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OHSAS 18001 Overview

Ron Scholtz- REA, CHMM

Manager- Environmental/Safety
Analog Devices, Inc.
Background
 ADI’s Silicon Valley semiconductor manufacturing operations total
around 900 employees.
 This operation had a very high accident and lost work day rate
around 10 years ago.
 As many as 70 OSHA recordable accidents per year (130 plus total
claims per year) with workers compensation costs over $400,000
per year.
 Twice as many workers compensation claims as another ADI
manufacturing site with twice as many employees.
 Reactive vs. proactive
 Hired full time occupational health nurse
 Implemented management safety committee
 Focus on ergonomic issues, training, exercises
 Implemented ISO 14001

 Accidentrates improved, but were still above industry benchmarks.

 ADI chose to implement OHSAS 18001 corporate-wide.

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What is OHSAS 18001?

 OHSAS 18001: Occupational Health and Safety Assessment

Series (OHSAS).
 Developed by the British Standards Institute.
 Voluntary standard for developing an occupational health and
safety management system (HSMS).
 Enables an organization to more proactively control health
and safety risks and improve performance.
 Developed in response to demands for a recognizable OHS
management system that compliments the ISO 14001
environmental management system.
 There is currently no comparable ISO related HSMS standard
available.

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What Are The Requirements?

 The 18001 standard features the following key elements:

 OH&S Policy Statement
 Planning
 Implementation and Operation
 Checking and Corrective Action
 Management Review
 Continual Improvement

 The OHSAS 18001 elements are very similar to the ISO 14001
elements.

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 ISO 18001 vs. ISO 14001 Elements
OHSAS 18001:1999 ISO 14001:2004
4.2 OH&S Policy 4.2 Environmental Policy
4.3 Planning 4.3 Planning
Hazard Identification and Risk Assessment Environmental Aspects
Legal and Other Requirements Legal and Other Requirements
Objectives Objectives, Targets, and Programs
OH&S Management Programs Environmental Management Programs
4.4 Implementation and Operation 4.4 Implementation and Operation
Structure and Responsibility Resources, Roles, Responsibility, Authority
Training, Awareness, Competence Competence, Training, Awareness
Consultation and Communication Communication
Documentation Documentation
Document and Data Control Control of Documents
Operational Control Operational Control
Emergency Preparedness and Response Emergency Preparedness and Response
4.5 Checking and Corrective Action 4.5 Checking and Corrective Action
Performance Measurement and Monitoring Monitoring and Measurement
Accidents, Incidents, Non-Conformances Evaluation of Compliance,
And Corrective and Preventative Action Corrective Action and Preventative Action
Records and Record Management Control of Records
Audit Internal Audit
4.6 Management Review 4.6 Management Review
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Policy Statement

 Includes a commitment to continual improvement

 Includes a commitment to at least comply with current OH&S
legislation
 Must be documented, implemented, and maintained
 Must be communicated to all employees
 Must be available to interested parties
 Must be reviewed periodically to ensure it is still relevant

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 Example Combined EH&S Policy

Analog Devices, Inc. and its employees are committed to

protecting the environment and the health & safety
of fellow employees, customers, and the public
by endeavoring to adhere to stringent regulatory and
industry standards across all our facilities, encouraging
pollution prevention, and striving towards continual
improvement. Analog seeks to go beyond compliance with
regulatory standards in order to achieve a standard of
excellence in environmental, health and safety management
practices, as an integral part of its total quality management
system.

