industrial safety & quality managementportal.unimap.edu.my/portal/page/portal30/lecture...
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Hazard:
A source or a situation with a potential for harm in
terms of
human injury or ill-health,
damage to property,
damage to the environment or
a combination of these.
DEFINITION
Risk:
A combination of the likelihood of an occurrence of a hazardous event and the severity of injury or damage to the health of people, property, environment.
Likelihood – an event likely to occur within the specific or in specified circumstances
Severity - outcome from an event such as severity of injury or health of people, or damage to property, or insult to environment, or any combination of those caused by the event.
RISK = likelihood X severity of injury
HOW TO MANAGE OCCUPATIONAL SAFETY
AND HEALTH AT THE WORK PLACE?
Requires the commitment of the manager to
complete 3 steps:
1) The workplace must have a Policy Statement on
Occupational Safety and Health;
2) Planning (including the implementation of HIRARC,
training, instructions and auditing) on Occupational
Safety and Health, and
3) To take remedial action for any improvement to be
made.
POLICY STATEMENT REQUIRED FOR
SAFETY AND HEALTH
The Occupational Safety and Health policy is a
written statement briefly stating the following
commitment:
The employer will provide safety, health and welfare for
the employee during the working hours by
implementing the relevant regulations and work
procedures; and
The employee will comply with the regulations and work
procedures so as to ensure their own safety.
The policy statement will be displayed is strategic
places that will be visible to the employee.
PURPOSE OF HIRARC
The purpose of HIRARC are as follows:
to identify all the factors that may cause harm to
employees and others (the hazards);
to consider what the chances are of that harm actually
be falling anyone in the circumstances of a particular
case and the possible severity that could come from it
(the risks); and
to enable employers to plan, introduce and monitor
preventive measures to ensure that the risks are
adequately controlled at all times.
PLANNING OF HIRARC ACTIVITIES
HIRARC activities shall be plan and conducted:
a) for situation:
i. where hazard appear to pose significant threat;
ii. uncertain whether existing controls are adequate; or/and
iii. before implementing corrective or preventive measures.
b) by organization intending to continuously improve OSH Management System.
It should be the duty of the employer to assign a trained personnel to lead a team of employees associated with one particular process or activity to conduct HIRARC.
PROCESS OF HIRARC
Process of HIRARC requires 4 simple steps:
1) classify work activities;
2) identify hazard;
3) conduct risk assessment (analyze and estimate risk
from each hazard), by calculating or estimating -
i. likelihood of occurrence, and
ii. severity of hazard;
4) decide if risk is tolerable and apply control measures
(if necessary).
CLASSIFY WORK ACTIVITIES
Classify work activities in accordance with their
similarity, such as:
geographical or physical areas within/outside premises;
stages in production/service process;
not too big e.g. building a car;
not too small e.g. fixing a nut; or
defined task e.g. loading, packing, mixing, fixing the door.
HAZARD IDENTIFICATION
Sources of Hazard
Man – Human behavior, unsafe act
Machinery – Installation, layout and design of equipment
Materials – substances such as chemicals and gases use
in the workplace
Method – the way people carry out their work
Medium – workplace condition i.e. air quality, ventilation,
lighting, noise, vibration etc.
CLASSIFICATION OF HAZARDS
Hazards can be classified in six ways:
1) Physical hazard
a) Mechanical hazard
b) Electrical hazard
2) Chemical hazard
3) Biological hazard
4) Ergonomics hazard
5) Psychosocial hazard
PHYSICAL HAZARD
Physical hazards are those substances which
threaten your physical safety. Physical hazards are
the most common and will be present in most
workplaces at one time or another. They include
unsafe conditions that can cause injury, illness
and death.
