ __ nttiiv _ __ _ __ __ _ __ __ ve __ __ __ _ __ __ __ aza __ __ __ __ H __ __ __ __ Ha __ __ __ __ _ en _ _ ___ ___ __ __ _ __ _ ___ ___ __ _ __ ___ __ ve __ ev __ __ __ __ __ __ __ __ __ __ _ P __ _ __ _ _ __ _ _ _ ___ __ Prre _ _ 1 ___ ___ __ __ _ __ _ _ __ _ ___ __ _ _ 1.. _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ __ __ _ __ __ __ __ __ _ __ __ __ __ __ __ __ __ __ __ __ _ __ __ __ __ 2 __ __ _ __ ___ 2.. _ __ _ ___ __ __ ___ __ __ __ __ _ __ __ __ __ __ _ __ _ __ _ n _ d __ _ __ __ _ _ __ ___ _ __ __ n:: _ _ rre ___ o _ ed __ _ __ __ i _ _ i _ _ _ _ o _ _ t _ i _ _ _ i _ u _ _ _ 3 _ _ t _ _ p _ _ u _ _ 3.. _ q i _ e __ ) R _ _ __ _ __ __ __ __ eq _ _ __ __ __ __ __ _ __ crrip __ __ __ __ sc _ __ e _ __ _ _ __ _ _ __ es _ __ _ ___ __ ((s __ _ D ___ s) R __ _ _ __ ___ _ _ _ _ _ e D _ _ _ _ _ _ _ 2 r _ e _ _ _ _ _ _ _ 2 _ r _ _ _ u _ _ __ __ _ p s __ ea _ ep __ __ __ __ __ __ su __ __ __ __ __ as __ __ S __ __ _ _ __ Stte arrd _ __ __ _ _ ___ _ M _ __ ds _ _ ___ __ _ __ _ _ __ ___ __ _ _ M e __ _ _ _ _ _ _ _ e __ _ _ _ _ _ a _ z _ _ _ e _ _ v _ __ _ _ _ z _ _ _ a i _ _ __ _ _ _ H __ __ _ __ __ nttiv __ __ __ __ __ __ ve _ __ __ Ha _ __ __ __ __ __ __ __ _ __ __ __ __ e ven __ __ __ _ _ ___ __ _ ___ __ _ ___ __ __ ___ __ _ __ ___ __ __ __ __ __ __ __ _ __ P __ __ _ Prre _ __ 1 _ __ _ _ _ _ _ _ 1.. _ __ _ _ __ ___ ___ __ __ _ _ _ ___ _ __ _ ___ __ _ ___ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ __ _ _ _ _ __ __ __ _ __ _ _ __ _ _ __ _ _ _ __ __ _ _ _ _ _ _ _ _ _ _ 2 _ _ _ _ _ _ _ _ _ _ 2.. _ __ _ _ _ _ __ _ __ _ _ __ __ _ __ __ _ __ _ __ __ __ _ __ __ __ __ __ __ ___ __ n:: _ __ _ _ __ __ _ _ _ _ ___ _ on _ __ _ _ ttiio __ _ __ ___ _ _ _ _ ___ _ 3 _ ___ _ _ _ _ __ p _ _ _ _ 3.. _ _ _ i _ _ _ p _ _ _ r _ _ _ _ i _ _ _ _ _ _ _ __ _ cr __ __ __ _ __ __ _ __ __ __ _ __ __ __ __ sc __ __ __ __ es __ __ __ __ De __ ___ ___ _ ___ _ _ ___ _ 3D __ __ ___ _ __ __ __ __ __ __ __ __ __ __ _ __ _ p3 s _ ep _ __ __ _ _ _ __ __ _ ___ _ _ __ _ ___ _ _ _ __ ___ __ _ _ _ _ __ _ _ _ _ S _ _ _ _ s _ _ _ d _ _ _ _ Stte za _ _ _ _ _ _ r _ d _ _ _ _ _ _ _ _ _ _ r _ _ _ _ __ _ __ __ __ __ _ _ __ __ __ _ __ __ __ __ __ __ __ __ __ _ aza __ H __ __ ___ _ Ha ___ _ __ ___ __ ___ _ __ ___ _ ___ __ __ __ __ __ __ __ _ ___ __ __ __ __ __ __ ___ _ ___ __ __ __ ___ _ ___ __ __ __ __ __ 1 __ __ ___ __ __ __ 1.. _ __ __ _ __ _ ___ __ _ _ __ _ __ _ ___ _ __ _ __ __ _ _ __ ___ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 2 __ _ __ __ __ _ __ __ __ _ 2.. __ __ __ __ __ __ __ e ___ _ __ ___ __ __ ___ _ ___ _ __ __ __ __ __ __ _ __ urre __ __ __ du 3 ___ __ ed ___ _ 3.. _ ___ _ __ __ __ __ ce __ oc ___ _ __ __ _ __ _ _ __ P __ _ ___ _ _ ___ __ Prro __ _ _ __ _ __ _ _ b _ _ _ _ _ _ b _ _ o _ _ _ _ _ _ _ o _ _ J _ _ __ __ _ e J __ __ _ __ _ __ __ _ __ __ __ __ affe __ S ___ ___ _ ___ __ Sa ___ __ __ ___ __ __ __

