Transcript SAFETY AUDIT

SAFETY AUDIT A KEY
HAZARD IDENTIFICATION
TECHNIQUE
A presentation by
Subbarao
•Cholamandalam AXA Risk Services
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What is Safety Audit
Verifying the existence and implementation of
elements of occupational safety and health
system and for verifying the system’s ability to
achieve defined safety objectives
~~~IS-14489-1998
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CONCERNS OF MANAGEMENT
• QUANTITY PRODUCED IN RELATION TO
PRODUCTION SCHEDULE AND MARKET
REQUIREMENT
• PRODUCT QUALITY
• PRODUCTION COSTS
• INTEGRATING THE STAKEHOLDERS
CONCERNS
•Is Safety Important? Not always
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SAFE AND SOUND
• A study of top companies in the world indicated
that
‘Safety and Loss Prevention
Programmes were essential for a
company’s prosperity and accepted as
part of good Business'.
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Why do organizations have to bother
about Safety
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Corporate Strategy
Finance
Human Resources
Marketing, Product Design and Product Liability
Manufacturing and operating policy
Information Management and systems
Societal Concerns
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Societal Concerns
• Increased concern about the impact on the public
not just the workforce concerned
• Public intolerance of risks which do not have clear
benefits to those affected
• Readiness to press for retribution on those who
cause harm and to seek compensation
• Demand for increased transparency
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• Demand for full information and for public
involvement
• A willingness to challenge and complain
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Corporate Strategy
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Business Mission, Philosophy and codes of ethics
Company image in the community
Environment impact
Management Professionalism
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Finance
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Loss Control and cost reduction strategies
Product liability, Legal liability, Property damage
Risk retention or transfer
Investment decisions concerning business
acquisitions
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Human Resources
• Work and job structuring
• Morale and retaining people
• Positive health structure
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Marketing, product design and product
liability
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Specification of product and service
Legal requirement
International requirement
Consumer protection act
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Manufacturing and operating policy
• Design/selection/construction/maintenance of
premises, plant, equipment and substances
• Quality management
• Environment management and waste disposal
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Information management and systems
• Identification of data critical to the management of
health and safety
• Selection of appropriate performance indicators
• Use of information technology in the collection
and analysis of essential data.
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Organizations carry out
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Safety Audit
Safety Survey
Safety Inspection
Safety Tour
Safety Sampling
HAZOP
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• Safety Survey: Detailed examination of a narrower
field of activity-e.g.- key areas revealed by safety
audits
• Safety Inspection: Routine inspection-work is
being carried in accordance with procedures etc.
• Safety Tour: Unscheduled examination-hazards
are removed-standards are removed
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• Safety Sampling: Trained observers record the
number of safety defects seen while touring
specified locations by a prescribed route.
Typically tours last for 15 min. and are conducted
at weekly intervals. The unweighted count of
defects is used to portray trends in the safety
situation.
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SAFETY AUDIT
MONITORING
• COMPARE ACTUAL
PERFORMANCE STANDARDS
• COMPREHENSIVE
• CONTINUOS
AUDIT
• NOT DONE BY
INSIDER
• NOT
COMPREHENSIVEDEPENDS ON SCOPE
• PERIODIC
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DIFFERENT TYPES OF AUDIT
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Electrical Audit
Fire Safety Audit
Pressure vessels Audit
Lifting Tackles Audit
Statutory Regulations Compliance Audit
Emergency Communication Audit
Pipe lines Audit
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Safety Depends on
•Work permit
•Accident and
incident
analysis
•Engineering
•Emergency
•Procurement
Hardware
Software
Humanware
•Leadership
•PPE
•Health and
Hygiene
•Task
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observation
SAFETY AUDIT
• OCCUPIERS ARE REQUIRED TO
DEMONSTRATE THEIR CAPABILITY TO
DESIGN LOCATE OPERATE AND MAINTAIN
THEIR FACILITIES TO STANDARDS
ACCEPTABLE TO THE GOVT. AND PUBLIC.
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AUDIT
• AN AUDIT IS A SYSTEMATIC
INDEPENDENT REVIEW TO VERIFY
CONFORMANCE WITH ESTABLISHED
GUIDE LINES OR STANDARDS. IT
EMPLOYS WELL DEFINED REVIEW
PROCESS TO ENSURE CONSISTENCE
AND TO ALLOW THE AUDITOR TO REACH
DEFENSIBLE CONCLUSIONS.
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OBJECTIVES OF THE SAFETY AUDIT
• DESIGN DEFICIENCIES AND ALSO
WEAKNESSES WHICH MIGHT HAVE
CROPPED UP DURING MODIFICATIONS
/ADDITIONS.
• FIRE PROTECTION ARRANGEMENTS AND
SAFETY SYSTEMS.
• OPERATING /MAINTENANCE PROCEDURESDEGRADED WITH TIME
• TRAINING, PREPAREDNESS FOR HANDLING
EMERGENCIES.
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SCOPE OF AUDIT
• FIRE AND EXPLOSION; PREVENTION,
PROTECTION AND EMERGENCY
MANAGEMENT.
• WORK INJURY PREVENTION.
• HEALTH HAZARDS CONTROL.
• CONSEQUENCES OF EMERGENCIES.
