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
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... 3 1.1 THE CENTERPIECE OF A SAFETY PROCESS, 4 1.2 HAZARD RECOGNITION AND CONTROL SYSTEMS, 5 1.2.1 Conducting a Risk Assessment of the Workplace, 5 1.2.2 Prioritizing the Risk Assessment Findings, 6 1.2.3 Developing Solutions to Resolve Risk-Related Issues, 6 1.2.4 Recommending and Implementing Controls, 6 1.2.5 Monitoring the Results, 6 1.3 DEVELOPING A SYSTEM TO IDENTIFY AND REPORT HAZARDS, 10 1.3.1 Company Safety Policy, 11 1.3.2 Involving Employees in the JHA Process, 11 1.3.3 Protecting Employees from Harassment, 12 1.3.4 Identifying Workplace Hazards, 12 1.4 MAINTENANCE WORK ORDERS, 15 1.5 FORMS USED TO REPORT HAZARDS, 16 1.6 ACTION PLANNING, 16 1.7 TRACKING HAZARDS, 17 1.7.1 Tracking by Committee, 17 1.7.2 Follow-up Reviews, 18 1.8 CODES OF SAFE WORK PRACTICES, 18 1.9 SUMMARY, 18 CHAPTER REVIEW QUESTIONS, 19 REFERENCES, 19 VII
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 39 2.1 ANALYSIS OF THE WORKPLACE, 40 2.2 INSPECTIONS AND AUDITS, 42 2.3 THE CHECKLIST, 42 2.3.1 Consultants and Outside Specialists, 43 2.3.2 Employee Interviews, 44 2.4 TYPES OF INSPECTIONS, 46 2.4.1 General Walk-Around Inspections, 46 2.4.2 Verification Reviews, 47 2.4.3 Focus Reviews, 48 2.4.4 Self-Assessment, 49 2.4.5 Document Review, 49 2.4.6 Written Inspection Reports, 49 2.5 WHO SHOULD REVIEW THE WORKPLACE?, 50 2.5.1 Supervisors, 50 2.5.2 Employees, 51 2.5.3 Safety Professionals, 51 2.6 PREVENTIVE MAINTENANCE PROGRAMS, 52 2.7 OTHER THINGS TO CONSIDER DURING A SITE INSPECTION, 53 2.7.1 Incident Investigations, 53 2.7.2 Trend Analysis, 54
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 105 3.1 HIERARCHY OF CONTROLS, 109 3.2 WHY ENGINEERING CONTROLS?, 110 3.3 ADMINISTRATIVE CONTROLS, 112 3.4 PPE, 114 3.4.1 PPE Limitations, 114 3.4.2 PPE Hazard Assessment, 115 3.5 WORK PRACTICES AND SAFETY RULES, 116 3.5.1 General Safety Rules, 116 3.5.2 Limitations of Work Practices and Safety Rules, 117 3.6 CHANGE ANALYSIS, 117 3.6.1 A Change in the Process, 119 3.6.2 Building or Leasing a New Facility, 119 3.6.3 New Equipment Installation, 120 3.6.4 Using New Materials, 121 3.6.5 Employee Changes, 122 3.6.6 Adapting to Change, 123 3.6.7 Other Analytical Tools for Consideration, 123 3.7 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
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 159 4 Understanding the Human Role in the Safety Process 161 4.1 HOW ARE AT-RISK EVENTS DEVELOPED?, 162 4.2 WHAT CONTRIBUTES TO AN AT-RISK EVENT?, 163 4.3 THE FEEDBACK LOOP, 166 4.4 BEHAVIORAL APPROACH, 168 4.5 CHANGING BEHAVIOR, 168 4.5.1 Understanding Why Employees Put Themselves at Risk, 169 4.6 UNDERSTANDING THE OTHER SIDE OF SAFETY, 171 4.7 BENEFITS OF BEHAVIOR-BASED SAFETY, 174 4.8 BEHAVIOR-BASED SAFETY AND INTEGRATED SAFETY MANAGEMENT FUNCTIONS, 174 4.8.1 Seven Guiding Principles of Integrated Safety Management, 175 4.9 WILL A BEHAVIORAL PROCESS WORK FOR YOU?, 176 4.10 SUMMARY, 176 CHAPTER REVIEW QUESTIONS, 177 REFERENCES, 178 Appendix J 179 J.I SAMPLE BEHAVIOR (AT-RISK EVENTS) LIST, 179 5 Effective Use of Employee Participation 181 5.1 WHY SHOULD EMPLOYEES BE INVOLVED?, 182 5.2 INVOLVING EMPLOYEES IN THE SAFETY MANAGEMENT SYSTEM, 184