Examples of physical hazards include:
Electrical hazards: frayed cords, missing ground pins, improper wiring
Mechanical hazards: unguarded machinery and moving machinery parts: guards removed or moving parts that a worker can accidentally touch
Constant loud noise
High exposure to sunlight/ultraviolet rays, heat or cold
Working from heights, including ladders, scaffolds, roofs, or any raised work area
Working with mobile equipment such as fork lifts (operation
of fork lifts and similar mobile equipment in the workplace
requires significant additional training and experience)
Spills on floors or tripping hazards, such as blocked aisle or
cords running across the floor.
i. Mechanical Hazard
Mechanical hazards are those associated with power-
driven machines, whether automated or manually
operated.
Safeguarding
Machine safeguarding is to minimize the risk of accidents
of machine-operator contact.
The contact can be:
An individual making the contact with the machine - usually
the moving part
From the machine via flying metal chips, chemical and hot
splashes, and circular saw.
Caused by the direct result of a machine malfunction,
including mechanical and electrical failure
Photoelectric presence-sensing screen Hold-outs or restraints for restraining the operator’s hands
from reaching into the danger zone at all times (compare
with pullbacks).
OSHA‟s Requirement for Machine Guarding
OSHA‟s requirement for machine guarding are
summarized as follows:
1) Types of guarding
2) General requirements for machine guards
3) Guarding the point of operation
4) Machines requiring point of operation guards
5) Exposure of blades
6) Anchoring fixed machinery
ii. Electrical Hazard
Using electrical current and electrical equipment can lead to
several hazards including electric shock, heat, and fire.
Electric shock hazard: When a person becomes part of an
electric circuit, they are a conductor of the electrical current.
Since electricity cannot be seen, the hazard is often
overlooked until too late. Bodily injury and death can occur.
Sources of electrical hazards are:
Equipment failure
Improper wiring
Insulation failure
Static electricity discharge
Using metal ladders to work on electrical equipment
Working on electrical equipment without ensuring that the
power has been shut off
Lightning strikes
There are various ways of protecting people from the
hazards caused by electricity, including insulation,
guarding, grounding, and electrical protective devices.
Workers can significantly reduce electrical hazards by
following some basic precautions:
Inspect wiring of equipment before each use. Replace
damaged or frayed electrical cords immediately.
Use safe work practices every time electrical equipment is
used.
Know the location and how to operate shut-off switches
and/or circuit breaker panels. Use these devices to shut off
equipment in the event of a fire or electrocution.
Limit the use of extension cords. Use only for temporary
operations. In all other cases, request installation of a new
electrical outlet.
Use only multi-plug adapters equipped with circuit breakers
or fuses.
Minimize the potential for water or chemical spills on or near
electrical equipment.
CHEMICAL HAZARD
Chemical hazards are present when a worker is
exposed to any chemical preparation in the
workplace in any form (solid, liquid or gas). Some
are safer than others, but to some workers who
are more sensitive to chemicals, even common
solutions can cause illness, skin irritation or
breathing problems.
Beware of:
liquids like cleaning products, paints, acids, solvents
especially chemicals in an unlabeled container (warning
sign!)
vapours and fumes, for instance those that come from
welding or exposure to solvents
gases like acetylene, propane, carbon monoxide and
helium
flammable materials like gasoline, solvents and
explosive chemicals.
BIOLOGICAL HAZARD
Biological hazards come from working with
animals, people or infectious plant materials.
Work in day care, hospitals, hotel laundry and
room cleaning, laboratories, veterinary offices and
nursing homes may expose you to biological
hazards.
The types of things you may be exposed to include:
blood or other body fluids
fungi
bacteria and viruses
plants
insect bites
animal and bird droppings.
ERGONOMICS HAZARD
“Ergonomics is a multidisciplinary science that
studies human physical and psychological
capabilities and limitations. This body of knowledge
can be used to design or modify the workplace,
equipment, products, or work procedures to improve
human performance and reduce the likelihood of
injury and illness”
Ergonomic hazards occur when the type of work, body
position and working conditions put strain on your body.
They are the hardest to spot since you don't always
immediately notice the strain on your body or the harm
these hazards pose. Short-term exposure may result in
"sore muscles" the next day or in the days following
exposure, but long term exposure can result in serious
long-term injuries.