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Hazard Identification and Risk Assessment
A risk assessment process needs to be developed and
implemented.
 ADI developed a process that looks at different job positions-
“Homogenous Exposure Groups” (HEG).
 A “Job Hazard Analysis” (JHA) is conducted by a core team
for each HEG.
 An employee representing the HEG is interviewed to better
understand their jobs and the hazards involved.
 JHA forms are used to score the identified hazards.
 Hazards with scores above a cut point are considered
significant.
 An additional safety analysis is performed on significant
hazards to determine needed improvements.
 When all JHA’s are completed, they will be revisited and
revised based on improvements made.
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Job Hazard Analysis Process Forms
Checksheet for Conducting a Job Hazard Analysis

HEG : ____________________________________ Evaluator : ____________________________________ Date: __________________

Step by Step Work Tasks Routine How Production Equipment Types of List Hazards Other/Comments
Task? Often? Used? Che micals/Gases Used? Involved
YES
NO

YES
NO

YES
NO

YES
NO

YES
NO

YES
NO

Page ___ of ___

9 See separate presentation for other JHA forms

Legal and Other Requirements

 Develop a comprehensive list of legislation and regulations

that apply to your operations.
 Add hyperlinks to regulations
 Develop a comprehensive list of permits, reports, and fees
and their due dates.
 Compliance calendar- automate
 Need to communicate relevant information to employees-
training, postings, website.
 “Other” Requirements:
 FM Global
 SEMI Standards
 OHSAS 18001
 ANSI
 Industry Benchmarking
 VPP

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Objectives and Targets

 Goals that result in continuous improvement in the Health

and Safety Management System.
 Consider the following factors:
 Legaland Other Requirements
 Hazards and Risks
 Views of Interested Parties

 Example Objectives and Targets:

 Reductions in Incident Rate
 Reductions in Severity Rate
 Reductions in Types of Emergency Responses (example: Odors)
 Emergency Preparedness- Completion of planned training, drills,
and equipment inspections
 Implementation of New Safety Programs (example: Heat Stress)

 Must be measurable where possible

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Targets and Objectives: Example
 Objective:Ensure compliance with EH&S and Other Requirements
 Target: Maintain 100% compliance with EH&S permit and
operating requirements
 Result Metrics:
 Submittal of permits, fees and reports on time (Goal 100%)
 Completion of all required life safety inspections on time (Goal 100%)
 Regulatory inspections with no violation notices/fines (Goal: 100%)
 EMS/HSMS Surveillance Audits with no Major Findings (Goal: 100%)
 Address FM Global Recommendations within completion plan (Goal: 100%)
 Process Measurements:
 Compliance Calendar monthly completion (Goal: 100%)
 Life Safety Calendar monthly completion (Goal: 100%)
 Compliance inspections completed on-time (Goal: 100%)
 Corrective Action Requests completed on-time (Goal: 100%)
 Improvement Projects:
 Corporate compliance audit (Goal: 100% AI’s addressed)
 Owner: Environmental/Safety

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Targets and Objectives: Example
 Objective: Reduce the numbers and severity of accidents
 Target:
 Reduce the 2006 OSHA recordable accident rate to 0.9 or below (SIA industry
rate)
 Meet or exceed the 2005 ADSiV OSHA recordable accident rate and severity
rate
 Result Metrics:
 Number of OSHA recordable accidents per month (Goal: Zero)
 Number of Lost Work Days per month (Goal: Zero)
 Process Measurements:
 Number of overdue accident reports (Goal: Zero)
 Number of overdue AIR corrective actions (Goal: Zero)
 Number of Job Hazard Analysis’ completed per quarter (Goal: 4)
 Number of overdue JHA corrective actions/improvements (Goal: Zero)
 Number of employees with overdue/not completed safety training (Goal: Zero)
 Improvement Projects:
 Fab microscope PMM team
 Job hazard analysis program implementation
 Implement Heat Stress safety program for Chem Techs and Maintenance
 Owner: Environmental/Safety, Health Services, Safety Committee
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Implementation and Operation
 Training
 OHSAS 18001 Awareness- employees and management
 OSHA Required Training- Forklift, Respirator, LOTO, etc.
 Training Records- need to be complete

 Communication
 External Communications- customers, agencies, public
 Internal Communications- safety alerts, posters, safety suggestions

 Operational Controls
 Operations and activities with identified risks that need controls
 Written procedures- controlled documents
 ADI- Silicon Valley maintains over 100 EHS related specifications
 Procedures are audited- make sure you do what the procedure says!

