Presenter: Byron Beattie Corporate EHS Compliance Manager Curtiss Wright Surface Technology Phone:

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Samson Doyle
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1 Presenter: Byron Beattie Corporate EHS Compliance Manager Curtiss Wright Surface Technology Phone:

2 Risk assessment defined 5 Steps in quality risk assessment #1 Defining your risk assessment team (your safety committee!) #2 Prioritizing which activities, events or jobs will be assessed #3 Review the process Task Review Hazard Identification Current Controls (or Non Controls) in Place #4 Developing the risk review Risk gap analysis Determining what is acceptable risk Document results Establishing corrective actions #5 Maintain your risk assessment program Selling your corrective actions to your management team Training Post Accident Review Risk Assessment Program Maintenance

3 77 facilities worldwide 77 EHS multi tasked facility contacts EHS secondary job Safety committees at each facility Risk assessments required For all primary operations (manufacturing, R&D, testing) Machine task specific Area specific (shipping/receiving, chemical sampling, etc.) Required to be reviewed and or updated Annually If a recordable injury or significannt near miss occurred Requirement reviewed within 30 days of event by safety committee initiated sharing of risk assessment across divisions

A Risk Assessment is a systematic method of looking at work activities, considering what could go wrong, and deciding on suitable control measures to prevent Injuries and fatalities damage loss The

Great tool to utilize as part of Accident Investigations injury reduction A tool to analyze jobs/procedures Define job steps Identify hazards to reduce/eliminate them Identify safe practices -

4 A Risk Assessment is a systematic method of looking at work activities, considering what could go wrong, and deciding on suitable control measures to prevent Injuries and fatalities damage loss The assessment should include the controls required to eliminate, reduce or minimize the risks. Great tool to utilize as part of Accident Investigations injury reduction A tool to analyze jobs/procedures Define job steps Identify hazards to reduce/eliminate them Identify safe practices - supervisor evaluation tool Evaluate process design/equipment layout - When work processes are changed or modified Training tool (new hires/review) consistency in training Transitional work/job description Help profitability Maintained by your facility s staff - integrate into your existing processers - QMS?? Risk Assessment defined as practices for identifying and controlling hazards in the workplace to prevent accidents and injuries

Fundamental requirement for doing businesses. MIOSHA OSHA required (examples)direct and indirect: PPE Utilization (Part33, 1910. 132) Respirators Part 451, 1910. 134) Confined Spaces (Part 490, 1910.

5 Fundamental requirement for doing businesses. MIOSHA OSHA required (examples)direct and indirect: PPE Utilization (Part33, ) Respirators Part 451, ) Confined Spaces (Part 490, ) Process Safety Management (Part 91, ) Abrasive Blasting (Part 523R (Ventilation)) Hazard Communication (GH MSDS development) ( ) *** Know, or appreciate where the risks are, you are putting yourself, your employees, your customers and your organization in danger. Review all work activities that could cause harm in order to decide whether they are doing enough to meet our Legal obligations, Employee safety Continuity of operations Protection of our assets Reduce risk as 'reasonably practicable'. 'Reasonably practicable' is a legal term that means employers must balance the cost of steps that they could take to reduce a risk against the degree of risk presented. When reckoning costs, the time, trouble and effort required should be included and not just the financial cost. In Summary - Risk Assessment s will: Identify existing hazards and potential hazards Prioritize corrective actions improve conditions, revise the risk assessment, job conditions change Reduce and/or eliminate hazards protects employees Increases personnel awareness of hazards and results improves morale Comply with a recognized industry standard or corporate policy Introduce good practice

6 MIOSHA / OSHA hazard based By country regulation EUOSHA (European Agency for Safety and Health at Work) UK required (HSE) Germany France Spain Italy Sweden Austria Belgium Ireland

At CWST, we utilize safety committees State required hazard identification training (not MIOSHA) VPP CalOSH, Oregon, Alaska, 4 other states Knowledge of tasks involved Team synergy Eyes and ears of

7 At CWST, we utilize safety committees State required hazard identification training (not MIOSHA) VPP CalOSH, Oregon, Alaska, 4 other states Knowledge of tasks involved Team synergy Eyes and ears of balance of workforce Reasons for involving employees: Familiarity Identify hazards not observable Avoids alienation Gains buy-in for necessary changes Typical members: Safety manager or EHS coordinator Safety team members Employees Supervisors Human Resources Engineering

8 High accident frequency Severe injury or high loss Potential to cause severe injury or high loss (near misses, close calls) New jobs without accident history (new equipment/procedures, changes from modifications on new/old equipment) Identified violations of MIOSHA standards Complex enough to require written instructions.

