New Process and Equipment Hazard Assessment - examples of framework
1. Southeastern Wisconsin Safety
Conference – UW Whitewater
October 27, 2016
Hazard Assessments - Frameworks
for New Process and Equipment
Move Evaluations
Brian Well, CSP
bewell@wi.rr.com
2. Today’s Overview and Context
Understanding your Hazard Assessment
Objective(s)
Resources
Method of communications
• Review some Risk Assessment
templates
• Apply methodology to scope
3. Upfront – before assessments begin
Four things to do before you start assessment
1 – Identify and confirm your Objective
2 - Confirm your resources (people/time/space)
3 - Plan training (who/how/when/where)
4 – Plan to widely communicate objectives
4. Safety and Health Program Management
Guideline – core elements
• Management Leadership
• Worker Participation
• Hazard Identification and Assessment
• Hazard Prevention and Control
• Education and Training
• Program Evaluation and Improvement
• Communication and Coordination for Host
Employers, Contractors and Staffing Agencies
7. Example 1 – EtQ
New Workflow Document 02/07/2016 07:36:00 AM
- 1 -
Draft
Number: Please Save
Reference:
Date Created : 02/07/2016
Created By: Brian Well
*Area/Equipment: Type: Forming/Press
*Plant Site: Whitewater, WI
Assessment Team : Brian Well
Initial Assessment Date : October 27, 2016
Post Assessment Date : schedule at conclusion of initial assesment
8. Example 1, Grouped Hazard Elements
1.0 General Machine Guarding
2.0 Life Safety
3.0 Material Handling
4.0 Industrial Hygiene
5.0 Chemical Safety
6.0 Documentation, Signs and Labels
7.0 General Guidelines
8.0 Regulatory Review
9.0 Electrical Safety
10. Example 2 – manual referencing
Management of Change Checklist
ManagementofChangeChecklist
11. Example 2 Outline
1. Electrical Safety Subpart S - Electrical- 1910.301
2. Mechanical Safety Subpart O-Machinery and Machine
Guarding-1910.212
3. Fire Protection Subpart L- Fire Protection- 1910.155
4. Industrial Hygiene
5. Process Safety
6. Job safety Analysis
7. Training
8. Ergonomics
9. Pre-startup preparation (sub checklist)
10. Slip, Trip & Fall Hazards
11. Environmental
Notice the punch list for notes – this is a working document
12. Example 2 - continued
Management of Change Authorization
Initial Inspection Additional Inspection Final Review
Date: Building:
Project Description:
Inspection Committee:
1. Project Leader/Sponsor:
Print Signature Date
2. Area Manager/Equipment User:
Print Signature Date
3. QA Manager:
Print Signature Date
4. EH&S Manager or Safety Rep:
Print Signature Date
5. Vendor:
Print Signature Date
Comment:
13. Example 3 – Three Part Equipment
Inspection/Assessment
Part 1 - Cover page identifies and references:
Type of inspection/assessment
Details of the work equipment or process
Participants
Results of inspection/assessment
Distribution List
14. Example 3, continued
• Part 2 – Instructions for the checklist
Scope
Use of the Checklist
Quantitative Risk Assessment
15. Example 3 - continued
Part 3 - The Checklist (section outline)
1. Documentation
2. Purpose of Work Equipment Use
3. Minimum Requirements (Directive)
4. Additional Requirements
Link to document
16. Example 3, continued
• Fourth Piece developed in house to track
changes to completion – Header:
https://youtu.be/Us32wyFi5Hg
Machine
Assessm
ent
tracking
spreadsh
eet
Exposure Probability Severity Risk Score Risk Measures
0.5 0.1 0.5 R < = 21 Assumed Acceptable Risk.
SITE NAME - YEAR 1 0.2 1 21 <R <=70 Possible Risk, requires attention.
2 0.5 2 70 <R <= 200
Important risks, improvement is required.
KPI Machine Review
3 1 7 200<R<= 400 High risk, immediate improvement.
6 3 15 R > 400 Very high risk, stop work.