Contents xi 5.2.1 Close Contact with Hazards, 185 5.2.2 Improved Support, 185 5.2.3 More Participation, More Awareness, 186 5.3 HAWTHORNE STUDY, 186 5.4 COMMITTEE PARTICIPATION, 188 5.4.1 Getting Employee Participation Started, 188 5.4.2 Form a Committee, 188 5.4.3 How to Use Employees in the Process, 189 5.5 AREAS OF EMPLOYEE PARTICIPATION, 191 5.5.1 Conducting Site Inspections, 191 5.5.2 Routine Hazard Analysis, 191 5.5.3 Developing or Revising Site-Specific Safety Rules, 193 5.5.4 Training Other Employees, 193 5.5.5 Employee Orientation, 193 5.5.6 Different Approaches: Union and Non-Union Sites, 193 5.5.7 Forms of Employee Participation, 196 5.5.8 What Can Management Do?, 196 5.6 SUMMARY, 197 CHAPTER REVIEW QUESTIONS, 199 REFERENCES, 199 Appendix K 201 K.I EXAMPLE OF A COMMITTEE TEAM CHARTER, 201 6 Defining Associated Risk 205 6.1 RISK MANAGEMENT, 206 6.2 GENERAL RISK MANAGEMENT THEORIES AND MODELS, 207 6.2.1 Employee Considerations, 209 6.2.2 The Environment, 210 6.2.3 Tools/Equipment/Material Considerations, 211 6.2.4 Management Support and Policies, and Procedure Considerations, 212 6.2.5 Job Steps and Task Considerations, 212 6.3 THE SYSTEM ENGINEERING MODEL, 213 6.4 RISK VERSUS BENEFIT, 214 6.5 RISK MANAGEMENT COMMUNICATION, 215 6.5.1 Risk Management Responsibilities, 215 6.5.2 Supervision Responsibilities, 216 6.5.3 Employee Responsibilities, 216 6.6 RISK ASSESSMENT, 216
xii Contents 6.7 CLASSIFICATION AND RANKING HAZARDS, 220 6.7.1 Risk versus Opportunity, 221 6.8 SAFETY SIGNIFICANCE, 227 6.9 WHAT DOES SUCCESS LOOK LIKE?, 229 6.10 SUMMARY, 230 CHAPTER REVIEW QUESTIONS, 231 REFERENCES, 231 7 Assessing Safety and Health Training Needs 233 7.1 HOW IS A GOOD TRAINER DEFINED?, 235 7.1.1 Basic Training Principles, 236 7.1.2 Types of Safety Education, 239 7.1.3 Training Plan Linked to Consequences, 243 7.2 STEPS IN THE COURSE DEVELOPMENT PROCESS, 244 7.2.1 Conducting a Training Needs Assessment, 244 7.2.2 Establishing Learning Objectives, 247 7.2.3 Course Content Development, 255 7.2.4 Safety Program Evaluation, 259 7.2.5 Recordkeeping, 262 7.2.6 Develop Improvement Strategies, 262 7.3 "BLUE'S CLUES" TRAINING TECHNIQUES, 262 7.3.1 Improved Self-Esteem?, 264 7.4 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 281 8 Planning for the Job Hazard Analysis 283 8.1 WHERE DO I BEGIN?, 284 8.1.1 Regaining the "Feel" of the Workplace, 284 8.1.2 Conducting the JHA, 285 8.1.3 Why Is a JHA Important?, 286
Contents xiii 8.2 WHY IS IT IMPORTANT TO GET EMPLOYEES INVOLVED IN THE PROCESS?, 291 8.3 SELECTING A TEAM, 292 8.4 HOW DO I KNOW THAT A JHA WILL WORK FOR ME?, 294 8.5 DEFINING THE JHA, 296 8.6 SELECTING THE JOBS FOR ANALYSIS, 298 8.6.1 Nonroutine Tasks, 303 8.7 SUMMARY, 303 CHAPTER REVIEW QUESTIONS, 304 REFERENCES, 305 Appendix M 307 M.I DESCRIPTION OF COMMON HAZARDS, 307 9 Breaking the Job Down into Individual Components 311 9.1 BASIC STEPS IN THE JHA DEVELOPMENT