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K-Y call

IMPROVE THE SENSIVITY OF
DANGER FOR ACHIEVING ZERO
ACCIDENT

K Y - KIKEN YOCHI ( JAPANESE WORD)
KIKEN - DANGER
YOCHI - PREDICTION

K-Y call

  1. 1. K-Y CALL Prepared By Md Aminul Islam Reliability Engineer SADAF-SABIC.
  2. 2. PURPOSE TO IMPROVE THE SENSIVITY OF DANGER FOR ACHIEVING ZERO ACCIDENT
  3. 3. INTRODUCTION K Y - KIKEN YOCHI ( JAPANESE WORD) KIKEN - DANGER YOCHI - PREDICTION IN 1982 SUMIMOTO METAL PLANT AT JAPAN COMPLIED THIS SAFETY PLAN FOR THEIR WORKER IN EACH WORK PLACES THROUGH PDCA CYCLE
  4. 4. DEFINATION KIKEN YOCHI -- IT IS A PROCEDURE FOR ON-THE-SPOT RISK ASSESSMENT IN WORK PLACE. THE GROUP OF WORKER FOR EACH WORK WILL DISCUSS AMONG THEMSELVES ABOUT THE HAZARD AND RISK AND PLANNED FOR COUNTERMEASURE & ACTION PLAN BEFORE START ANY WORK.
  5. 5. HOW TO IMPLEMENT a) IDENTIFY THE POTENTIAL RISK AT THE WORK SPOT WITH ALL THE WORKER. b) SELECT THE HAZARD / RISK PRIORITY WISE ACCORDING TO SERIOUSNESS. c) PROPOSED COUNTERMEASURE PLAN d) ACTION TAKEN. WHY TO IMPLEMENT TO ELIMINATE THE RISK & UNSAFE ACT. WHEN TO IMPLEMENT EVERYDAY BEFORE START OF ANY WORK.
  6. 6. WORK FLOW DIAGRAM WORK PLAN WPS ISSUE JSA & SOP BRIEFING AMONG THE WORKER GATHER AT WORK PLACE KY DISCUSSION AT SITE RECORDED IN TOOLBOX MEETING &SAFETY MEASURE TAKEN JOB EXCUTED 5-S COMPLETED WPS HAND OVER
  7. 7. VARIOUS STEPS FOR SAFETY AT WORK PLACE a)TOOL BOX MEETING. b) SOP - STANDARD OPERATION PROCEDURE. c) SAFETY NOTICE. d) HATTO HIARI . e) KY. f) JSA -JOB SAFETY ANALYSIS.
  8. 8. RELATION WITH K-Y AND OTHER SEFETY PROCEDURE 1. TOOL BOX MEETING.- AFTER K-Y, ALL THE SAFETY MEASURE/PPE TO BE SELECT IN THE TOOL BOX MEETING. 2.SOP- IT DESCRIBE THE STEPS TO BE FOLLOWED & TO BE CONSIDER BEFORE K-Y. 3. SAFETY NOTICE- IT IS A GENERAL INFORMATION FOR EQUIPMENT,ENVIRONMENT FOR THAT PARTICULAR AREA & WHICH TO BE CONSIDER WITH K-Y. 4. JSA- IT BRIEFING THE SAFETY STEPS TO BE FOLLOWED AS PER SOP & WHICH TO BE INCLUDED IN K-Y FINDINGS.
  9. 9. GUIDE LINE FOR K-Y ANALYSIS 1. TECHNICALLY.- a) WORKIBILITY. b) HEALTH HAZARD. c) ACCIDENT PROBABILITY. 2. HARMFULL SUBSTANCE.-a) ORGANIC SOLVENTS. b) DUST. c) RADIATION. d) GASES. 3. WORKING ENVIRONMENT.- a)VENTILATION. b) NOISE. c) TEMPERATUR. d) POSTURE. 4. WORKING DISPLAY.- a) HOT JOB. b) CONFINED SPACE WORK. c) FRAGILE ROOF.
  10. 10. DESCRIPTION FOR RISK ANALYSIS ON FINDINGS. 1. WORKIBILITY/ ACCIDENT PROBABILITY -- OPERATIONALAREA/ ROATATING EQUIPMENT / WORKING AT HEIGHT. 2. HEALTH HAZARD-- FALL/BURN/ELECTRIC SHOCK/ GAS POISENED. 3. ORGANIC SOLVENT / DUST / NOISE / GASE / RADIATION TEMPERATURE-- EFFECT ON HUMAN BODY. 4. HOT JOB.-- FIRE 5.POSTURE -- DIFFICULT TO WORK 6. CONFINED SPACE JOB / VENTILATION -- OXYGEN DEFFICIENCY. 7. FRAGILE ROOF -- BREAK / FALL