Ergonomic hazards include:
poor lighting
improperly adjusted workstations and chairs
frequent lifting
poor posture
awkward movements, especially if they are repetitive
repeating the same movements over and over
having to use too much force, especially if you have to
do it frequently.
Workplace Musculoskeletel Disorders
Carpal Tunnel Syndrome
- a medical condition in which the median nerve is
compressed at the wrist, leading to pain, paresthesias,
and muscle weakness in the forearm and hand.
Cumulative Trauma Disorders (CTD) / Repetitive Strain Injuries
- caused by repetitive tasks, is any of a loose group of conditions resulting from overuse of a tool, eg. computer, guitar or knife
Musculoskeletal Disorders
- Caused either by the work itself or by the employees' working environment. They can also result from fractures sustained in an accident.
- Typically, MSDs affect the back, neck, shoulders and upper limbs; less often they affect the lower limbs
PSYCHOSOCIAL HAZARD
The psychosocial hazard has recently been
acknowledged in legislation as a workplace
hazard. This type of hazard relates to mental
health and behavioral disorders.
The hazard involves human motivation and the
direction of human behaviour.
Psychosocial hazards in the workplace contribute
to work-related stress.
Psychosocial hazards include:
bullying and harassment;
occupational violence or
customer aggression;
fatigue resulting from long hours of work or shiftwork;
demands in excess of a worker‟s capacity to deliver;
and
alcohol and drug misuse.
Psychosocial hazards have grown in prominence in
recent years in response to a number of factors
including
increasing work intensification (in terms of longer
working hours and greater workloads),
changes in organizational practices, and
changing social expectations of how employees should
be treated by their supervisors, managers and fellow
workers.
These hazards are also harder to define and to
investigate than the traditional physical hazards in
a workplace.
Factors outside of the workplace can also
contribute to stress on individuals.
Hence the detection, management and regulation
of work-related stress presents challenges to
employers and regulators alike.
MATERIAL HANDLING AND STORAGE
Handling of material in manufacturing plant can be as hazardous as the industrial process itself.
General hazards of material-handling equipment are :
Being struck by an industrial truck or conveyor
Automatic or remote control nature (conveyor accidents)
Material storage standards; bags, containers, or bundles stored in tiers shall be “stacked, blocked, interlocked, and limited in height so that they are stable and secure against sliding or collapse.”
Material Handling Categories
Material transport equipment
- to move materials inside a factory, warehouse, or other
facility
- e.g. industrial truck.
- Important factors that should be consider in reducing
hazards regarding industrial trucks: truck selection,
operations, driver training, passengers
Storage
- to store materials and provide access to those materials when required
- Material characteristics affect type of transport and storage equipment required
- Safety risk : explosive, flammable, toxic, corrosive
Unitizing equipment
- refers to containers to hold materials and equipment used to load and package the containers
- e.g. pallets, bags, containers, or bundles stored in tiers shall be “stacked, blocked, interlocked, and limited in height so that they are stable and secure against sliding or collapse.”
PERSONAL PROTECTIVE EQUIPMENT
Personal protective equipment (PPE) must be
properly selected to match the hazard
Employer must be trained to use PPE properly
Example:
Hearing protection
Eye and face protection
Respiratory protection
Head protection
Hearing Protection
Important factor in selecting a type of noise protection
is probably effective in reducing decibel level of noise
exposure.
Various types of ear protection:
- Cotton ball
- Swedish wools
- Earplugs
- Molded Ear Caps
- Earmuffs
METHODS OF IDENTIFYING
HAZARDS
Hazards are identified by the following methods:
Review of documents and publications
Inspection and observation at the workplace
Measurement of the atmosphere, monitoring the
environment or medical surveillance of workers.
Hazard Analysis
1) Identifying Hazards by Document
Review
Reports of accidents, accident investigation and
audits
Could find hazards not previously identified.
Information from publications
New information not previously available
Regulations and Code of Practice
Information on a known hazardous conditions,
materials or practice
Statistics
Information on common accidents to watch out for
Handbooks, etc.
