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صOSH 366 Hazard Identification and Control
Week 3: Chapter 2
Workplace Hazard Analysis and Review of Associated Risk
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2.0 Learning Goals
Identify the use of audits and inspections
Use the tools to gather information and analyze for the workplace review
Define the roles played by outside specialists, Spvrs, Ee’s
Identify sources for risk and hazard data
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2.1 Analysis of the Workplace
The starting point in analysis and evaluation development is to consider workplace as a system of cause and effect with inherent risk built into the work environment.
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2.1 Analysis of the Workplace
Steps to select the methods or tools that can be used to identify and analyze the work environment include:
Review current job descriptions and protocols for employee tasks…. (this includes interviews)
Performing specific task analysis taking into consideration hazards and associated risk
Utilizing workplace surveys based on existing standards, procedures, regulations or guidelines that have been customized and tested for consistency
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2.1 Analysis of the Workplace
Utilizing change analysis of planned, new, modified or relocated facilities, processes, materials and equipment to update procedures and/or guidelines
Utilizing walk-around inspections conducted by knowledgeable Ee’s
Reviewing documentation of the history of similar industries past work experiences.
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2.1 Analysis of the Workplace
NOTE:
Site analysis has important elements that are critical for an effective overview:
Analysis should cover all areas of the workplace
Analysis should be conducted at regular intervals.. Frequency will depend on the size of the workplace and the potential hazards and severity of risks.
Ee’s should be trained on hazard recognition/risk and expand the hazard inventory to update JHA.
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Conduct Comprehensive
Baseline survey
Identify hazards
Develop/update hazards inventories
Develop/Update controls
Conduct periodic surveys
Figure 2-1 Overview of a Comprehensive Baseline Review
Let’s now turn to the Job Hazard Analysis. What is a JHA? As stated before, it is a “management tool” used to anticipate and assess the existing and potential hazards of a job, to understand the consequences of the risk, and to act as an aid in helping identify, eliminate, or control hazards. So the bottom line is that the JHA is a tool that focuses on the relationship between the employee; the job as a whole unit; the steps that make up the job; the tasks that are defined in each step; the tools, materials and equipment being used; Existing and potential hazards; the consequences of exposure to those hazards; potential at-risk events associated with each task; existing policies and procedures; and the nature of the physical environment that the job is completed within.
Thus, the assessing of all of the components of a task, a comprehensive overview is developed that allows one to focus on the essential areas where change may be needed.
Now let us begin with reviewing the individual steps in the JHA process found as Figure 2-1 in the text. This is the preplanning stage. Again, JHA’s are concerned with identification and the controlling hazards.
The JHA process involves 5 steps… JHA always begins with:
Step 1. Conducting a comprehensive baseline survey.
A comprehensive baseline survey means first identifying all occupations and job tasks by occupation/position and evaluate them for existing and potential hazards. Yes, this does mean every job title such as maintenance workers, painters, electricians and even laborers etc. and all the tasks involved that employee is required to perform.
To make the baseline survey process more meaningful and save on your time, focus your efforts on identifying the “critical tasks” for each job. “Critical tasks” are those in which there is potential to produce major loss to people, property, process and/or environment when not performed properly. For example a critical task could be emergency shut down actions for specific equipment, a control room operator’s procedures for instrumentation loss or donning of escape breathing apparatus. Remember most accidents occur in a work area to which a worker is not accustomed and during a task that a worker’s unusual task.
Be mindful that sometimes-occupational titles maybe generic in nature and the worker may or may not be performing tasks you think they are performing.
Step 2. Identify all the hazards that are critical for each job title or task. These means both safety and health hazards and inventory them. Inventories of hazards are important in that they will assist the safety professional to keep an accurate account of all the hazards that they are aware. Be aware this list of hazards for each job and specific tasks may grow over time. Inventories are important, as they will keep track of what works and what doesn't.