  11. 11. BENEFITS OF K-Y 1. EVERY DAY PRACTICE FOR EACH WORK. 2. ON THE SPOT ACTIVITES GATHER DETAILS KNOWLEDGE OF PROBLEM. 3. PARTICIPATION & INVOLVMENT OF ALL WORKER. 4. AVOIDING UNSAFE ACT. 5. ON THE SPOT COUNTERMEASURE WILL PREVENT CHANCES OF ACCIDENT. 6. SELF DEVELOPMENT & DISIPLINE AT WORK PLACE.
  12. 12. K-Y CALL MAIN / TOP PRIORITY ACTION PLAN AS PER K-Y FINDINGS FOR A PARTICULAR JOB TO BE CONSIDER AS A K-Y CALL FOR THAT PARTICULAR WORK. A COMMON K-Y CALLALSO MAY BE CONSIDER FOR DEPARTMENT WISE AS PER PREVIOUS EXPERIENCE / AS PER GENERAL WORK ACTIVITY. IT CAN BE WEEKLY / MONTHLY / YEARLY AND TO BE CALL / TAKING AS A OATH BEFORE START THE DAILY ACTIVITY.
  13. 13. MECHANICAL K-Y CALL ………...EXAMPLE……………. MONDAY-CONFIRM SAFETY TREATMENT BEFORE EXECUTE ANY JOB AT SITE. TUESDAY- ALWASYS USE TESTED TOOLS & TACLES IN EXECUSION OF JOB. WEDNESSDAY- DO NOT SHORT CUT IN OVERHAULING JOB. THRUSDAY- ALWAYS USE SOP & JSA IN REGISTERED RISK JOB. FRIDAY-DO NOT MOVE UNDER LOAD LIFTING AREA. SATURDAY- ALWAYS USE PROPER PPE. SUNDAY-DON’T HIDE ANY MISTAKE.
  14. 14. MECHANICAL K-Y CALL ………...FOR-2008……………. MONDAY-USE FLASHBACK ARRESTER IN GAS CUTTING SET. TUESDAY- CONFIRM UNDERGROUND CABLE & PIPE BEFORE EXCAVATION. WEDNESSDAY- DON’T THROW ANY OBJECT FROM HEIGHT. THRUSDAY- DON’T WORK ON AUTO START MACHINE FRIDAY-USE FULL BODY HARNESS FOR HEIGHT JOB. SATURDAY- USE OF MASK IS COMPULSORY IN DUST GENERATING JOB. SUNDAY- DON’T USE LOOSE UNIFORM AT MACHINE SHOP AREA.
  15. 15. K-Y TRAINING EXAMPLES & ANALYSIS FOR SELF IMPROVEMENT. EXAMPLE-2 CONDITION - A PERSON IS SETTING SLEEPER & SIGNALING TO CRANE. UNSAFE FINDINGS.- 1. HEAVY LOAD MAY FALL ON HIS HAND DUE TO SIGNALING & PLACING SLEEPER AT A SAME TIME & DIRECTION. 2. WHILE GETTING BACK, THE BACK SIDE SLEEPER MAY HIT HIS LEG & GETTING INJURED. CORRECTIVE MEASURES. 1. PLACING & SIGNALING SHOULD NOT BE AT A TIME. 2. SAME PERSON SHOULD NOT DO PLACING & SIGNALING. K-Y CALL - DO NOT WORK UNDER LOADING CRANE.
  16. 16. K-Y TRAINING EXAMPLES& ANALYSIS FOR SELF IMPROVEMENT. EXAMPLE-3 CONDITION-A PERSON IS DOING PAINTING IN UNDERGROUND TANK UNSAFE FINDINGS-- 1. RESCUE FACILITY NOT AVAILABLE SUCH AS SEFETY BELT,LADDER WITH THE MAN. 2. VOC PREVENTION FACILITY SUCH AS AIR LINE MASK, VENTILATOR NOT PRESENT. 3. PAINTING CONTAINER MAY DROP AS IT NEAR BY OPENING. CORRECTIVE MEASURE-- 1. CONFINED SPACE PAINTING PROCEDURE TO BE FOLLOWED . 2.SPOTTER SHOULD PRESENT. 3.NO MATERIAL KEEP NEAR OPENING. K-Y CALL- FOLLOW CONFINED SPACE PAINTING PROCEDURE.
  17. 17. K-Y TRAINING EXAMPLES & ANALYSIS FOR SELF IMPROVEMENT. EXAMPLE-4 CONDITION- GRINDING WORK IN TABLE GRINDING MACHINE UNSAFE FINDINGS- 1.PPE NOT USE SUCH AS HAND GLOVES,GOGGLES, MASK. 2. WHEEL COVER NOT FOUND IN GRINDING MACHINE. 3. MANY MATERIALS LAYING ON WORKING TABLE WHICH MAY FALL ON LEG. CORRECTIVE MEASURE- 1. PPE SHOULD BE USED IN GRIDING MACHINE WORK. 2. GRINDING WHEEL COVER TO BE FIXED FOR PROTECTION OF SPARK & BROKEN PIECE. 3. WORKING TABLE SHOULD BE KEPT CLEANED. K-Y CALL- PROPER PPE TO BE USED IN MACHINE WORK.