Practical information
Chemical Safety Data Sheet (CSDS) or Material
Safety Data Sheet (MSDS)
Information on hazardous materials, control measures
first-aid and emergency response.
2) Identifying Hazards by Inspections and
Observation
Types of inspections: Statutory inspection, periodic
inspection, formal and informal inspection.
Documentation : Checklist and inspection
worksheet (standard approach and record)
Activities: to involve Supervisors, Managers and
Employees.
Inspection outcome : to include actions and
timeframes
3) Identifying Hazards by Exposure
Monitoring
Exposure monitoring is concerned with the
identification of physical, chemical and biological
“stressors” such as noise, dust, toxic gases, and
harmful bacteria, in the workplace environment.
One definition of the term stress is “the common
response to environmental change”. Stress in the
working environment maybe created in a number
of ways as a result of, for instance, the installation
of noisy plant and equipment.
Stress factors may also take many forms, for
example:
extremes of temperature,
poor levels of lighting and ventilation, or
the presence of hazardous dusts, gases, vapours and
bacteria,
(all of which have a detrimental effect on the health of
workers.)
Environmental monitoring is an important
measure in identifying individuals and group
exposure to these stressors and in ensuring
compliance with Factories and Machinery Act
1967, Occupational Safety and Health (Use and
Standard of Exposure of Chemical Hazardous to
Health) Regulations 2000 and other regulations.
There are two types of monitoring:
Personal monitoring
Area monitoring
Personal monitoring is conducted to determine
exposure levels or for the need for medical
consultation, examination and/or surveillance.
Area monitoring can be used to estimate exposure
of the area when the substance exposure levels
are relatively constant and employees are not
mobile.
Exposure monitoring is done for noise, heat,
radiation, air contaminants, chemicals and etc.
4) Hazards Analysis
Used in new plant design especially in process
plants where the process is complex, raw
materials are hazardous and the likelihood of fire,
explosion and asset loss is great.
This is to ensure that safety is built into the design
before the plant is built.
Many formal techniques have been developed for
the systematic analysis of complex systems.
Some of the techniques used are:
Job Safety Analysis (JSA)
Hazards and Operability Studies (HAZOP)
Fault Tree Analysis (FTA)
Failure Mode and Effect Analysis (FMEA)
Event Tree Analysis (ETA)
Hazards Analysis (HAZAN)
Checklist Analysis
What-if Analysis
Relative Ranking/Risk Indexing
Example 1: Job Safety Analysis (JSA)
Definition:
It is a method for systematically identifying and
evaluating hazards associated with a particular job or
task.
It focuses on the relationship between the worker, the
task, the tools and the work environment.
Example 1: Job Safety Analysis (JSA)
It is used to help operate a safe system of work and
formulate safe work procedures.
The written procedures are the basis for all jobs training
ensuring all aspects of the job are covered in a uniform
way.
Ideally all jobs should be subjected to a JSA. Factors to be
considered when assigning priority of jobs for JSA include:
Accident frequency and severity
Newly established jobs or infrequently performed jobs – due
to lack of experience in these jobs, hazards may not be
evident.
The basic procedure for job safety analysis is to undertake the following, in consultation with employees and the supervisor to raise awareness.
a) Select the job to be analysed.
b) Break the job down into its component parts in an orderly and chronological sequence of job steps.
c) Critically observe and examine each component of the job to determine potential hazards or accidents.
d) Develop preventive measures to eliminate or reduce the risk of accidents using the hierarchy of control.
e) Formulate written and safe systems of work and job safety instructions for the job.
f) Review safe systems of work and job safe practices at regular intervals to ensure their utilisation.
The completed JSA is used to formulate a safe
work procedure.
It may be used as a standard for safety
inspections and it will assist in completing
comprehensive accident investigations.
The side-by-side format used in JSA worksheets is
not an ideal one for communicating instructions to
employees. Better results can be achieved by
using a narrative-style format.