Step 3. You are then to develop or update controls and inventory them. Once hazards are identified you are responsible for designing and implementing controls. Remember controls have a specific order to be followed:
1.Design/Engineering Controls
2. Administrative Controls
3. PPE
Step 4. Once controls are implemented they must be periodically checked for effectiveness. Think of this as a quality assurance check. At this point as a safety professional you are doing things such as questioning employees about the hazards and the controls, performing monitoring, etc.
JHA’s are a continuous cycle used to control hazards in the workplace. A review of workplace hazards is a systematic cause and effect relationship approach with an evaluation of risk built into the work environment. You must evaluate both the hazard and the risk of the hazard to cause harm. Risk assessments is defined as a chance or loss or gain a measure of potential loss that considers both the magnitude of a loss and its likelihood of occurring and it uses a process used to identify, quantify or rank risk. Organizations should consider that even adequate controls have been put into place there will be residual risks. Safety professionals are to reduce the level of risk to within acceptable levels. Residual risk is the level of risk remaining after all risk control measure has been implemented.
Specific tools used to identify and analyze the work environment hazards, which include:
Reviewing job descriptions and specific tasks workers must complete
Performing specific job analysis, taking consideration of hazards and risks
Utilizing workplace surveys based on existing standards, procedures, regulations or guidelines that are uniform
Utilizing change analysis
Walk around inspections
Similar industry research
One of the most important issues when being confronted with implementing a job safety analysis program is which jobs do we do first. Is it the jobs that are the highest paying jobs, the jobs that are historically the most risky jobs, or do we just start at one end of the plant and go through it job by job. Well, my recommendation, and the recommendation of OSHA is that you establish a priority list. At the top of the list should be the following jobs:
jobs with the highest injury or illness rates;
jobs with the potential to cause severe or disabling injuries or illnesses, even if there is no history of previous accidents;
jobs in which one simple human error could lead to a severe accident or injury;
jobs that are new to your operation or have undergone changes in processes and procedures; and
jobs complex enough to require written instructions.
So, how do we begin. Well, OSHA recommends the following steps.
First, Involve your employees. Your employees have a unique understanding of the jobs they do. This knowledge can be invaluable when trying to determine what hazards are associated with the job. What may look extremely easy when watching an employee work may in actuality be very difficult and strenuous. Involving employees in creating the job steps and determining the hazards associated with those job steps will help avoid oversights, ensure quality analysis, and help obtain worker “buy-in” to the process and solutions. They will share in the ownership of the JHA and will be less willing to deny knowledge of the hazards associated with the job and less willing to avoid following the safety protocol designed by you and the employee.
Second, Review the accident history. Reviewing on your own and with your employees the accident history of the job being examined, as well as the company history will also help with buy-in and help in determining which jobs should receive priority in having a JHA done on that job first. In addition, determining or reviewing “near misses” on that job is important in designing the JHA for that job. Near misses are those situations where an accident didn’t happen but could have or nearly resulted in an injury or death. These near misses are indicators that the existing hazard controls (if any) may not be adequate and certainly deserve a closer examination.
Third, conduct a preliminary job review. This is where you want to discuss with your employees the hazards that they know exist in their job(s). You should also brainstorm with them for ideas on how to eliminate or control those hazards. Of course, if an employee points out some hazard that poses an immediate danger to the employees life or health, you should take immediate action to eliminate the hazard to protect the worker. Do not wait to complete your JHA.
Fourth, List, rank and set priorities for hazardous jobs. List those jobs that present the most unacceptable hazards, whether they be physical or environmental hazards. Check off the ones that are most likely to occur and the ones with the most severe consequences. These jobs should get your second highest priority, next to those the present an immediate danger to life or health.
Fifth, Outline the steps or tasks.
So, we have our pre-planning stages above, but here is where we actually start the formal process of a JHA - that is, breaking down a job to its individual components, or job tasks or what we prefer to call job STEPS. When beginning a JHA, watch the employee perform the job and list each step as the worker takes it. Be sure to record enough information to describe each step without getting overly detailed. Avoid making the breakdown of steps so detailed that it becomes unnecessarily long or so broad that it does not include basic steps. Of course, you should have the employee who performs the job review your listing of steps and see if you can combines some outlined steps into one or if you need to break them apart because they require separate tasks or key physical efforts. Remember, when you talk to the employee make sure they understand that you are evaluating the job, not their job performance. You may also want to video-tape the employee while they are performing the job. These visual recordings can certainly help when an employee is performing complex tasks or doing the steps fairly quickly.
