Job Hazard Analysis. A Guide for Voluntary Compliance and Beyond. From Hazard to Risk: Transforming the JHA from a Tool to a Process

Transcription

1 Job Hazard Analysis A Guide for Voluntary Compliance and Beyond From Hazard to Risk: Transforming the JHA from a Tool to a Process James E. Roughton Nathan Crutchfield E L S E V I E R AMSTERDAM. BOSTON. HEIDELBERG LONDON NEW YORK OXFORD PARIS SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY TOKYO Butterworth-Heinemann is an imprint of Elsevier

2 Contents About the Authors Foreword Preface Introduction Acronyms xvii xix xxi xxix xxxvii Part 1 Developing a Toolkit for Identifying Workplace Hazards and Associated Risk 1 1 Preparing for the Hazard Analysis and Risk Assessment THE CENTERPIECE OF A SAFETY PROCESS, HAZARD RECOGNITION AND CONTROL SYSTEMS, Conducting a Risk Assessment of the Workplace, Prioritizing the Risk Assessment Findings, Developing Solutions to Resolve Risk-Related Issues, Recommending and Implementing Controls, Monitoring the Results, DEVELOPING A SYSTEM TO IDENTIFY AND REPORT HAZARDS, Company Safety Policy, Involving Employees in the JHA Process, Protecting Employees from Harassment, Identifying Workplace Hazards, MAINTENANCE WORK ORDERS, FORMS USED TO REPORT HAZARDS, ACTION PLANNING, TRACKING HAZARDS, Tracking by Committee, Follow-up Reviews, CODES OF SAFE WORK PRACTICES, SUMMARY, 18 CHAPTER REVIEW QUESTIONS, 19 REFERENCES, 19 VII

3 viii Contents Appendix A 21 A.I SAMPLE GUIDANCE IN WRITING A POLICY STATEMENT, 21 A.2 CLOSING STATEMENT, 23 A.3 SUMMARY, 26 Appendix B 27 B.I SAMPLE FORMS FOR EMPLOYEE REPORTING OF HAZARDS, 27 Appendix C 33 C.I ACTION PLANNING: THREE SAMPLE VERSIONS ARE INCLUDED, 33 Appendix D 37 D.I CODES OF SAFE WORK PRACTICES, 37 2 Workplace Hazard Analysis and Review of Associated Risk ANALYSIS OF THE WORKPLACE, INSPECTIONS AND AUDITS, THE CHECKLIST, Consultants and Outside Specialists, Employee Interviews, TYPES OF INSPECTIONS, General Walk-Around Inspections, Verification Reviews, Focus Reviews, Self-Assessment, Document Review, Written Inspection Reports, WHO SHOULD REVIEW THE WORKPLACE?, Supervisors, Employees, Safety Professionals, PREVENTIVE MAINTENANCE PROGRAMS, OTHER THINGS TO CONSIDER DURING A SITE INSPECTION, Incident Investigations, Trend Analysis, 54

4 Contents ix 2.8 SUMMARY, 55 CHAPTER REVIEW QUESTIONS, 56 REFERENCES, 56 Appendix E 57 E.I SELF-INSPECTION CHECKLIST, 57 3 Developing Systems to Manage Hazards HIERARCHY OF CONTROLS, WHY ENGINEERING CONTROLS?, ADMINISTRATIVE CONTROLS, PPE, PPE Limitations, PPE Hazard Assessment, WORK PRACTICES AND SAFETY RULES, General Safety Rules, Limitations of Work Practices and Safety Rules, CHANGE ANALYSIS, A Change in the Process, Building or Leasing a New Facility, New Equipment Installation, Using New Materials, Employee Changes, Adapting to Change, Other Analytical Tools for Consideration, SUMMARY, 123 CHAPTER REVIEW QUESTIONS, 124 REFERENCES, 124 Appendix F 127 F.I SAMPLE SAFETY RULES, 127 Appendix G 129 G.I PERSONAL PROTECTIVE EQUIPMENT (PPE) ASSESSMENT, 129 G.2 GUIDELINES FOR COMPLYING WITH PPE REQUIREMENTS, 129 G.3 HAZARD ASSESSMENT FOR PPE, 130 G.4 JOB HAZARD ANALYSIS ASSESSMENT FOR PPE, 137 G.5 EXAMPLE PERSONAL PROTECTIVE EQUIPMENT TRAINING CERTIFICATION FORM, 142

