Transcript SAFETY AUDIT

SAFETY AUDIT A KEY
FOR
HAZARD IDENTIFICATION
TECHNIQUE
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What is Safety Audit
Verifying the existence and implementation of
elements of occupational safety and health
system and for verifying the system’s ability to
achieve defined safety objectives
~~~IS-14489-1998
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CONCERNS OF MANAGEMENT
• QUANTITY PRODUCED IN RELATION TO
PRODUCTION SCHEDULE AND MARKET
REQUIREMENT
• PRODUCT QUALITY
• PRODUCTION COSTS
• INTEGRATING THE STAKEHOLDERS
CONCERNS
•Is Safety Important? Not always
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SAFE AND SOUND
• A study of top companies in the world
indicated that
‘Safety
and
Loss
Prevention
Programmes were essential for a
company’s prosperity and accepted as
part of good Business'.
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Why do organizations have to bother
about Safety
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Corporate Strategy
Finance
Human Resources
Marketing, Product Design and Product
Liability
• Manufacturing and operating policy
• Information Management and systems
• Societal Concerns
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Societal Concerns
• Increased concern about the impact on
the public not just the workforce
concerned
• Public intolerance of risks which do
not have clear benefits to those
affected
• Readiness to press for retribution on
those who cause harm and to seek
compensation
• Demand for increased transparency
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• Demand for full information and
for public involvement
• A willingness to challenge and
complain
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Corporate Strategy
• Business Mission, Philosophy and
codes of ethics
• Company image in the community
• Environment impact
• Management Professionalism
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Finance
• Loss Control and cost reduction
strategies
• Product liability, Legal liability,
Property damage
• Risk retention or transfer
• Investment
decisions
concerning
business acquisitions
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Human Resources
• Work and job structuring
• Morale and retaining people
• Positive health structure
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Marketing, product design and product
liability
• Specification of product and
service
• Legal requirement
• International requirement
• Consumer protection act
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Manufacturing and operating policy
• Design/selection/construction/maintenance
of premises, plant, equipment and
substances
• Quality management
• Environment management and waste
disposal
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Information management and systems
• Identification of data critical to the
management of health and safety
• Selection of appropriate performance
indicators
• Use of information technology in the
collection and analysis of essential
data.
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Organizations carry out
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Safety Audit
Safety Survey
Safety Inspection
Safety Tour
Safety Sampling
HAZOP
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• Safety Survey: Detailed examination of a
narrower field of activity-e.g.- key areas
revealed by safety audits
• Safety Inspection: Routine inspection-work
is being carried in accordance with
procedures etc.
• Safety Tour: Unscheduled examinationhazards are removed-standards are removed
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• Safety Sampling: Trained observers
record the number of safety defects
seen while touring specified locations
by a prescribed route. Typically tours
last for 15 min. and are conducted at
weekly intervals. The unweighted
count of defects is used to portray
trends in the safety situation.
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SAFETY AUDIT
MONITORING
• COMPARE ACTUAL
PERFORMANCE STANDARDS
• COMPREHENSIVE
• CONTINUOS
AUDIT
• NOT DONE BY
INSIDER
• NOT
COMPREHENSIVEDEPENDS ON SCOPE
• PERIODIC
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DIFFERENT TYPES OF AUDIT
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Electrical Audit
Fire Safety Audit
Pressure vessels Audit
Lifting Tackles Audit
Statutory Regulations Compliance
Audit
• Emergency Communication Audit
• Pipe lines Audit
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SAFETY AUDIT
• OCCUPIERS
ARE
REQUIRED
TO
DEMONSTRATE THEIR CAPABILITY TO
DESIGN LOCATE OPERATE AND MAINTAIN
THEIR
FACILITIES
TO
STANDARDS
ACCEPTABLE TO THE GOVT. AND PUBLIC.
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AUDIT
• AN
AUDIT
IS
A
SYSTEMATIC
INDEPENDENT REVIEW TO VERIFY
CONFORMANCE
WITH
ESTABLISHED
GUIDE LINES OR STANDARDS. IT
EMPLOYS
WELL DEFINED
REVIEW
PROCESS TO ENSURE CONSISTENCE
AND TO ALLOW THE AUDITOR TO REACH
DEFENSIBLE CONCLUSIONS.
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OBJECTIVES OF THE SAFETY AUDIT
• DESIGN
DEFICIENCIES
AND
ALSO
WEAKNESSES
WHICH
MIGHT
HAVE
CROPPED UP DURING MODIFICATIONS
/ADDITIONS.
• FIRE PROTECTION ARRANGEMENTS AND
SAFETY SYSTEMS.
• OPERATING /MAINTENANCE PROCEDURESDEGRADED WITH TIME
• TRAINING, PREPAREDNESS FOR HANDLING
EMERGENCIES.
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SCOPE OF AUDIT
• FIRE AND EXPLOSION; PREVENTION,
PROTECTION AND EMERGENCY
MANAGEMENT.
• WORK INJURY PREVENTION.
• HEALTH HAZARDS CONTROL.
• CONSEQUENCES OF EMERGENCIES.
• ON SITE EMERGENCY CONTROL
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Elements of Occupational Safety and
Health System-IS14489
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Occupational Health and Safety Policy
OS&H organizational set up
Education and Training
Employees participation in OS&H Management
Motivational and Promotional measures for
OS&H
• Safety Manual and Rules
• Compliance with Statutory Requirements
• New Equipment review and inspection
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Elements contd..