As your text points out, JHA’s are not stand alone processes or procedures. They must be done in conjunction with your other safety programs and policies. For example, how does this fit within your employee handbook, or union contract? Are employees encouraged to report safety hazards and how is this reporting accomplished? In Appendix B of your textbook, a sample form for reporting hazards can be found. Of course, you can design your own form using this as a template or suggestion. How can you improve these means of communications? If this information is reported, are employee concerns being addressed quickly enough or just ignored? Do work orders get generated from these reports and are they acted upon in a timely manner. If not, are employees informed of any holdup or are they left with the impression that this is just another safety program or joke of the month? Are these reports of hazard tracked and by what means? Are they complied and then used in future JHA’s or used to revise existing JHA’s? Answers to all of these questions will greatly impact your organizations actual and perceived commitment to safety and health. A breakdown in any one of these components can negatively impact your overall success.
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Modes of Workplace Analysis
There are several modes (techniques) of workplace analysis safety departments or safety directors can utilize. They include:
Inspections and audits
Checklists
Use of consultants and Outside specialists
Ee’ Interviews
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Inspections and Audits
Inspections and audits are two important and most frequent aspects of an effective workplace analysis in development of a JHA.
Inspections are “tactics” generally “walk-around” to identify conditions that do not comply with defined safety procedures and requirements (time consuming)
Audits are a “strategy” that attempts to program status by assigning numerical value to program elements.
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2.3 Checklists
Checklists are often developed from negative experiences, where system failed or unidentified hazards resulted in injuries or other loss-producing events.
Beware of generic checklists
Modify checklist to be site specific
See Appendix E for sample checklist
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Appendix E E.1 SELF INSPECTION CHECKLIST
Employer Postings | Yes | No |
Is the required OSHA workplace poster displayed in a prominent location where all employees are likely to see it? | ||
Are emergency telephone numbers posted where they can be readily found in case of emergency? | ||
Where employees may be exposed to any toxic substances or harmful agents, has appropriate information concerning employee access to medical and exposure records and MSD Sheets been posted or otherwise made readily available to affected employees? | ||
Are signs concerning egress from buildings, room capacities, floor loading, biohazards, exposures to x-ray, microwave, or other harmful radiation or substances posted where appropriate? |
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2.3.1 Consultants and Outside Specialists
Outside services may be necessary for safety departments and safety directors who lack specific knowledge in an area such as:
Engineers
Workers compensation specialists
Consulting Services
Environmental Sciences
Industrial Hygienist
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Industrial Hygienists
Industrial hygiene is generally defined as the art and science dedicated to the anticipation, recognition, evaluation, communication and control of environmental stressors in, or arising from, the work place that may result in injury, illness, impairment, or affect the well being of workers and members of the community.
These stressors are divided into the categories biological, chemical, physical, ergonomic and psychosocial.
IH testing includes air, dust, vapors, noise, etc.
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2.3.2 Employee Interviews
Often overlooked mode of hazard identification include employee interviews. Forms of interviews include:
One-on-one interviews
Informal conversations with Ee’s
Voluntary anonymous surveys
Note: See General Guidelines that can be used when conducting Ee’ interviews pg. 44
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2.4 Types of Inspections
There are many types of inspections that can be performed which include:
General walk-around inspections
Verification reviews (Fig. 2-2)
Focus Reviews
Self-Assessment
Document Review
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2.4.1 General Walk-around Inspections
Walk-around inspections are used to conduct periodic and daily inspections of the workplace. They identify obvious blatant hazards and visible at-risk events.
Mgrs and Supvrs should conduct routine walk-around inspections
Safety committee members as well
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Table 2-1 Important Elements of Site Reviews
Important elements of regular site reviews and show how critical follow-up reviews are to the process.