10 6 40
10
Asset Tag
Number
Machine Description
initiated
Responsible owner
Date ready Status Exposure Probability Severity
Risk Score Remarks/proposed improvements
by when plan actual Mar-15 E P S
17. Ergonomics – Lifting, reaching…
You can use the NIOSH Lifting Guide and/or train
to specifics.
18. Choose wisely - Match your
methodology to scope
• Large process change? Gather the troops and
pre-plan.
• One mechanical machine move or, multiple
machines of various risk factors?
• Qualitative vs. Quantitative
20. Resources, Training & Communication
Do your homework, practice & plan ahead
Utilize cross functional teams to assess risks
Train Managers, Supervisors and line employees to conduct risk assessments
Broadly publicize all corrective actions
Some potentially helpful Links –
• EC directive 89/655/EEC (use of work equipment) http://eur-lex.europa.eu/legal-
content/EN/TXT/?uri=CELEX:52004DC0062
• https://osha.europa.eu/en/legislation/directives/3
• 29 CFR 1910.132(d) – OSHA assessment requirement for PPE determination
• http://www.sunycnse.com/libraries/contractor_documents/ehs-
00016_r10_new_equipment_process_change_management_procedu.sflb.ashx
Procedure example
• http://www.arenasolutions.com/resources/articles/manufacturing-change-
process/ - Tips for change process that works
Just to settle everyone in, this sessions topic is Hazard Assessments for New Process and Equipment Moves and there are 3 handouts each of you should have.
I am Brian Well, a CSP – With 20 years experience on EHS issues in manufacturing. In addition to a Bachelor of Science degree in Economics, I hold a post-Graduate Certificate in Safety from UW Whitewater.
I’ve been a Professional member of ASSE since 1997, served and held all elected positions at one time or another on the ASSE WI Chapter board.
Today, I’d like to share with you some practical knowledge I’ve attained through my experience managing EHS programs regarding New Process and Equipment Moves along with 3 assessment templates to share, specifically for new processes or equipment prior to commissioning.
The 3 main discussion point today are:
1 - Understanding your organization’s hazard assessment objectives, resources and means of communication.
2 - Reviewing some risk assessment templates
3 - Applying your chosen methodology to the scope of your work
To begin – before assessments, begin with Pre-Assessment / Pre-planning.
1 – Identify and Confirm your Objective. This means understanding the organization first. This will help identify scope. Who are the “players”? Who can support?
2 – Confirm your resources – Determine, gather and validate your team, explain the expected timeline, know the footprint you are dealing with and details: reserve conference rooms for follow up meetings. Talk with: Dept. Managers, Maintenance, Engineering, Safety and environmental Coordinators
3 – Get team trained on HAZ ID, chosen assessment tool methodology , clarify expectations. You must understand it first and allow time for this to become second nature.
4 – Communicate assessment objectives to all - not only to the team but to the organization - especially important during abnormal operations of change.
As you probably know, the main objectives of hazard assessment are to identify, prioritize and control exposures. However it is important to understand the context of hazard assessments from OSHA’s perspective. This revised list of core elements is one OSHA recently released.
Notice how the 3rd bullet seems to stand alone but, don’t misunderstand. Haz ID & Assessment ties into all of these.
You must tie these together to achieve, and sustain, systematic success.
Part of your job is to anticipate hazards.
Most often, an organization knows it’s hazards and is in a repetitive stage of re-training on the same issues. Knowing these hazards in advance can help you and others anticipate new hazards.
When equipment gets moved, new equipment comes in, a process changes or is newly introduced, it is critical to anticipate and identify these potential hazards, which, in turn, help you to conduct the assessment. The more you study your site, the better off you are.
Imagine……you have the scenario of consolidation efforts where 2 plants are closing and processes and equipment are moving into your main facility. Currently with 400 employees, employee count is going to expand by 25% and 50 new machines will be moved in. All in the same footprint.
This presentation covers examples of safety assessments that have allowed companies I have worked with under these circumstances to complete proper assessments prior to commissioning. Please refer to your handouts where we will review 3 practical assessment methods, in use today that cover
New Process & Equipment moves, Management of Change and Machine/Equipment assessment.