9 Complete a process map (tell a story!!!) Identify all sub tasks Include startup and shutdown activities Include housekeeping activities Sub task analysis Identify all physical parameters, such as Temperatures Pressures Line Speed Hazards at each subtask Ph of solutions Add pictures of each sub task Discuss process with employees performing the job and explain purpose Involve employee in all phases after job selection Higher success rates More effective risk assessment results MIS HIT: Don t break the job down into steps so small as to be meaningless or too broad that something is missed.

10 1. Directly observe the job task, to evaluate each step and understand the hazards involved. 2. Ask questions of the operators and draw upon their knowledge of established procedures, problems, and difficult areas 3. THEN get safety committee members together and who have knowledge of the job and discuss. 1. Tools to use 1. Video camera 2. Digital Camera 3. Tape recorder / tape measurer 4. Light meter 5. Voltmeter (amps, volts, mhos) 6. Noise dosimeter 7. Notebook Identifying Hazards Interviewing Techniques 1. Conduct interview near work area 2. Explain only looking for facts 3. Ask open ended questions 4. Ask employee to write down job steps 5. Thank person for helping 1. Recorded steps must be examined to determine hazards that exist or might occur. 2. Identification of hazards should include the hazards associated with: machines, tools, supplies, job procedures, and the surroundings

11 What can go wrong? What are the consequences? How could it happen? What are other contributing factors? How likely is it that the hazard will occur?

12 1. Select job for analysis 1. Break the job down into steps 2. Identify hazards and unsafe behaviors 1. Observe the job from start to finish several times 2. Separate the job into distinctive steps 3. Sequentially list the actions needed to complete every step of the job 1. Is there an identifiable hazard with this step? 2. Is there an exposure to this hazard to the employee(s) or the environment? 3. Any exposure shown from previous accidents, injuries or near misses 4. Is there a potential of an accident? 5. Review your sources (SDS, employee interviews, SOPs, equipment manuals, PM records 3. Identify the current control in place that assists in reducing or eliminating the hazard from injuring the employee in preparation of eliminating or correct the hazard and reducing the risk List the current control that is place to protect the employee 1. Engineering control (guard, physical barrier, etc. 2. Administrative control (procedure) 3. PPE 4. Combination of the above

Unsafe conditions are those things in the physical environment that could ca use injury or illness

machinery and environments that could cause physical harm Unsafe acts are work habits, activities,

13 Unsafe conditions are those things in the physical environment that could ca use injury or illness including: faulty equipment dangerous materials improperly maintained tools poorly designed machinery and environments that could cause physical harm Unsafe acts are work habits, activities, and/or processes or procedures that i n and of themselves put an employee at risk of injury or illness. Left unchecked, these practices can turn an otherwise safe workplace into one in which accidents occur. Unsafe procedures are either not fully defined to provide a safe administrativ e (procedure) in place

Hazard Identifications STARTS WITH Hazard Recognition As a result of Hazard Recognition, employees will be able

risk behaviors as primary causes of accidents and injuries Distinguish between personal responsibility and company

for themselves and others Discover an effective technology for accident and injury prevention Reduce stress Learn

14 Hazard Identifications STARTS WITH Hazard Recognition As a result of Hazard Recognition, employees will be able to: Minimize the number and severity of accidents and injuries on and off the job Understand the role of personal risk behaviors as primary causes of accidents and injuries Distinguish between personal responsibility and company responsibility Be responsible and accountable for the safety of themselves and others Increase safety awareness for themselves and others Discover an effective technology for accident and injury prevention Reduce stress Learn the skills to manage others for appropriate safety behavior Bring forth their personal commitment to everyone s safety