  18. 18. K-Y TRAINING PHOTOGRAPHS & ANALYSIS FOR SELF IMPROVEMENT. CASE-1 CONDITION - UNDER GROUND EXCAVATION IN PLANT AREA. UNSAFE FINDINGS- 1. UNDER GROUND CABLE & PIPE EXISTS IN EXCAVATION AREA. 2.NO BARRICADING / NOTICE ARROUND EXCAVATION AREA. 3.GUMBOOT NOT USED IN SLUSH EXCAVATION AREA. CORRECTIVE MEASURES- 1. NOTICE BOARD FOR UNDERGROUND PIPE & CABLE TO BE DISPLAY BEFORE STARTING THE EXCAVATION. 2. BARRICATION TO BE DONE. 4. TEMPORARY SUPPORT / COVER TO BE PROVIDED FOR PIPE / CABLE. K-Y CALL- CONFIRM UNDERGROUND FACILITIES LAYOUT BEFORE WORK.
  19. 19. K-Y TRAINING PHOTOGRAPHS & ANALYSIS FOR SELF IMPROVEMENT. CASE-2 CONDITION- PAINTING WORK IN PLANT AREA UNSAFE FINDINGS.- 1. NO SCAFFOLDING, PAINETR IS DOING PAINT IN HANGING POSITION. 2. SAFETY BELT NOT USED THOUGH HE WEAR FULL BODY HARNESS. CORRECTIVE MEASURES. 1. SCAFFOLDING FOR HEIGHT JOB SHOULD BE DONE AS MCPI STANDARD. 2. PROPER PPE & THEIR USE TO BE MAINTAINED. 3. PAINT COTAINER TO BE KEPT NEAR BY SO THAT HANDLING WILL BE EASY & PAINT DROPS WILL BE MINIMUM. K-Y CALL - USE SCAFFOLDING FOR HEIGHT JOB
  20. 20. K-Y TRAINING PHOTOGRAPHS & ANALYSIS FOR SELF IMPROVEMENT. CASE-3 CONDITION- PAINTING WORK NEAR ROATATING MACHINE. UNSAFE FINDINGS.- 1. THE PAINTER IS RESTING HAND ON ROATATING SHAFT COVER WHICH MAY SLIP & CAUSED TO TOUCH ON SHAFT AND ACCIDENT MAY HAPPEN. 2. PAINT DROPS MAY FALL ON ROATATING PARTS & CAUSED DAMAGED OR MAY CAUSED FIRE DUE TO HEAT OF FLAMMABLE MATERIAL. CORRECTIVE MEASURES .-- 1. NO PAINT , NO TOUCH ON ROATATING MACHINES PART. 2. CARE SHOULD BE TAKEN ON AUTO START MACHINE ALSO. K-Y CALL - NO PAINT NO TOUCH ON ROATATING EQUIPMENT.
  21. 21. K-Y TRAINING PHOTOGRAPHS & ANALYSIS FOR SELF IMPROVEMENT. CASE-4 CONDITION- A PERSON IS DOING SCAFFOLDING FOR COMPRESSOR DUCT . UNSAFE FINDINGS. 1. SCAFFOLDING STANDARD NOT MAINTAIN,LONG HORIZINTAL PIPE BEND & ANY TIME IT WILL FALL. 2. PLATFORM JALLI FIXED WITH COIRSTRING, WHICH MAY CUT AND FALL ANY TIME. 3. HAND RAIL / GUARD PIPE NOT AVAILABLE. CORRECTIVE MEASURES-- 1. SCAFFOLDING TO BE MADE AS PER MCPI STANDARD. 2. MINIMUM 2 PERSON REQUIRED FOR HANDLING THE HEAVE TYPE PLTFORM JALLI. K-Y CALL - SCAFFOLDING STANDARD TO BE MAINTAIN.
  22. 22. K-Y CALLAT SITE BY CONTRACTOR EMPLOYEE
  23. 23. K- Y CALLAT SITE BY MECHANICAL MEMBER
  24. 24. CONCLUSION FIND OUT THE PROBLEM IN EACH OF OUR DAILY ACTIVITY TO APPLY THE PREVENTION ACTION THROUGH TBM / JSA / K-Y FOR MINIMISE THE HAZARD / RISK / ACCIDENT & ALSO CONTINUAL MONITORING FOR IMPOROVEMENT OF OURSELVES & OUR SUPPORTING CONTRACTOR.

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