For example:
Park vehicle.
i. Drive vehicle off the road to an area well clear of traffic,
even if it requires driving with a flat tire. Turn on the
hazard warning lights to alert passing drivers, so that
they will not hit you.
ii. Choose a firm, level area so that you can jack up the
vehicle without it moving.
And so on…
Example 2: Hazard and Operability
Studies (HAZOP)
The HAZOP technique was developed in the early
1970s by Imperial Chemical Industries Ltd.
HAZOP can be defined as the application of a formal
systematic critical examination of the process and
engineering intentions of new or existing facilities to
assess the hazard potential that arise from deviation
in design specifications and the consequential effects
on the facilities as a whole.
The prime aim is to design out risk at the early stages
of a new project, rather than have to enter into costly
modifications once the process is up and running.
This technique is usually performed using a set of
guidewords: NO/NOT, MORE OR/LESS OF, AS
WELL AS, PART OF REVERSE, AND OTHER THAN.
From these guidewords, a scenario that may result
in a hazard or an operational problem is identified.
At one time HAZOP‟s were mainly focused on fire
and explosion endpoints, while now the scope
usually includes toxic release, offensive odour, and
environmental impacts.
Example 3: Fault Tree Analysis (FTA)
Fault tree analysis (FTA) is a top-down approach to
failure analysis, starting with a potential
undesirable event (accident) called a TOP event,
and then determining all the ways it can happen.
The analysis proceeds by determining how the TOP
event can be caused by individual or combined
lower level failures or events.
The causes of the TOP event are “connected”
through logic gates.
Fault Tree Analysis Construction
Define the TOP event in a clear and unambiguous
way. Should always answer:
What e.g., “Fire”
Where e.g., “in the process oxidation reactor”
When e.g., “during normal operation”
What are the immediate, necessary, and sufficient
events and conditions causing the TOP event?
Connect via AND- or OR-gate
Proceed in this way to an appropriate level (=basic
events)
Appropriate level:
Independent basic events
Events for which we have failure data
Example 4: Event Tree Analysis (ETA)
Analysis technique for identifying and evaluating
the sequence of events in a potential accident
scenario following the occurrence of an initiating
event.
Focused on:
To analyse how and why incident could occur
Graphic technique – traces branches of events
To calculate probability of end event
Example: Water Pumping System
a) No water flow occurs if both pumps fail or if the control
valve fails.
b) If the individual initiating event probabilities P(A), P(B),
and P(C) are known, then the probability of P(T) the top or
end event can be calculated.
Below is an example ETA for a fire detection and suppression system in an office
building. This ETA analyzes all the possible outcomes of a system fire. The IE for
the ET is “fire starts.” Note the range of outcomes resulting from the success or
failure of the safety subsystems (pivotal events).
Note from this example that when computing the success/fail probability for each
contributing PE that the PE states must always sum to 1.0, based on the reliability
formula that PSUCCESS + PFAILURE = 1. Also note that in this case there are three
contributing PEs that generate five possible different outcomes, each with a
different probability.
Example 5: Failure Mode & Effects
Analysis (FMEA)
FMEA is a procedure by which each potential
failure and the kinds of failures that could happen,
at the component level, in the system are
examined and analysed to determine its effect on
the system, in terms of maximum potential loss.
The results are classified according to its severity.
FMEA has gained wide acceptance by the aerospace and the military industries. In fact, the technique has adapted itself in other form such as misuse mode and effect analysis.
The FMEA is used to assure that component failure modes and their effects have been considered and either eliminated or controlled; that information for maintenance and operational manuals has been provided; and that input to other safety analyses has been generated.
RISK ASSESSMENT
Risk Assessment Approaches
Determining Severity and Likelihood of Hazard
Occurrence in three types of approach:
1. Quantitative
2. Semi – Quantitative
3. Qualitative
Qualitative Risk Assessment
Approach
Risk assessment process:
Gather information about each hazard identified.
Think about how many people are exposed to each
hazard and for how long.
Use the information to assess the likelihood and
severity of each hazard and produce a qualitative risk
table.
Likelihood
How likely is it that a hazardous event or situation
will occur?