• Accident reporting analysis investigation and
implementation and recommendations
• Risk Assessment including hazard identification
• Safety inspections
• Health and safety improvement plan/targets
• First aid facilities-Occupational health center
• Personal Protective Equipment
• Good housekeeping
• Machine and general area guarding
• Material handling equipment
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Elements contd..
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Electrical and Personal safeguarding
Ventilation, illumination and noise
Work environment monitoring system
Prevention of occupational diseases including
periodic medical examination
Safe operating procedures
Work Permit systems
Fire Prevention, Protection and fighting systems
Emergency Preparedness plans(onsite/offsite)
Process Plant modification procedure
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Elements contd..
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Transportation of hazardous substances
Hazardous waste treatment and disposal
Safety in storage and warehousing
Contractor safety systems
Safety for customers(including MSDS)
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Records to be examined during Audit
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OS&H Policy
Safety organization chart
Training Records on safety, fire and first aid
Accident investigation reports
Accidents and dangerous occurrences-Statistics and
analysis
Records of tests and examination of equipment and
structures
Safe operating procedures for various operations
Record of work permits
Record of montioring of flammable and explosives
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Records- Contd..
• Maintenance and testing records of fire detection
and fire fighting equipment
• Medical records of employees
• Records of industrial hygiene surveys(noise,
ventilation, illumination levels, airborne and toxic
substances, explosive gases)
• MSDS
• Onsite emergency plans and record of mockdrills
• Records of waste disposal
• Records of effluent discharge to the environment
• Housekeeping inspection records
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Records contd..
• Minutes of Safety committee meetings
• Approval of layouts and other approvals from statutory
authorities
• Records of any modifications carried out in plant and
process
• Maintenance procedure records
• Calibration and testing records
• Shutdown maintenance procedures
• In service inspection manuals, records including that of
material handling
• Safety Budget
• Statutory Records, Previous audit reports,
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Transportation of Hazardous substances
TOPICS ON WHICH INFORMATION IS
COLLECTED
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SAFETY ORGANIZATION.
CONTRACTOR EMPLOYEE ACTIVITIES.
MATERIAL SAFETY DATA.
OCCUPANCY.
SAFETY AND HEALTH POLICY.
OPERATION AND MAINTENANCE OF
SAFETY MANUAL.
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• EXPANSION MODIFICATION AUTHORIZATION PROCEDURES.
• SAFETY EDUCATION , TRAINING.
• STATUTORY STANDARDS, SAFETY IF
• JOB SAFETY ANALYSIS.
• JOB SAFETY INSTRUCTIONS
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.TOPICS CONTD.
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SAFETY INSPECTION.
SAFETY OBSERVATIONS.
WORK PERMIT SYSTEM.
FIRE PROTECTION ARRANGEMENTS
FIRE EMERGENCY CONTROL
PROCEDURES.
• WORK ENVIRONMENT MONITORING.
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• PERSONAL PROTECTIVE EQUIPMENT.
• MEDICAL/AMBULANCE FACILITIES.
• ACCIDENT/INCIDENT-REPORTING
INVESTIGATION ANALYSIS.
• IDENTIFICATION OF CRITICAL EQUIPMENT AND
PREUSE
INSPECTION
OF
CRITICAL
EQUIPMENT
• OFF THE JOB -SAFETY.
• STATISTICAL INF. ON LOSSES INJURIES.
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Manufacture, Storage and import of
Hazardous Chemicals Rules, 1989
• Safety Audit is required to be carried out by
by the occupiers of both the new and the
existing industrial activities with the help of
an expert not associated with such industrial
activities.
• This is required under Rule No.10-subrule
(4)
• This has come into effect from 3/10/94
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Traits of an auditor
• Dispel the myth that it is policing on
behalf of management
• Is questionnaire useful?
• Knowledge in the area being visited
• Blinkered view?
• Discussion is more importantFacilitator rather than an inspector.
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Are you a good auditor?
• FINISHED
RESULT
FILES
OF
ARE
THE
YEARS
OF
SCIENTIFIC
COMBINED
STUDY
WITH
THE
EXPERIENCE OF YEARS
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Safety Leadership is key to success
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Safety Depends on
•Work permit
•Accident and
incident
analysis
•Engineering
•Emergency
•Procurement
Hardware
Software
Humanware
•Leadership
•PPE
•Health and
Hygiene
•Task
observation
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Safety Culture
• Liveware
• Safety Culture
• Hardware
Software
Acts-Practice-Habit-Behavior-Culture
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Coincident or Not ?
If,
ABC D EFGHI J K L M N O PQ R S T U V W X Y Z
Equals,
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Then,
K+ N +O +W+ L +E+D+G+E
11 + 14 + 15 + 23 + 12 + 5 + 4 + 7 + 5 = 96%
H+A+R +D+W+ O+ R +K
8 + 1 + 18 + 4 + 23 + 15 + 18 + 11 = 98%
Both are important, but the total falls just short of 100%
But,
A+T +T + I+T + U +D+E
1 + 20 + 20 + 9 + 20 + 21 + 4 + 5 = 100%
Safety really is about attitude. Make 100% Safe Behavior your choice
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Safety and Incident Prevention
Depends how much on ATTITUDE ?
A
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D
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1
20
20
9
20
21
4
5
100%
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