5 x Contents G.6 EXAMPLE PERSONAL PROTECTIVE EQUIPMENT TRAINING QUIZ, 143 G.7 SAMPLE PPE POLICIES, 144 Appendix H 151 H.I SAFETY REVIEW OF NEW/RELOCATED EQUIPMENT MAJOR MODIFICATION SIGN-OFF FORM, 151 Appendix I 153 I.I OTHER ANALYTICAL TOOLS FOR CONSIDERATION, 153 Part 2 Developing Systems that Support Hazard Recognition Understanding the Human Role in the Safety Process HOW ARE AT-RISK EVENTS DEVELOPED?, WHAT CONTRIBUTES TO AN AT-RISK EVENT?, THE FEEDBACK LOOP, BEHAVIORAL APPROACH, CHANGING BEHAVIOR, Understanding Why Employees Put Themselves at Risk, UNDERSTANDING THE OTHER SIDE OF SAFETY, BENEFITS OF BEHAVIOR-BASED SAFETY, BEHAVIOR-BASED SAFETY AND INTEGRATED SAFETY MANAGEMENT FUNCTIONS, Seven Guiding Principles of Integrated Safety Management, WILL A BEHAVIORAL PROCESS WORK FOR YOU?, SUMMARY, 176 CHAPTER REVIEW QUESTIONS, 177 REFERENCES, 178 Appendix J 179 J.I SAMPLE BEHAVIOR (AT-RISK EVENTS) LIST, Effective Use of Employee Participation WHY SHOULD EMPLOYEES BE INVOLVED?, INVOLVING EMPLOYEES IN THE SAFETY MANAGEMENT SYSTEM, 184

6 Contents xi Close Contact with Hazards, Improved Support, More Participation, More Awareness, HAWTHORNE STUDY, COMMITTEE PARTICIPATION, Getting Employee Participation Started, Form a Committee, How to Use Employees in the Process, AREAS OF EMPLOYEE PARTICIPATION, Conducting Site Inspections, Routine Hazard Analysis, Developing or Revising Site-Specific Safety Rules, Training Other Employees, Employee Orientation, Different Approaches: Union and Non-Union Sites, Forms of Employee Participation, What Can Management Do?, SUMMARY, 197 CHAPTER REVIEW QUESTIONS, 199 REFERENCES, 199 Appendix K 201 K.I EXAMPLE OF A COMMITTEE TEAM CHARTER, Defining Associated Risk RISK MANAGEMENT, GENERAL RISK MANAGEMENT THEORIES AND MODELS, Employee Considerations, The Environment, Tools/Equipment/Material Considerations, Management Support and Policies, and Procedure Considerations, Job Steps and Task Considerations, THE SYSTEM ENGINEERING MODEL, RISK VERSUS BENEFIT, RISK MANAGEMENT COMMUNICATION, Risk Management Responsibilities, Supervision Responsibilities, Employee Responsibilities, RISK ASSESSMENT, 216

7 xii Contents 6.7 CLASSIFICATION AND RANKING HAZARDS, Risk versus Opportunity, SAFETY SIGNIFICANCE, WHAT DOES SUCCESS LOOK LIKE?, SUMMARY, 230 CHAPTER REVIEW QUESTIONS, 231 REFERENCES, Assessing Safety and Health Training Needs HOW IS A GOOD TRAINER DEFINED?, Basic Training Principles, Types of Safety Education, Training Plan Linked to Consequences, STEPS IN THE COURSE DEVELOPMENT PROCESS, Conducting a Training Needs Assessment, Establishing Learning Objectives, Course Content Development, Safety Program Evaluation, Recordkeeping, Develop Improvement Strategies, "BLUE'S CLUES" TRAINING TECHNIQUES, Improved Self-Esteem?, SUMMARY, 264 CHAPTER REVIEW QUESTIONS, 265 REFERENCES, 265 Appendix L 267 L. 1 SAMPLE SAFETY AND HEALTH TRAINING POLICY, 267 L.2 ANSI GUIDELINES FOR EVALUATING TRAINING PROGRAMS, 274 L.3 SAMPLE SAFETY TRAINING PROGRAM AUDIT, 275 L.4 SAMPLE TRAINING CERTIFICATION, 278 Part 3 Developing an Effective Job Hazard Analysis Planning for the Job Hazard Analysis WHERE DO I BEGIN?, Regaining the "Feel" of the Workplace, Conducting the JHA, Why Is a JHA Important?, 286