_ _ __ _ __ __ __ _ __ __ _ __ __ __ __ __ _ ___ _ ___ __ __ ___ _ ___ _ __ __ __ __ __ ___ __ ___ _ _ ___ _ _ __ _ __ _ __ _ __ __ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ __ __ __ __ _ __ ___ _ ___ __ __ __ __ _ ___ __ __ __ __ __ __ _ __

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i-Physical inspections
Identifying high risk job activities/ procedures/ controls and exposures to the hazards. 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? 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.

See sample of safety inspection checklist

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ii-Questionnaires & hazard survey

Observations, informal and formal, are quite important in daily workplace safety. Employees and managers can spot hazardous conditions and unsafe or inappropriate behaviors while they conduct their other tasks.

iii-Trend analysis / illness records and operational study

_ __ __ T __ ET __ EE __ __ HE __ SH __ KS __ RK __ __ OR __ WO _ __ __ __ __ __ IS W __ __ SIS Y __ _ __ _ YS __ L _ __ _ L _ _ _ A _ _ _ A _ _ N AN __ __ __ __ __ __ DA _ __ __ __ RD __ __ __ __ AR __ __ __ _ _ __ ZA _ A __ __ _ _ __ _ AZ _ _ _ H _ _ _ _ H _ _ _ _ _ _ _ B _ _ _ __ __ d __ e _ __ __ __ uir OB __ JO ed __ __ __ __ __ __ __ EJ __ __ _ __ ___ __ quir __ __ LE __ __ _ __ PL __ eq __ __ __ M __ Re _ _ __ )) R _ __ MP _ ___ __ __ _ ___ _ _ __ _ __ (s A _ _ _ _ _ _ _ S _ _ (s _ _ _ _ SA _ _ _ _ _ re _ u re _ __ __ __ as __ __ __ __ __ __ __ _ __ _ __ __ __ _ __ _ __ _ asu _ _ _ e _ _ _ _ _ _ _ _ e _ _ _ _ _ _ M _ _ _ _ __ __ __ __ __ __ tiv __ _ __ _ e M __ __ __ __ __ __ _ _ __ _ ve __ __ _ __ _ _ _ _ _ _ _ ti _ n _ _ _ _ _ _ _ _ _ _ _ _ n e _ _ _ _ _ _ _ _ v e __ _ _ __ __ __ __ __ __ Pre __ _ _ __ _ __ __ __ __ __ _ _ __ _ rev __ __ _ _ _ _ _ _ _ _ : _ P _ _ _ _ _ _ _ _ : n _ _ _ _ _ _ _ _ _ __ on __ __ _ ti __ __ __ __ _ _ __ _ __ tio _ __ p _ __ __ __ _ _ __ _ _ p _ __ _ _ _ _ ri _ _ _ _ _ _ _ _ ri _ _ _ _ c _ _ _ _ _ _ _ __ __ sc __ d __ __ __ __ _ _ __ es _ __ __ :: _ _ __ D __ _ _ _ __ _ __ _ __ De n d ___ e _ _ _ _ _ _ b _ _ n _ _ _ o e _ _ _ ir _ _ b _ _ _ o _ _ o _ ti _ _ J _ _ __ __ _ uir __ __ __ Jo __ Re _ __ _ pti __ __ ri qu _ __ __ _ __ _ __ rip __ c eq _ __ _ _ _ _ _ _ _ _ c _ _ s _ _ _ _ R ___ _ _ _ _ ) _ _ _ s _ _ e _ _ _ _ ) _ _ _ _ _ (s De _ _ __ __ __ __ __ __ __ ure _ ___ _ __ __ 1 __ _ __ __ _ __ _ __ 1D re(s __ __ __ _ _ _ _ _ p _ _ _ _ _ u _ _ s _ _ _ p _ _ _ _ _ _ _ _ s _ _ a te _ _ _ _ _ _ s ea S _ __ __ __ __ __ __ __ Ste za _ __ __ __ __ _ __ _ M rd __ __ __ _ __ __ _ __ _ M e __ rds __ __ _ __ __ _ e _ _ __ _ _ a _ _ _ _ _ _ e _ _ v _ _ __ z _ _ a _ _ _ _ _ _ v _ _ ti _ __ H _ _ __ __ __ __ _ __ ve __ _ H a __ __ __ _ __ __ __ __ nti __ __ __ __ __ _ __ __ en __ __ __ __ __ _ _ ___ __ ___ __ __ ___ __ _ __ _ ___ ___ __ rev __ __ _ P __ ___ __ __ __ __ Pre 1 __ __ _ 1.. _ __ __ _ __ ___ ___ __ _ _ ___ ___ __ __ __ __ _ ___ __ __ __ __ __ __ __ __ __ _ __ ___ __ __ __ ___ __ __ __ _ ___ __ __ _ __ __ __ _ _ ___ 2 __ _ __ _ __ _ __ _ _ __ 2.. _ __ __ _ _ ___ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ : _ _ __ d _ _ _ _ _ _ _ _ : _ __ e _ _ uir __ n __ _ ed __ __ _ __ __ __ _ __ __ __ on __ __ __ __ __ 3 tio __ 3.. _ __ pti _ __ quir __ ___ __ _ __ _ _ ___ ___ __ rip __ eq __ __ __ __ _ cri __ __ Re __ )) R __ sc _ __ e _ _ __ _ _ __ __ _ _ ___ __ es _ __ _ ___ __ (s __ _ D ___ _ __ __ _ _ _ (s _ _ D _ _ _ _ _ _ _ 2 re _ _ _ _ _ _ _ _ _ 2 _ re _ _ _ p u _ __ __ _ __ ea __ _ __ __ _ __ __ su __ _ __ __ __ _ __ _ __ _ __ as tep rds __ _ __ S __ __ _ _ _ _ s _ _ e _ _ Ste _ _ _ _ _ _ _ _ M _ _ _ _ _ _ _ _ _ _ _ _ _ M _ rd _ _ a _ __ _ __ __ e __ __ __ __ __ __ __ nti za _ _ __ _ __ __ ve __ __ __ __ __ az _ _ __ _ __ H __ tiv __ __ __ __ _ _ _ _ _ _ _ Ha _ _ _ _ n _ e _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ e _ v _ _ _ _ _ _ _ __ __ _ _ __ _ __ __ _ __ __ __ __ __ _ __ __ __ __ __ P _ __ __ __ rev __ __ _ __ __ __ __ Pre __ 1 __ _ _ 1.. _ __ __ ___ __ _ _ ___ _ ___ __ __ ___ __ __ __ __ ___ __ __ __ __ __ __ __ __ __ _ __ _ __ __ __ _ _ _ _ ___ __ _ __ __ _ ___ __ _ __ ___ __ _ __ _ __ _ ___ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 2 _ _ _ _ _ _ _ _ _ _ _ _ _ 2.. _ __ _ _ _ _ __ _ __ _ _ _ __ __ _ _ __ _ __ _ __ _ _ _ __ _ _ __ _ __ __ n _ _ __ __ __ _ _ __ ___ _ _ n:: _ __ _ _ _ o _ _ _ _ _ _ _ _ _ _ . _ _ o _ _ _ _ ti _ _ _ _ _ _ _ . 3 _ _ _ ti _ _ _ __ 3 p _ _ __ __ __ _ __ _ _ _ __ _ __ _ _ __ _ rip __ __ _ __ c _ _ __ _ __ __ _ _ __ cri __ _ _ s _ _ _ _ _ _ _ _ _ _ _ s _ _ e _ _ _ _ _ _ _ _ _ _ _ _ _ _ e _ _ _ _ _ D _ _ _ _ _ _ __ _ __ _ 3 D __ __ _ __ _ _ __ _ __ __ _ __ _ _ __ __ _ __ __ p __ __ _ __ _ __ _ _ _ _ p3 s _ _ _ _ _ _ _ _ _ _ _ _ te _ _ _ _ _ _ _ _ _ _ _ _ _ te _ _ _ _ _ S S za _ _ _ __ _ __ __ _ __ __ _ __ __ _ _ __ _ _ __ _ __ rds __ _ __ __ __ __ __ _ __ __ __ ard __ _ _ _ _ _ _ _ _ _ z _ _ _ a _ _ _ _ _ _ _ _ _ _ _ _ _ a _ _ _ _ _ _ H _ _ _ H _ __ __ _ __ _ __ _ __ __ __ __ _ __ __ __ _ __ __ __ __ __ __ __ __ __ __ __ __ __ ___ _ ___ _ __ ___ ___ _ __ ___ __ __ __ __ 1 __ __ __ _ __ 1.. _ __ __ __ __ __ ___ _ __ ___ _ __ ___ __ __ __ __ __ __ __ __ __ _ ___ __ __ __ __ __ __ ___ _ ___ __ __ __ __ 2 __ __ __ _ 2.. _ __ __ __ __ ___ __ __ __ ___ __ __ __ __ __ __ __ __ __ re __ __ ___ __ __ __ __ ure __ __ _ __ _ __ du e _ __ 3 _ __ ___ _ _ _ __ ed _ __ 3.. _ c _ __ _ _ _ _ _ _ c _ _ _ _ _ _ _ _ _ ro _ _ _ _ _ _ _ ro _ _ _ P _ _ __ _ __ __ _ __ __ __ _ __ _ __ __ b P __ __ ob Jo ___ _ ___ _ __ ___ __ ___ _ __ __ ___ _ __ fe J __ __ __ afe _ S ___ __ ___ __ _ __ ___ __ Sa