Reviews should cover all areas of the workplace, targeting high-hazard operations
Reviews should be conducted at regular intervals. The frequency will depend on the size of the workplace and the nature of the risks and hazards
Use JHA’s to review the steps and tasks that are being completed and ensure that the correct tools, equipment, materials, etc. are in use
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2.4.2 Verification Reviews
Items identified from walk-around inspections must be reviewed for appropriate completion.
Avoid “pencil whipping”
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Analyze work
Define subsystems
Identify
Hazards
Define ongoing haz. situations
Determine haz. events
Analyze harm or exposure
Estimate risk
Is risk tolerable
Introduce corrective/action
No change necessary monitor results
Verify
Yes
No
Fig. 2-2 Flow Diagram of the Risk Toolkit
2.4.3 Focus Reviews
Narrows the scope of a inspection to one process or audit component that needs greater assistance in implementing a sustainable hazard control.
JHA are used to target jobs and tasks where the hazards of specific actions or elements pose the greatest threat
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2.4.5 Document Review
Document and records are to be inspected to verify that what you said you would do that you did. All documents should be properly completed, stored and secured. Documents to be reviewed.
Policy statements
Training
Procedures
Recordkeeping
JHA’s
NOTE: Keep all document filed both electronically and hard copies
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2.4.6 Written Inspection Reports
Necessary to record hazards identified, responsible person for corrective action and tracking of hazards to completion.
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2.5 Who should Review the workplace
Everyone is responsible for actively reviewing the workplace. However Ee’s with specific skills and perspectives should be involved in reviewing the workplace.
Each level of employee should have specific responsibilities based on their authority and responsibility.
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Management Workplace Inspections/JHA Role
Management must:
Identify hazards in the workplace that could result in injury or illness
Evaluate the level of risk to help determine what controls to implement
Select an appropriate solution to control the hazard and/or protect
the employee.
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We have discussed a lot information concerning the importance of JHA and value to the organization, steps to perform a JHA now we will turn our attention the organizational roles impacting JHA success. Each level of employee within the organization plays a role in JHA success. For the purposes of this course employee also refers to management.
Lets start with management:
Management must:
Identify hazards in the workplace that could result in injury or illness
Evaluate the level of risk to help determine what controls to implement
Select an appropriate solution to control the hazard and/or protect
the employee.
Management should establish a hazard reporting initiative which is executed by supervisors. A hazard reporting initiative is basically creating a system for worker to feel comfortable to report hazards to management so they can be fixed.
A good hazard reporting initiative includes management should receive feedback from both supervisors and employees on the control of risk and hazards because of:
Budget Resources
Set Program standards
Set objectives related to inspections
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Management Workplace Inspections/JHA Role
A good hazard reporting initiative includes management should receive feedback from both supervisors and employees on the control of risk and hazards because of:
Budget Resources
Set Program standards
Set objectives related to inspections
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We have discussed a lot information concerning the importance of JHA and value to the organization, steps to perform a JHA now we will turn our attention the organizational roles impacting JHA success. Each level of employee within the organization plays a role in JHA success. For the purposes of this course employee also refers to management.
Lets start with management:
Management must:
Identify hazards in the workplace that could result in injury or illness
Evaluate the level of risk to help determine what controls to implement
Select an appropriate solution to control the hazard and/or protect
the employee.
Management should establish a hazard reporting initiative which is executed by supervisors. A hazard reporting initiative is basically creating a system for worker to feel comfortable to report hazards to management so they can be fixed.
