Transcript Accident Prevention

Work Design:
Productivity and Safety
IE 419
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Basics of Accident Prevention
(Heinrich, Petersen, Roos – Industrial Accident Prevention)
• Accident Prevention – direct control of
workers, machines, environment to
prevent accidents
• Safety Management - long range
planning, education, training to prevent
accidents
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Accident Prevention Process
Identify Problem
Collect Data
Monitor
Analyze Data
Apply Remedy
Select Remedy
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Domino Theory (Identify Problem)
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Ex. #1 - Domino Theory
Sparks from grinder ignite nearby gasoline
causing operator to be burned.
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Lack of Control
Basic Causes
Immediate Causes
Accident
Injury
Multiple causation!
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Accident Causation
Unsafe Acts
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Unsafe Conditions
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Accident “Iceberg”
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3 E’s of Accident Prevention
• Engineering – redesign of job/workplace
• Education – training
• Enforcement – discipline, rules
Accident Causation Models →
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Life Change Unit Theory
• Accident probability
is situational
• Overload taxes
person’s capacity
• Leads to accidents
(or illness)
• >300 → 79% in 2 yrs
• >200 → 51% in 2 yrs
• >150 → 37% in 2 yrs
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Rank Life Event Units
100
2
Death of
spouse
Divorce
4
Jail term
63
6
Injury
53
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End school
26
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Vacation
13
1
73
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Motivation-Reward Satisfaction Model
(Identify Problem)
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Behavioral Based Training
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ABC approach
A – antecedents
B – behavior
C - consequences
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Collect Data – Analyze Data
• Systematic approach
• Who, what, where, when, how, why
• Inspection
– Job/methods analysis
– Worksite analysis
– Job Safety Analysis (JSA)
– (Look beyond direct causes!!)
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Job Safety Analysis (JSA)
(Job Hazard Analysis, Methods Safety Analysis,
Critical Incident Technique, Failure Mode and Effects
Analysis (FMEA), Hazard and Operability Study (HAZOP))
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2)
3)
4)
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Break down job into elements
List them in sequential order
Examine them critically
Focus on:
Worker
Method
Machine
Material
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Ex. #2 - JSA
Scenario: Two inspectors smashed their toes
when a stack of armor plate (36x24x⅜ in),
standing on end against workbench, slid to the
floor. They were stacked there because of
insufficient room to leave them on delivery pallet,
towed from Receiving. Since each piece needed
to Rockwell tested, the inspectors stacked the
plates on end rather than laying them flat on the
floor, which would require later lifting (NIOSH!!).
Similar accidents had occurred earlier, but
without injuries.
Typical Solution:
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Ex. #2 – JSA con’t (Old Method)
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Ex. #2 – JSA con’t (New Method)
Recommendation:
Adjustable, powered
transporter (two)
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Advantages of JSA
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Maps out all details
Quick, simple, objective
Compares old & new methods
Examines effects on production
Analyze safety before accident occurs
Leads into Fault Tree Analysis
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Select Remedy
Decision-Making Tools - Hazard Action Table
Conditions
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Ex. # 3 - Value Engineering
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Value Engineering - Safety
• Define Factors:
– Effect on safety
– Cost
– Morale
– Social/environment
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Choose Alternatives – depends
Determine Weights – judgmental
Rate each alternative by factor - relative
Resulting Value (sum of products) selects
proper alternative
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Risk Analysis – Basics
• Basic premise/approach
– All risks can not be eliminated
– However, can reduce potential loss
– Go for max cost effectiveness
• Risk of loss increases with:
– ↑ probability that hazard will occur
– ↑ exposure to the hazard
– ↑ consequences of hazardous event
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Risk Analysis - Procedure
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Assign numerical values to factors
Multiply factors → overall risk score
Risk score is a numerical value
Good for relative comparison (not
absolute)
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Factor Values
Likelihood
Values
Exposure
Values
Expected
10
Continuous
10
Possible
6
Daily
6
Unusual
3
Weekly
3
Remote
1
Monthly
2
1
~ Conceivable
0.5
Few/year
~ Impossible
0.1
Yearly
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0.5
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Possible Consequences
Possible Consequences
Catastrophe (many fatalities, $108 damage)
Disaster (few fatalities, $107 damage)
Very serious (fatality?, $106 damage)
Serious (serious injuries, $105 damage)
Important (injuries, $104 damage)
Noticeable (first aid, $103 damage)
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Value
100
40
15
7
3
1
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Risk Score
Risk Situation
Very high risk, discontinue operations
High risk, immediate correction
Substantial risk, correction needed
Possible risk, attention needed
Risk?, perhaps acceptable
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Value
400
200-400
70-200
20-70
< 20
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Ex. #4 - Risk Calculation
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Ex. #5 - Risk and Cost Effectiveness
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Apply Remedy and Monitor
• Who applies remedy
– Safety specialist/engineer
– Line supervisors
– Workers
• Monitor effectiveness of
accident prevention
– Close the feedback loop
– Variety of statistical
approaches
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Identify
Problem
Collect
Data
Monitor
Analyze
Data
Apply
Remedy
Select
Remedy
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Accident and Injury Statistics
• Incidence (frequency) rate
IR = # incidents x 200,000
# hrs exposure
• Severity rate
SR = # days lost x 200,000
# hrs exposure
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Chi-Square Analysis
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χ2 = ∑ (Ei – Oi)2/ Ei
Ei = HixOT/HT
M = # areas
Ei = expected
Oi = observed
OT = Total observed
Hi = hours worked in area i
HT = total hours worked
ν = m -1
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Ex. #6 - Chi-Square Analysis
Dept.
A
B
C
Total
# CTD
22
4
10
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# Hours
900,000
600,000
1,400,000
2,900,000
IR
Ei
1.3
1.4
2.5
7.4
17.4
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χ2 = ∑ (Ei – Oi)2/ Ei
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Red Flagging – Control Chart
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Red Flagging - Monitor
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