_ _ __ _ __ __ __ _ __ __ _ __ __ __ __ __ ___ _ ___ __ __ _ ___ _ ___ _ __ __ __ __ __ __ ___ __ ___ _ ___ _ __ __ __ __ __ __ _ __ __ __ ___ _ ___ __ __ __ __ __ __ __ _ ___ _ __ _ __ _ __ _ __ _ _ _ _ _ _ _ _ _ _ _ __ __ __ _ __ ___ __ __ __ _ __

Using available medical reports, job performance analysis, attendance records and etc.

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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?

Writing Effective Inspection Reports

Watch your language. Keep it simple. Format; Background/Introduction Findings Recommendations Conclusion/Summary

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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 = HAZARD x RISK x PERSONS AT RISK

Highest no. people affected High no. people affected Medium no. people affected Low no. people affected Lowest no. people affected More than 50

PERSON AT RISK

21~49
11~20 6~10 1~5

Common occurrence
Possible occurrence

Oily floor fall down

Unlicensed forklift driveraccident Roof collapse Disease, loss of limbs or death

RISK

MEASURING SEVERITY

Improbable occurrence
Serious risk

HAZARD

Moderate risk

Broken bones, burns, scalds

Anxiety, stress, Minimal risk minor injuries

DETAILS

WEIGHT

FACTOR

RANK

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SEVERITY CODING
CATEGORY ACTION CODE
GREEN 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. Efforts should be made to reduce the risks, but the costs of prevention should be carefully measured and limited. Risk reduction should be implemented within 3~6 months , depending on the no. of people exposed to the hazards. Work should not be started until the risk has been reduced. If the risk involves WIP job, the problem should be remedied within 1~3 months, depending on the no. of people exposed to the hazards 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

Moderate

YELLOW

Substantial/ considerable

ORANGE

Intolerable/ impossible

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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The causes of injuries and accidents

Strains Burns Cuts
Un gu ard

Direct Cause of Injury

Harmful transfer of energy that produces injury or illness.

ed

ma c

hin

H or

sep

lay

Surface causes
rd
d

Bro
C h em

k en

too

ls

Crea

a za te a h

ical sp ill

Ignore

r a haza

Specific hazardous conditions or unsafe behaviors that result in an accident.

y

Defe

ctive

PPE

po to re Fails

jur rt in

Untrained

worker

Fails to inspect

Lack of time

Fails to enforce

work To much

Fails to tr ain

Inadequate training No discipline procedures No orientation process Inadequate training plan No accountability policy

Lack of vision No mission statement

No recognition

Root causes
Common behaviors and conditions that ultimately result in an accident.

Inadequate labeling
Outdated hazcom program
No recognition plan

No inspection policy

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HIERARCHY OF RISK CONTROL

ELIMINATION
Removing the hazard or hazardous work practice from the workplace Replacing a hazard or hazardous work practice with a less hazardous one 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 the hazards -noise, thermal, etc) Should be considered only when other control measures are not applicable
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SUBTITUTION

ISOLATION

ENGINEERING CONTROL
ADMINISTRATIVE CONTROL PPE

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

EXAMPLE
ENGINEERING CONTROL

PPE

ADMINISTRATIVE CONTROL

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COMMON HAZARD CONTROLLING PRACTICES Housekeeping & 5S

Is the orderly arrangement of tools, equipment, storage facilities and supplies For 5S, deeper concept housekeeping because includes self-discipline

SEIRI (CLEARINGsort & discard)

SHITSUKE
(SELF DISCIPLINE)

SEITON

5S

(ORGANISINGsystematically arrange)

SEIKETSU
(MAINTAININGstandardise)

SEISO
(CLEANINGspick & span)
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5S main objectives ; SAFETY (Preventing accident) QUALITY (Preventing error)

5S

PRODUCTIVITY (Eliminating wastes)

EQUIP. MAINTENANCE (Eliminating breakdown)

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

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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 hazards x. 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 training

When 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