Occupational Health and Safety in Manufactoring

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Implementing and Improving
Occupational Health and Safety in
Manufacturing
Gianandrea Gino
g.gino@sirt.it
www.sirt.it
Chemical Engineer – EHS consultant
Certified Occupational Hygienist
Certified Forensic engineer
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.
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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
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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
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Prevention: all the steps or measures taken or
planned at all stages of work in the undertaking to
prevent or reduce occupational risks
MITIGATIONHAZARD
RISK
f (F ; M)
EFFECTS
Emergency plans
first aid,
fire-fighting
& evacuation
MAGNITUDO
FREQUENCY ( likelihood of occurrence of a hazard)
PREVENTIVE ACTIONS
PROTECTIVE
MEASURES
A graphical representation (Bow tie)
RiskCause/
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
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t
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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
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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 ?
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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
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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
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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
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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
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Hazards classification
4 Main Kinds
(often inter-linked) Physical Hazards
Chemical Hazards
Biological hazards
Psychosocial hazards
FORK LIFTING ?
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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
LIKEHOOD
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
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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!
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Mail to g.gino@sirt.it
Milan - Italy
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