• ON SITE EMERGENCY CONTROL
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Elements of Occupational Safety and
Health System-IS14489
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Occupational Health and Safety Policy
OS&H organizational set up
Education and Training
Employees participation in OS&H Management
Motivational and Promotional measures for
OS&H
• Safety Manual and Rules
• Compliance with Statutory Requirements
• New Equipment review
and inspection
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Elements contd..
• Accident reporting analysis investigation and
implementation and recommendations
• Risk Assessment including hazard identification
• Safety inspections
• Health and safety improvement plan/targets
• First aid facilities-Occupational health center
• Personal Protective Equipment
• Good housekeeping
• Machine and general area guarding
• Material handling equipment
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Elements contd..
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Electrical and Personal safeguarding
Ventilation, illumination and noise
Work environment monitoring system
Prevention of occupational diseases including
periodic medical examination
Safe operating procedures
Work Permit systems
Fire Prevention, Protection and fighting systems
Emergency Preparedness plans(onsite/offsite)
Process Plant modification procedure
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Elements contd..
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Transportation of hazardous substances
Hazardous waste treatment and disposal
Safety in storage and warehousing
Contractor safety systems
Safety for customers(including MSDS)
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Records to be examined during Audit
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OS&H Policy
Safety organization chart
Training Records on safety, fire and first aid
Accident investigation reports
Accidents and dangerous occurrences-Statistics and
analysis
Records of tests and examination of equipment and
structures
Safe operating procedures for various operations
Record of work permits
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Record of montioring
of flammable and explosives
Records- Contd..
• Maintenance and testing records of fire detection
and fire fighting equipment
• Medical records of employees
• Records of industrial hygiene surveys(noise,
ventilation, illumination levels, airborne and toxic
substances, explosive gases)
• MSDS
• Onsite emergency plans and record of mockdrills
• Records of waste disposal
• Records of effluent discharge to the environment
• Housekeeping inspection
records
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Records contd..
• Minutes of Safety committee meetings
• Approval of layouts and other approvals from statutory
authorities
• Records of any modifications carried out in plant and
process
• Maintenance procedure records
• Calibration and testing records
• Shutdown maintenance procedures
• In service inspection manuals, records including that of
material handling
• Safety Budget
• Statutory Records, Previous
audit reports,
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Transportation of Hazardous substances
TOPICS ON WHICH INFORMATION IS
COLLECTED
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SAFETY ORGANIZATION.
CONTRACTOR EMPLOYEE ACTIVITIES.
MATERIAL SAFETY DATA.
OCCUPANCY.
SAFETY AND HEALTH POLICY.
OPERATION AND MAINTENANCE OF
SAFETY MANUAL.
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• EXPANSION MODIFICATION AUTHORIZATION PROCEDURES.
• SAFETY EDUCATION , TRAINING.
• STATUTORY STANDARDS, SAFETY IF
• JOB SAFETY ANALYSIS.
• JOB SAFETY INSTRUCTIONS
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.TOPICS CONTD.
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SAFETY INSPECTION.
SAFETY OBSERVATIONS.
WORK PERMIT SYSTEM.
FIRE PROTECTION ARRANGEMENTS
FIRE EMERGENCY CONTROL
PROCEDURES.
• WORK ENVIRONMENT MONITORING.
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• PERSONAL PROTECTIVE EQUIPMENT.
• MEDICAL/AMBULANCE FACILITIES.
• ACCIDENT/INCIDENT -REPORTING
INVESTIGATION ANALYSIS.
• IDENTIFICATION OF CRITICAL
EQUIPMENT AND PREUSE INSPECTION
OF CRITICAL EQUIPMENT
• OFF THE JOB -SAFETY.
• STATISTICAL INF. ON LOSSES INJURIES.
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Manufacture, Storage and import of Hazardous Chemicals
Rules, 1989
• Safety Audit is required to be carried out by by the
occupiers of both the new and the existing
industrial activities with the help of an expert not
associated with such industrial activities.
• This is required under Rule No.10-subrule (4)
• This has come into effect from 3/10/94
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Traits of an auditor
• Dispel the myth that it is policing on behalf of
management
• Is questionnaire useful?
• Knowledge in the area being visited
• Blinkered view?
• Discussion is more important-Facilitator rather
than an inspector.
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Are you a good auditor?
• FINISHED FILES ARE THE
RESULT OF YEARS OF
SCIENTIFIC STUDY
COMBINED WITH THE
EXPERIENCE OF YEARS
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Safety Leadership is key to success
Wayne Pardy,
CRSPwww.cholaaxa.com Survey by Linkage, inc., 1999
Safety Culture
• Liveware
• Safety Culture
• Hardware
Software
Acts-Practice-Habit-Behavior-Culture
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Coincident or Not ?
If,
ABC D EFGHI J K L M N O PQ R S T U V W X Y Z
Equals,
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Then,
K+ N +O +W+ L +E+D+G+E
11 + 14 + 15 + 23 + 12 + 5 + 4 + 7 + 5 = 96%
H+A+R +D+W+ O+ R +K
8 + 1 + 18 + 4 + 23 + 15 + 18 + 11 = 98%
Both are important, but the total falls just short of 100%
But,
A+T +T + I+T + U +D+E
1 + 20 + 20 + 9 + 20 + 21 + 4 + 5 = 100%
Safety really is about attitude. Make 100% Safe Behavior your choice
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both ON and OFF the job
Safety and Incident Prevention
Depends how much on ATTITUDE ?
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1
20
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9
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21
4
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100%
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