Module 2: Embedding Safety into Work Processes

1. Safety Begins with ME! Module 2:Embedding Safety into Work Processes Created by with funding from Oregon OSHA

2. Assignments What safety concerns did you spot/report/fix this week? • Spot and report workplace safety concerns • Work as a team to 5-S an area What area did you 5-S? (Before/After Pictures, if possible)

3. Safety Begins with ME! Leading Safety Influencing Safe Behaviors Embedding Safety into Work Processes Embedding Safety into Work Processes Recognizing (and Controlling) Safety Hazards

4. Broken?! Have you ever found yourself annoyed by something not working as it should? http://youtube.com/watch?v=9V6SSO-IxcY(Egg processing line)

5. People vs. Process “80% of problems are caused NOT by bad PEOPLE, but by bad PROCESS.” - Deming, father of quality movement If you pit a great PERFORMER against a lousyPROCESS, the process will win every time. – Geary Rummler, Performance Consultant

6. PREVIEW Module Preview Embedding Safety into Work Processes • Types and Causes of Hazards • Job Safety Analysis • Work Instructions • Assignments

7. Health Hazards Chemicals: Solvents, gases, etc. Physical: Noise, vibration, heat/cold, radiation Biological: Bacteria, fungi, insects Ergonomic: Workplace design, repetitive motion Safety Hazards Machine: Moving parts, belts, blades Energy: Pneumatics, hydraulics, steam, kinetic, electricity Material handling: hand carts, conveyors Work Practices Two Types of Hazards

8. Causes of Hazards • Materials – Wrong types or improper handling • Equipment – Tools & machines used • Process – Combination of above: flow of work, design, organization • Environment – Conditions of surfaces, ventilation, lighting, temperature, noise, housekeeping • Energy – In various forms may harm if not controlled • People – Actions people take (or do not take) Causes of Hazards Wall Poster

9. Job Safety Analysis PURPOSE: To identify potential hazards within a process and take proactive steps to eliminate them or minimize the risk. WHO:Need people who know the work/task to participate in this process (and know HOW to do this) STEPS: • List basic job steps • Identify potential hazards • Resolve hazards Job Safety Analysis Wall Poster Job Safety Analysis Job Aid Job Safety Analysis Form

10. Exercise Job Safety Analysis Exercise Purpose: To practice conducting a Process Safety Analysis. • Step 1: List Sequence of Basic Job Steps (Column 1)(If possible, view a videotape of the process as you do this) • Step 2: Identify Potential Hazards (Column 2) • Step 3: Recommend Safe Job Procedures (Column 3)

11. Exercise Job Safety Analysis – Step 1:List Sequence of Basic Job Steps (Column 1) • List step-by-step what must be done • Choose level of detail that is fairly specific • May help to list steps on post-it-notes or sheets of paper that can be moved around on the wall

12. Exercise Possible Resources: Wall Poster: Causes of Hazards Handout: Safety: I KNOW it when I SEE it Hazard Cards Various industry checklists Job Safety Analysis – Step 2: Identify Potential Hazards (Column 2) • Remember Hazards can be of two types: • Health hazards (ergonomic concerns, noise, chemicals, bacteria) • Safety hazards (moving parts, energy, material handling) • And may be caused by: • Materials • Equipment • Process • Environment • Energy • People

13. Exercise Job Safety Analysis – Step 3:Recommend Safe Job Procedures (Column 3) Ways to Increase Job Safety: • Eliminate the hazards • Control exposure • Avoid general warnings to “be careful” which do little good • If you find too many hazards, question the entire task. Should it really be done?

14. Safe Equipment – Engineering Controls Good Housekeeping (5-S) Safe Work Practices – Management/Administrative Controls Personal Protective Equipment (PPE) Temporary Measures Hazard Control Measures Hazard Control Measures Hazard Control Measures Wall Poster

15. Procedure Manual Forms of Work Instructions Procedure Manuals

16. Forms of Work Instructions Job Aids

17. Forms of Work Instructions Placards – Visual Work

18. More Visual Instructions

19. SD Drivers are reminded of highway fatalities at many points along their route – one sign for each death. Each Sign Reads: “X Marks the Spot. THINK! Drive Safely” On the back it says: “Why Die?” Would we be more careful if we were reminded daily at work of injuries that had occurred? South Dakota Highway Sign

20. ? Important Questions ? • What is your responsibility for work instructions? • Whose responsibility is it to know and follow the documented work instructions? • Whose responsibility is it to make sure that everyone is following safe work procedures? ?

21. REVIEW Module Review • Hazards come in many shapes and sizes – • Health hazards and Safety hazards • Six broad causes: M E P E E P • Job Safety Analysis is a disciplined approach to identifying and minimizing hazards • Work instructions can be formal (procedure manuals) or informal (job aids andplacards) • Everyone is responsible to identify and control workplace hazards

22. Assignments • Perform a Job Safety Analysis – Each area should schedule time to perform a JSA of an important task they perform • Improve or create a new work instruction. Be sure that any work instructions associated with jobs that have been analyzed (in #1) are revised to reflect the safety improvements

23. Thank You for Participating Just a little bit of prevention . . . . . . can prevent a whole lot of pain! Let’s be sure that we BUILD SAFETY into our work processes.