Chemical Hazards - Routes of entry (inhalation, skin absorption,

or sensitizers Physical Properties, such as Flammable or combustible

Asphyxiates (prevents the body from using the oxygen Corrosive (acids

15 Chemical Hazards - Routes of entry (inhalation, skin absorption, ingestion, puncture wound (injection) and ocular (eye) Irritants and or sensitizers Physical Properties, such as Flammable or combustible characteristics Ability to violently mix with air or other chemicals Asphyxiates (prevents the body from using the oxygen Corrosive (acids or bases) Reactive This should be highlighted (emphasized) when reviewing the SDS

16 Physical hazards Electrical Extreme temperatures (i.e. boilers, furnaces, liquid nitrogen) Entanglement Entrapment Flammables/combustibles High pressure systems Compressed air Impact tools, powered industrial vehicles (PITs, forklifts) Noise Vibration

Ergonomics Employees posture during operation

pulling) Frequent or heavy lifting Work cell or

areas Location of machine Location of tools

17 Ergonomics Employees posture during operation Repetitive motion Significant force (pushing or pulling) Frequent or heavy lifting Work cell or plant design Travel pathways Location of staging areas Location of machine Location of tools Balance Leverage Coordination Range of motion Strength with Control

18 Setup Housekeeping Cleaning Transfer processes Coatings Material handling From storage or shipping / receiving In process Away from the job Maintenance Lockout tagout Equipment prepping Packaging Differences between operators Differences between shifts Differences between facilities

19 Questions to answer during the safety process map development What is the source of the hazards? What PPE is available? Has worker been adequately trained? Is the worker positioned properly? Is lockout/tag out being used? What are the sources of chemicals, noise, etc.?

Task: Unwrap parts from customer and place part in fixture Task Hazard: sharper edges (lacerations) Control Measure in Place: Check condition of

screw or place on holding rod in machine Task: Shut down and energize machine Task Hazard: Control Measure in Place: Ensure all operations are OK

air pressure nozzle Task: Review quality of part Task Hazard: handling part possible sharp points (laceration) Control Measure in Place: use gloves

21 Task: Unwrap parts from customer and place part in fixture Task Hazard: sharper edges (lacerations) Control Measure in Place: Check condition of parts prior to job, use gloves if needed Task: Place part fixture in machine Task Hazard: Torqueing (hand sprain) Control Measure in Place: evenly screw or place on holding rod in machine Task: Shut down and energize machine Task Hazard: Control Measure in Place: Ensure all operations are OK before startup Task: Remove Part machine, blow off part with residual shot Task Hazard: air force (contusion) Control Measure in Place: Use reduce air pressure nozzle Task: Review quality of part Task Hazard: handling part possible sharp points (laceration) Control Measure in Place: use gloves as needed Task: Place part in customer provided transport box Task Hazard: splinters from box (lac) Control Measure in Place: Ensure box has no contact hazards

22 Elimination Substitution Engineering Controls Engineer the hazard out of the job Administrative Controls Alter the sequence or process to eliminate or reduce the hazard PPE When exposure to hazards cannot be removed or reduced to an acceptable level by Engineering or Administrative controls

1. Identify and document all sub tasks and the hazards at each sub task 1. Safety Process map 2. For each identified hazard, identify/document who might be harmed and how? 3.

Risk involved if the hazard happened 4. For each hazard identified, complete the current hazard controls (or none) for each hazard identified 5.

23 1. Identify and document all sub tasks and the hazards at each sub task 1. Safety Process map 2. For each identified hazard, identify/document who might be harmed and how? 3. As a team, identify the following for each hazard identified using a risk assessment summary: 1. Probability of the hazard happening 2. Severity if the hazard happened 3. Risk involved if the hazard happened 4. For each hazard identified, complete the current hazard controls (or none) for each hazard identified 5. If the hazard is not minimized, or the team feels additional controls (engineering, administrative or PPE) need to be in place to reduce the risk, identify in the Additional Actions Identified column next steps 1. Please note that if the team does not have the next level identified, then investigate additional engineering controls as part of the action steps is acceptable 2. Identify viable due date 3. Identify what the risk level will be after the action item is completed