EtQ example – important to note this template happens to reflect one that is derived through ETQ….and DISCLAIMER - I am not endorsing any company or template version.
New Process and Equipment OUTLINE. To ease in workflow reference, hazards were segmented into these categorized groups. Refer to document.
Last but not least – a place to capture assignments and dates of escalation.
Let’s now look at Example #2. It
is a MOC Checklist which mainly involves Manual input whether on paper or inputted into the electronic document.
This simply provides a shared document for the paper trail.
Example categorizes assessment topics into groups.
Approach makes sense, standardizes the process, makes easier to follow. Tailor your topics to your site/situation.
Here, some OSHA standards called out - you could add in or take these out.
With tailored topics, review each of the sub-assessment issues to fit your organization.
Let’s look at some of these. REVIEW SOME SECTIONS.
Notice the punch list for notes – this is a working document
Just as in example #1, the last section of example #2 pulls together the cross-functional committee of managers/leaders as responsible parties, specifying dates and the project description.
Let’s look closely at Example 3# noting up front it’s specific to equipment (not) processes and comprises 3 main parts: Cover page, Instructions and Checklist.
This assessment also has a different approach than previous examples, offering quantitative risk scoring as well as qualitative questions,
The cover page identifies project details/descriptions, providing an overview, at a glance.
The cover calls out (review actual document with audience): points on the slide
Part #2 provides INSTRUCTIONS, introducing the user to the checklist with three sections: 1- Scope, 2 - Use of the Checklist and, 3 – Quantitative Risk Assessment. These instructions are a great reference. I recommend using in training the teams conducting assessments.
1 - The instruction refers to Scope as embracing the EC Directive as minimum requirements & introduces the qualitative assessment piece.
2 – How to USE THE CHECKLIST (RUN THROUGH THIS)
3 – How the RISK ASSESSMENT is carried out –the players and, importantly, how the quantitative method applies
This checklist is divided into 4 sections:
Documentation
Purpose of Work Equipment Use
Minimum Requirements, and
Additional Requirements
Section 3 is the “working end” of this example, particularly section 3.8 where it covers potential contact with moving parts – a good place to focus any equipment safety assessment.
LINK TO DOCUMENT AND RUN THROUGH IT WITH AUDIENCE
Tracking assessments in this Example involves manual input into a excel spreadsheet where it can be shared, reviewed, revised and archived.
Let’s watch a short video explaining general approaches to risk assessments. LINK TO YOUTUBE VIDEO.
SHOW TRACKING SPREADSHEET AND RUN THROUGH IT’S USE.
NO! We are NOT covering the NIOSH Lifting Guide here today.
As a side note of reference, you may have a narrow scope with some assessments, focused, say, on Ergonomics or chemical processing.
Just plan ahead to gather reference material for training assessment teams. The NIOSH Lifting Guide is an example. Chemical processing references would be SDS’s, labeling requirements, etc.. Any completed JSA’s relating to the assessment referring to particular PPE may be helpful
So, just like you train your employees – THINK BEFORE YOU ACT! This applies to you in this case!
THINK before you assess – spend time pre-planning.
1 - Know your organization and the scope of the assessment
2 - Identify and communicate the plan to your assessment team
3 - Understand your organization’s hazard assessment objectives, resources and means of communication.
4 - Become intimately familiar with your chosen risk assessment template so you can apply that chosen methodology to the scope of your work.
To review, you need to UNDERSTAND your organization’s scope - the mission, goal and objective – to make the best choice of framework you use. The more you know about the overall scope of work, the better. It will make life easier.
Your framework should be standardized but flexible to accommodate all sites. Think about whether your framework needs to be integrated with other areas (QA, EMS, etc.)
As much as possible, automate the process and be prepared to manage expectations.
Your 1st objective might be Identifying and training cross-functional teams. Or, it may be personally reviewing hazards.
Students – You wouldn’t take an exam without doing your homework.
Do your homework, practice & plan ahead
Utilize cross functional teams to assess risks
Train Managers, Supervisors and line employees to conduct risk assessments
Broadly publicize all corrective actions
Here are some links. I hope they are helpful.
Please email me if you'd like a copy of any materials discussed today including this presentation.
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