PROCESS, 311 9.2 TASKS DEFINED, 317 9.3 USING A CHECKLIST, 320 9.4 METHODS FOR BREAKING DOWN THE JOB INTO STEPS AND TASKS, 320 9.4.1 Discussion Method, 320 9.4.2 Observation Method, 321 9.5 WHAT TOOLS CAN BE USED TO ENHANCE THE JHA PROCESS?, 323 9.5.1 Cameras and Video Equipment, 323 9.5.2 Drawings and Sketches, 323 9.6 "CAN'T SEE THE FOREST FOR THE TREES", 324 9.7 SUMMARY, 325 CHAPTER REVIEW QUESTIONS, 326 REFERENCES, 327 Appendix N 329 SAMPLE FACILITY CHECKLIST, 329 10 Putting Together the Puzzle Pieces 333 10.1 COMPLETING THE JHA FORM, 335 10.1.1 The Header, 335 10.1.2 Body of JHA, 338
xiv Contents 10.2 BENEFIT REVIEW: GETTING THE BIGGEST BANG FOR THE BUCK, 348 10.3 OKAY, I HAVE COMPLETED THE JHA: NOW WHAT?, 348 10.3.1 Review JHAs until Employee Understands Hazards of Job, 349 10.4 REVISING THE JHA, 349 10.5 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, 361 0.5 COMPARISON JHA ON CHANGING A TIRE: TRADITIONAL vs. NEW VERSION, 362 0.6 JOB HAZARD ANALYSIS, CANADIAN CENTRE FOR OCCUPATIONAL HEALTH & SAFETY (CCOHS) REPRINTED WITH PERMISSION, 363 11 Standard or Safe Operating Procedures (SOP) 371 11.1 HOW FAR IS FAR ENOUGH? WHY DEVELOP AN SOP?, 371 11.2 ELEMENTS OF AN SOP, 373 11.3 SUMMARY, 375 CHAPTER REVIEW QUESTIONS, 375 REFERENCES, 375 Appendix P 377 P.I STANDARD OPERATING PROCEDURE FOR SPLICING: {INSERT SIMPLE INSTRUCTIONS}, 377
Contents xv Part 4 Additional Tools That Can Be Used to Develop a Successful JHA 379 12 Overview of a Safety Management Process 381 12.1 PROCESS ELEMENTS, 383 12.1.1 What Are the Voluntary Protection Programs?, 383 12.1.2 How Does VPP Work?, 383 12.1.3 How Does VPP Help Employers and Employees?, 383 12.2 MANAGEMENT COMMITMENT AND LEADERSHIP, 387 12.3 EMPLOYEE PARTICIPATION, 387 12.4 HAZARD IDENTIFICATION AND ASSESSMENT, 388 12.5 HAZARD PREVENTION AND CONTROL, 389 12.6 EDUCATION AND TRAINING, 390 12.6.1 Employee Training, 390 12.6.2 Management Training, 391 12.7 EVALUATION OF PROCESS EFFECTIVENESS, 391 12.8 THE NATURE OF ALL SAFETY SYSTEMS, 391 12.9 INDICATORS AND MEASURES, 395 12.10 ASSESSMENT TECHNIQUES, 395 12.11 MULTI-EMPLOYER WORKPLACE, 396 12.12 EMPLOYEE RIGHTS, 396 12.13 HEALING A SICK SYSTEM, 397 12.14 THE PDSA CYCLE, 399 12.15 VOLUNTARY PROTECTION PROGRAM, 400 12.16 SUMMARY, 404 CHAPTER REVIEW QUESTIONS, 405 REFERENCES, 405 13 Six Sigma as a Management System: A Tool for Effectively Managing a JHA Process 407 13.1 SIX SIGMA EXPOSED, 408 13.1.1 The Beginning, 408 13.1.2 What Does Process Improvement Mean?, 409 13.1.3 What Does Process Improvement Look Like?, 411 13.1.4 Benefits of Improving a Process, 412 13.1.5 Improving the Process Using the Six Sigma Methodology, 412
xvi Contents 13.2 A BASIC SIX SIGMA PROCESS IMPROVEMENT MODEL, 413 13.2.1 DMAIC Methodology, 414 13.2.2 Define Phase, 416 13.2.3 Measure Phase, 421 13.2.4 Analyze Phase, 427 13.2.5 Improve Phase, 431 13.2.6 Control Phase, 432 13.3 KEY AREAS OF SIX SIGMA, 434 13.4 SIX SIGMA LEVELS, 435 13.5 INVESTING IN PREVENTION PAYS OFF!!, 436 13.6 POSITIVE CHANGES TO CORPORATE CULTURE, 438 13.7 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