 Emergency Preparedness
 Procedures for responding to emergencies that will prevent injuries
 Review and periodically test procedures

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Checking and Corrective Action

 Performance Measurement and Monitoring

 Objectives and Targets
 Proactive Measures
 Reactive Measures- including “near misses”

 Accidents, Incidents, Non-Conformances

 Investigation of accidents, incidents and non-conformances
 Initiation and completion of corrective and preventative actions-
close the “loop”
 Audit
 Internalaudit program to ensure the HSMS meets OHSAS 18001
 Conducted by personnel independent of the activity being audited
 “Compliance Audits”- required by regulations (Confined Space,
Respirator, Forklift, LOTO, etc.)

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Management Review
 Top management needs to review the HSMS at predetermined
intervals (example: quarterly)
 Excellent way for getting top management feedback and
support for key projects
 Establish a set agenda for the reviews:
 Objectives and Targets Update
 Regulatory Issues
 Audit and Regulatory Inspection Results
 Communications
 Action Items From Last Review

 Management reviews need to documented:

 Meetingminutes with attendees
 Hand-outs
 PowerPoint slides

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Benefits of OHSAS 18001

 Gives a structured approach to managing an EHS Department

 Allows for standardization within companies that have
multiple sites
 Increased regulatory compliance
 Potential cost savings- workers compensation, manufacturing
disruptions
 Systematically plan, control, and monitor operations through
operational controls
 Top management involvement
 Increased employee awareness and involvement
 Positive image with customers
 Positive image with stakeholders (stockholders)

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Why Bother With Registration?

 It’s really up to top management just how far they want to go

with a HSMS
 Value added
 Bare minimum
 Take beyond OHSAS 18001

 Why third party registration?

 Provides independent verification of HSMS effectiveness
 Demonstrates transparency
 Regular surveillance audits helps to “keep the focus”
 Auditor recommendations can lead to opportunities for further
HSMS improvement
 Registration certificate satisfies many customer surveys

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OHSAS 18001 Registration Process
Reschedule
Pre-Assessment
Audit

No
Perform Gap Close
Apply for 18001
Analysis Gaps Project Monitor:
With Registrar
vs. Standard Identified Are All Gaps
Addressed?

Yes Pre-Assessment
Reschedule Project Monitor: Yes
Registration Audit Major Audit By
Findings? Registrar

No

Address Address
Registration
Pre-Assessment Registration
Audit
Audit Findings Audit Findings
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 Example Implementation Schedule

Task Start Finish

1. Perform gap analysis 3/1/04 3/31/04

2. Implement Job Hazard Analysis 4/5/04 8/23/04

3. Address other deficiencies from gap analysis 4/5/04 8/23/04

4. Internal Auditing of all 18001 elements 4/12/04 8/23/04

5. Finalize Objectives and Targets 4/12/04 4/26/04

6. 18001 Awareness training 4/26/04 5/28/04

7. Pre-Assessment audit with Eagle 8/24/04 8/25/04

8. Address findings from Pre-Assessment Audit 8/25/04 9/7/04

9. Registration audit with Eagle 9/8/04 9/10/04

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Some Lessons Learned

 If your facility is already ISO 9001 certified, many of the

needed elements are already in place
 If you can implement ISO 14001 and OHSAS 18001 at the
same time, some redundant work can be avoided
 Policystatement
 Operational controls
 Combined EMS and HSMS manuals

 Use your “Injury and Illness Prevention Plan” (IIPP) as your

Health and Safety Management System Manual
 Give yourself time to adequately implement- 9 to 12 months
 Consider a corporate-wide registration vs. individual facilities

 ANSI Z10 Standard

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 We Have Come a Long Way!

40
35
# OSHA ACCIDENTS

30
25
20
15
10
5
0
FY2000 FY2001 FY2002 FY2003 FY2004 FY2005
OSHA Accidents 30 37 23 19 7 6

Zero lost work days in FY 2005!

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