8 Contents xiii 8.2 WHY IS IT IMPORTANT TO GET EMPLOYEES INVOLVED IN THE PROCESS?, SELECTING A TEAM, HOW DO I KNOW THAT A JHA WILL WORK FOR ME?, DEFINING THE JHA, SELECTING THE JOBS FOR ANALYSIS, Nonroutine Tasks, SUMMARY, 303 CHAPTER REVIEW QUESTIONS, 304 REFERENCES, 305 Appendix M 307 M.I DESCRIPTION OF COMMON HAZARDS, Breaking the Job Down into Individual Components BASIC STEPS IN THE JHA DEVELOPMENT PROCESS, TASKS DEFINED, USING A CHECKLIST, METHODS FOR BREAKING DOWN THE JOB INTO STEPS AND TASKS, Discussion Method, Observation Method, WHAT TOOLS CAN BE USED TO ENHANCE THE JHA PROCESS?, Cameras and Video Equipment, Drawings and Sketches, "CAN'T SEE THE FOREST FOR THE TREES", SUMMARY, 325 CHAPTER REVIEW QUESTIONS, 326 REFERENCES, 327 Appendix N 329 SAMPLE FACILITY CHECKLIST, Putting Together the Puzzle Pieces COMPLETING THE JHA FORM, The Header, Body of JHA, 338

9 xiv Contents 10.2 BENEFIT REVIEW: GETTING THE BIGGEST BANG FOR THE BUCK, OKAY, I HAVE COMPLETED THE JHA: NOW WHAT?, Review JHAs until Employee Understands Hazards of Job, REVISING THE JHA, SUMMARY, 352 CHAPTER REVIEW QUESTIONS, 352 REFERENCES, 353 Appendix O 355 O.I SAMPLE INSTRUCTIONS ON HOW TO CHANGE A TIRE ON A CAR, 355 O.2 SAMPLE JHA PRE-HAZARD ASSESSMENT WORKSHEET, 357 O.3 JHA - CHANGING A TIRE, 358 O.4 ANNOTATED JHA - CHANGING A TIRE EXAMPLE, COMPARISON JHA ON CHANGING A TIRE: TRADITIONAL vs. NEW VERSION, JOB HAZARD ANALYSIS, CANADIAN CENTRE FOR OCCUPATIONAL HEALTH & SAFETY (CCOHS) REPRINTED WITH PERMISSION, Standard or Safe Operating Procedures (SOP) HOW FAR IS FAR ENOUGH? WHY DEVELOP AN SOP?, ELEMENTS OF AN SOP, SUMMARY, 375 CHAPTER REVIEW QUESTIONS, 375 REFERENCES, 375 Appendix P 377 P.I STANDARD OPERATING PROCEDURE FOR SPLICING: {INSERT SIMPLE INSTRUCTIONS}, 377

10 Contents xv Part 4 Additional Tools That Can Be Used to Develop a Successful JHA Overview of a Safety Management Process PROCESS ELEMENTS, What Are the Voluntary Protection Programs?, How Does VPP Work?, How Does VPP Help Employers and Employees?, MANAGEMENT COMMITMENT AND LEADERSHIP, EMPLOYEE PARTICIPATION, HAZARD IDENTIFICATION AND ASSESSMENT, HAZARD PREVENTION AND CONTROL, EDUCATION AND TRAINING, Employee Training, Management Training, EVALUATION OF PROCESS EFFECTIVENESS, THE NATURE OF ALL SAFETY SYSTEMS, INDICATORS AND MEASURES, ASSESSMENT TECHNIQUES, MULTI-EMPLOYER WORKPLACE, EMPLOYEE RIGHTS, HEALING A SICK SYSTEM, THE PDSA CYCLE, VOLUNTARY PROTECTION PROGRAM, SUMMARY, 404 CHAPTER REVIEW QUESTIONS, 405 REFERENCES, Six Sigma as a Management System: A Tool for Effectively Managing a JHA Process SIX SIGMA EXPOSED, The Beginning, What Does Process Improvement Mean?, What Does Process Improvement Look Like?, Benefits of Improving a Process, Improving the Process Using the Six Sigma Methodology, 412

11 xvi Contents 13.2 A BASIC SIX SIGMA PROCESS IMPROVEMENT MODEL, DMAIC Methodology, Define Phase, Measure Phase, Analyze Phase, Improve Phase, Control Phase, KEY AREAS OF SIX SIGMA, SIX SIGMA LEVELS, INVESTING IN PREVENTION PAYS OFF!!, POSITIVE CHANGES TO CORPORATE CULTURE, SUMMARY, 439 CHAPTER REVIEW QUESTIONS, 440 REFERENCES, 440 Appendix Q 441 Q.I XY MATRIX, 441 Q.2 DEVELOPING THE MATRIX, 441 Final Words: Can You Develop a Culture That Will Sustain Itself? 451 TAKING A CLOSER LOOK AT REALITY, 452 REFERENCE, 454 Appendix R 455 R.I OSHA LISTINGS, 455 Glossary 469 Index 477