24 Can a non-hazardous process be substituted for a hazardous process? Spray Painting Dipping or Brushing

25 Can a hazardous work area layout be improved? Engineering revisions? Hot Work Stacked Electrical Boxes Main Work Area Chemical Storage Pipe Storage Tool Room

26 Chemical storage area was moved away from hot work and electrical hazards. Hot Work Electrical Stacked Boxes Main Work Area Tool Room Pipe Storage Chemical Storage

27 Can a non-hazardous product be substituted for a hazardous product? Pesticides Solder Cleaning agents Solvents

28 Can you reduce the frequency of performing the hazardous task? Job Redesign? Procedure Revision?

29 Can employees be rotated to reduce exposure time?

30 Can employees be trained to recognize hazards and employ safe work practices?

31 If the hazard cannot be eliminated or reduced to an acceptable level, the employee must be protected from exposure. This protection requires that the employee wear and/or use appropriate personal protective equipment. Hard hats Eye protection Face protection Respiratory protection Hearing protection Body wear Sleeves Gloves Protective footwear

RISK REDUCTION Safer way to do the job Describe each step that has an identified hazard and what either the control is or what the

controls, are the first choice because they can eliminate the hazard, such as machine guards, improved lighting, better ventilation

possible, such as rotating jobs, changing the steps, training Changes in personal protective equipment When engineering and

32 RISK REDUCTION Safer way to do the job Describe each step that has an identified hazard and what either the control is or what the action item is Be specific don t use generalizations like Be Careful Changes in equipment Equipment changes, or engineering controls, are the first choice because they can eliminate the hazard, such as machine guards, improved lighting, better ventilation Changes in work processes Administrative controls, or changes in how the task is done, can be used if engineering controls aren t possible, such as rotating jobs, changing the steps, training Changes in personal protective equipment When engineering and administrative controls aren t possible or don t adequately protect the workers, use personal protective equipment, such as gloves, hearing protection

34 Identifying acceptable risk

35 Accountability for carrying out actions should be clearly assigned understood initialed by the respective person indicating their personal commitment and accountability for that action. Important! to assure that all members of the work team understand the actions that must be put in place to assure safety protect the environment while the job is performed assures personal accountability allows everyone to be clear who will implement the action

36 Use pictures! Review each step to see if the job efficiency can be improved without compromising safety Have your plant manager review and/or approve the completed risk assessment Ensure each job step has a corresponding potential hazard and a engineering control and/or safe procedure and/or PPE Keep the Risk Assessments completed accessible for all employees at anytime On floor next to SDS /MSDS accessible to all employees Management of Change (Critical!!!) When an accident or injury occurs When the job changes After a close call (near miss) Following an employee complaint If equipment suffers damage Per a scheduled review (soon be annually, also aligns with existing lockout tag out review, and PPE certification processes)

37 Correct the unsafe conditions and processes. Train all employees who do the job on the changes Make sure they understand the changes

plan Add action plan to your safety committee meeting minutes until closed

38 Telling a story Be descriptive, remember you are providing a tool for New hires Fellow employees Hazard identification and control Itemize your action plan Add action plan to your safety committee meeting minutes until closed Update your risk assessment when the action items are completed Congratulate your team!

39 Align with existing systems integrate QMS / EMS LEAN 6 Sigma problem solving methods Tie to safety vision statement.. Reduce or eliminate risk Safety of employees, continuity of operations protection of assets Input into safety policy statement "a thing is safe if its risks are judged to be acceptable. Lowe 1976 Establish a path!!! Develop the methodology Train your safety committee on the methodology front line employees Provide tools Conduct baseline risk assessments Establish a schedule review annually / new processes / injuries / new hazards Monitor Ensure action items within safety committee meeting minutes Employees reviewing? Reduce First aid cases? New injuries? Use as part of Management of change for new processes or changed processes Accident investigation process

PROGRAM OVERVIEW JOB HAZARD ANALYSIS (JHA) SAFETY PROGRAM REGULATORY STANDARD: 29 CFR

PROGRAM OVERVIEW JOB HAZARD ANALYSIS (JHA) SAFETY PROGRAM REGULATORY STANDARD: 29 CFR 1910.132-138. INTRODUCTION: Injuries in the workplace often occur because employees are not adequately trained in the