1) Very likely – could happen frequently
2) Likely – could happen occasionally
3) Unlikely – could happen, but only rarely
4) Highly unlikely – could happen, but probably never will
Likelihood of harm can be increased by Unsafe
Conditions or Unsafe Acts found.
Unsafe conditions:
1) Assess the likelihood due to failure of plant,
machinery, safety devices and failure of utilities
(electricity and water) and exposure of plants or
equipment to weather (rain, dust and sun)
2) Exposure to hazardous substances e.g. frequency and
duration of exposure; concentration and toxicity of
substances
3) Exposure to hazardous substance environments
(sound, vibrations, radiations, etc.)
4) Number of personnel exposed.
Unsafe Acts by persons who:
1) Horseplay and taking shot
2) May not know what the hazards are
3) May not have the knowledge, physical capacity, or
skills to do the work.
4) Underestimate risks exposure
5) Underestimate value of safe working methods.
Severity
1) Fatality
2) Major injuries (normally irreversible injury or
damage to health)
3) Minor injuries (normally reversible injury or
damage to health requiring days off work)
4) Negligible injuries (first aid, near miss)
Once you‟ve decided on the likelihood and
consequence of each hazardous event or situation,
you need to rate them according to how serious
the risk is.
This „risk table‟ is one way of doing this. You can
use it to translate your assessments of likelihood
and consequence into levels of risk.
Events or situations assessed as very likely with
fatal consequences are the most serious (HIGH
risk); those assessed as highly unlikely with
negligible injuries are the least serious (LOW risk).
When you‟re developing risk control strategies,
you should tackle anything with a HIGH rating first.
Quantitative Risk Assessment
Approach
Risk = Consequence X Likelihood
In practice people estimate risk quantitatively (i.e.
using numbers)
Numbers are given to represent the level of
„likelihood‟ and „severity‟.
Numbers can be multiplied together, ranked by value
To get the estimated risk, multiply the two numbers
(representing consequence and likelihood).
Calculation
i. If likelihood of a hazard is estimated = 2
ii. If the severity is estimated = 4
iii. Risk = 2 x 4 = 8
RISK CONTROL
Information on control measures can come from:
a) Codes of practice
b) Industry or trade associations
c) Specialists
d) MSDS
e) Other publications including those by manufacturers
and suppliers.
Material Safety Data Sheet (MSDS)
MSDS are special sheets that summarize all pertinent
information about a specific chemical.
The hazard communication standard of the OSH act
requires that chemicals suppliers provide users with an
MSDS for each chemical covered by the standard.
An MSDS should contain the following information:
Manufacturer‟s name
Address
Telephone number
List of hazardous ingredients
Physical & chemical characteristics
Fire and explosion hazard information
Reactivity information
Health hazard information
Safety precautions for handling
Recommended control procedures
The following hierarchy should be used when considering control measures.
Most effective
Elimination – removing the hazard or hazardous work practice from the workplace. This is the most effective control measure;
Fairly Effective
Substitution – substituting or replacing a hazard or hazardous workplace with a less hazardous one;
Isolation – isolating or separating the hazard or hazardous work practice from people not involved in the work or the general work areas. This can be done by marking off hazardous areas, installing screens or barriers;
Least Effective
Administrative control – includes introducing work practices
that reduce the risk. This could include limiting the amount
of time a person is exposed to a particular hazard; and
Personal Protective Equipment (PPE) – should be considered
only when other control measures are not practicable or to
increase protection. As last resort measure.
Process Flow of HIRARC
Implementation
Hazard identification
• List down the steps to complete a task
• identify possibility of hazard in every step
• List down the hazards
Risk Assessment • List down safety control available
(eg: Emergency switch, SOP, fire ext) at the workplace
• Determine the existing type of control
-Eliminate -Replace -Engineering Control -Administrative control -PPE
• Assessment • Scoring
Risk Control • List down the new/ additional
safety control required • Refer to hierarchy of control • Priority must be given to
engineering control. PPE the last choice
• Finalize