A good hazard reporting initiative includes management should receive feedback from both supervisors and employees on the control of risk and hazards because of:
Budget Resources
Set Program standards
Set objectives related to inspections
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Supervisors Workplace Inspections/JHA Role
Supervisors must review all work areas for hazards (perform inspections and audits) and hazards identified and reported by employees should be reported to supervisors:
Supervisors should encourage employees to report hazards document and track them
Supervisors should be attempt to control hazards which they can
Complete inspections of workplaces
Be involved in audits
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Supervisors must review all work areas for hazards (perform inspections and audits) and hazards identified and reported by employees should be reported to supervisors:
Supervisors should encourage employees to report hazards document and track them
Supervisors should be attempt to control hazards which they can
Complete inspections of workplaces
Be involved in audits
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Supervisor Obstacles to Inspections and Audits
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These include:
Fear of losing their job
No money available for needed changes identified during the hazard identification
There is a risk in spending money for safety
The “what’s in it for me?” attitude
Many employees want to change but are afraid to take responsibility for it
No support from upper Management
No time or follow-through from top Management
Make it work or “can do attitude
James Rougthon and James Mercurio book Developing an Effective Safety Culture they have identified several obstacles which causes supervisors to neglect to perform inspection and auditing duties.
These include:
Fear of losing their job
No money available for needed changes identified during the hazard identification
There is a risk in spending money for safety
The “what’s in it for me?” attitude
Many employees want to change but are afraid to take responsibility for it
No support from upper Management
No time or follow-through from top Management
Make it work or “can do attitude
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Employees Workplace Inspections/JHA Role
Employees play a role in the JHA process. Employees must understand hazard analysis is a work requirement
Employees need to be involved in hazard analysis from the beginning so:
The process that is taking place is better understood
The value of a change is seen by the employee
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Employees play a role in the JHA process. Employees must understand hazard analysis is a work requirement
Employees need to be involved in hazard analysis from the beginning so:
The process that is taking place is better understood
The value of a change is seen by the employee
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Employee Obstacles to Successful Inspection and Auditing
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Obstacles which causes employees to neglect to perform inspection and auditing duties. These include:
Fear and a lack of trust
Supervisors not willing to listen and support
Communication is one way (top-down)
Organization is not alignment on safety; production is number one at the line level
Supervisors not willing to hear problems and receive feedback
Intimidation
People not willing to take personal responsibility; too easy to shift blame
Lack of consistency and follow-through, past efforts fade away
Obstacles which causes employees to neglect to perform inspection and auditing duties. These include:
Fear and a lack of trust
Supervisors not willing to listen and support
Communication is one way (top-down)
Organization is not alignment on safety; production is number one at the line level
Supervisors not willing to hear problems and receive feedback
Intimidation
People not willing to take personal responsibility; too easy to shift blame
Lack of consistency and follow-through, past efforts fade away
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2.5.3 Safety Professionals
Safety professionals can act as a mentor and provide guidance on methods to conduct inspection.
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2.6 Preventive Maintenance
Preventive maintenance (PM) has a direct relationship with safety performance. Good PM programs plays a major role in ensuring that hazard controls continues by:
Keeping new hazards from occurring due to equipment malfunction or product defect
Target areas of potential high risk
Review maintenance records for proper PM
Poor housekeeping and maintenance are direct indicators' of poor PM
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Safety Committees
Joint labor-management committees or a safety committee are popular methods of increasing employee participation in workplace inspections.
If a safety committee is to part of a JHA or participates in hazard identification be certain they are adequately trained and they are to assist in the correction of hazards.
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Joint labor-management committees or a safety committee are popular methods of increasing employee participation in JHA’s. Safety committees come in various sizes and differing responsibilities such as incidents and accident investigations, administering workplace surveys or participating or JHA’s. If a safety committee is to part of a JHA or participates in hazard identification be certain they are adequately trained and they are to assist in the correction of hazards.
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2.7 Other things to consider
Retroactive analysis tools that assist in ensuring controls stay in place and new hazards do not appear include data collection and analysis of:
Incident investigations
Injury and illness trend analysis
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2.7 Incident Investigations
Incident investigations are used to identify and uncover hazards that were missed of created when a process or operation has slipped out of control.
Gather information on near-misses
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2.7.2. Trend Analysis
The analysis of trends over time for the determination of the effectiveness of your safety processes. Are you losses decreasing? Items to review for trend analysis include:
Injury and illness records (OSHA 300 Logs)
First Aid Reports
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