New Process and Equipment Hazard Assessment - examples of framework

Southeastern Wisconsin Safety Conference – UW WhitewaterOctober 27, 2016

Hazard Assessments - Frameworks for New Process and Equipment Move Evaluations

Brian Well, [email protected]

Today’s Overview and Context

Understanding your Hazard Assessment Objective(s) Resources Method of communications• Review some Risk Assessment templates • Apply methodology to scope

Upfront – before assessments begin

Four things to do before you start assessment

1 – Identify and confirm your Objective2 - Confirm your resources (people/time/space)3 - Plan training (who/how/when/where)4 – Plan to widely communicate objectives

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

Groups of Hazards

Change happens!

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, 2016Post Assessment Date : schedule at conclusion of initial assesment

Example 1, Grouped Hazard Elements

1.0 General Machine Guarding 2.0 Life Safety3.0 Material Handling4.0 Industrial Hygiene5.0 Chemical Safety6.0 Documentation, Signs and Labels7.0 General Guidelines8.0 Regulatory Review9.0 Electrical Safety

Example 1, Notes and References

Example 2 – manual referencing

Management of Change Checklist Management of Change Checklist

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- 1910.1554. Industrial Hygiene

5. Process Safety6. Job safety Analysis7. Training8. Ergonomics9. Pre-startup preparation (sub checklist)10. Slip, Trip & Fall Hazards11. Environmental

Notice the punch list for notes – this is a working document

Example 2 - continued

Management of Change AuthorizationInitial Inspection   Additional Inspection   Final Review  

 Date: Building: Project Description:

Inspection Committee:1. Project Leader/Sponsor:        Print Signature Date2. Area Manager/Equipment User:        Print Signature Date3. QA Manager:        Print Signature Date4. EH&S Manager or Safety Rep:        Print Signature Date5. Vendor:      

  Print Signature DateComment:

Example 3 – Three Part Equipment Inspection/Assessment

Part 1 - Cover page identifies and references:Type of inspection/assessmentDetails of the work equipment or processParticipantsResults of inspection/assessmentDistribution List

Example 3, continued

• Part 2 – Instructions for the checklist

ScopeUse of the ChecklistQuantitative Risk Assessment

Example 3 - continued

Part 3 - The Checklist (section outline)1. Documentation2. Purpose of Work Equipment Use3. Minimum Requirements (Directive)4. Additional Requirements

Link to document

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 <= 200Important risks, improvement is required.

KPI Machine Review3 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 improvementsby when plan actual Mar-15 E P S

Ergonomics – Lifting, reaching…You can use the NIOSH Lifting Guide and/or train to specifics.

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

Mission/Goal/Objective

UNDERSTAND your organization’s scope - the mission, goal and objective.

Automate the process and manage expectations

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_equip

ment_process_change_management_procedu.sflb.ashx Procedure example

• http://www.arenasolutions.com/resources/articles/manufacturing-change-process/ - Tips for change process that works

THANK YOU!Brian Well, CSP [email protected]