IE 419 Work Design: Productivity and Safety

Dr. Andris Freivalds

Class #21
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Basics of Accident Prevention

(Heinrich, Petersen, Roos Industrial Accident Prevention)

Accident Prevention direct control of workers, machines, environment to prevent accidents

Safety Management - long range planning, education, training to prevent accidents
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Accident Prevention Process

Identify Problem Collect Data

Monitor
Apply Remedy Select Remedy
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Analyze Data

Domino Theory (Identify Problem)

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Ex. #1 - Domino Theory

Sparks from grinder ignite nearby gasoline causing operator to be burned.
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Lack of Control Basic Causes Immediate Causes Accident Injury

Multiple causation!
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Accident Causation
Unsafe Acts Unsafe Conditions

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Accident Iceberg

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3 Es of Accident Prevention
Engineering redesign of job/workplace Education training Enforcement discipline, rules Accident Causation Models

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Life Change Unit Theory

Accident probability is situational Overload taxes persons capacity Leads to accidents (or illness) >300 79% in 2 yrs >200 51% in 2 yrs >150 37% in 2 yrs
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Rank Life Event Units 1 2 4 6

Death of spouse Divorce Jail term Injury

100 73 63 53

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End school
Vacation

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Motivation-Reward Satisfaction Model

(Identify Problem)

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Behavioral Based Training

ABC approach A antecedents B behavior C - consequences

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Collect Data Analyze Data

Systematic approach Who, what, where, when, how, why Inspection
Job/methods analysis Worksite analysis Job Safety Analysis (JSA) (Look beyond direct causes!!)
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Job Safety Analysis (JSA)

(Job Hazard Analysis, Methods Safety Analysis, Critical Incident Technique, Failure Mode and Effects Analysis (FMEA), Hazard and Operability Study (HAZOP))

1) 2) 3) 4)
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Break down job into elements List them in sequential order Examine them critically Focus on:
Worker Method Machine Material

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Ex. #2 - JSA
Scenario: Two inspectors smashed their toes
when a stack of armor plate (36x24x in), standing on end against workbench, slid to the floor. They were stacked there because of insufficient room to leave them on delivery pallet, towed from Receiving. Since each piece needed to Rockwell tested, the inspectors stacked the plates on end rather than laying them flat on the floor, which would require later lifting (NIOSH!!). Similar accidents had occurred earlier, but without injuries. Typical Solution:
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Ex. #2 JSA cont (Old Method)

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Ex. #2 JSA cont (New Method)

Recommendation: Adjustable, powered transporter (two)

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Advantages of JSA
Maps out all details Quick, simple, objective Compares old & new methods Examines effects on production Analyze safety before accident occurs Leads into Fault Tree Analysis

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Select Remedy
Decision-Making Tools - Hazard Action Table
Conditions

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Ex. # 3 - Value Engineering

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Value Engineering - Safety

Define Factors:
Effect on safety Cost Morale Social/environment

Choose Alternatives depends Determine Weights judgmental Rate each alternative by factor - relative Resulting Value (sum of products) selects proper alternative
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Risk Analysis Basics

Basic premise/approach
All risks can not be eliminated However, can reduce potential loss Go for max cost effectiveness

Risk of loss increases with:

probability that hazard will occur exposure to the hazard consequences of hazardous event
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Risk Analysis - Procedure

Assign numerical values to factors Multiply factors overall risk score Risk score is a numerical value Good for relative comparison (not absolute)

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Factor Values
Likelihood Expected Possible Unusual Values 10 6 3 Exposure Values

Continuous
Daily Weekly Monthly Few/year

10
6 3 2 1

Remote
~ Conceivable ~ Impossible

1
0.5 0.1

Yearly

0.5

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Possible Consequences
Possible Consequences Catastrophe (many fatalities, $108 damage) Disaster (few fatalities, $107 damage) Very serious (fatality?, $106 damage) Serious (serious injuries, $105 damage) Important (injuries, $104 damage) Noticeable (first aid, $103 damage)
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Value 100 40 15 7 3 1
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Risk Score
Risk Situation Very high risk, discontinue operations High risk, immediate correction Substantial risk, correction needed Possible risk, attention needed Risk?, perhaps acceptable Value 400 200-400 70-200 20-70 < 20

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Ex. #4 - Risk Calculation

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Ex. #5 - Risk and Cost Effectiveness

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Apply Remedy and Monitor

Who applies remedy
Safety specialist/engineer Line supervisors Workers
Identify Problem Collect Data Monitor Analyze Data Apply Remedy Select Remedy

Monitor effectiveness of accident prevention

Close the feedback loop Variety of statistical approaches
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Accident and Injury Statistics

Incidence (frequency) rate
IR = # incidents x 200,000 # hrs exposure

Severity rate
SR = # days lost x 200,000 # hrs exposure

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Chi-Square Analysis
2 = (Ei Oi)2/ Ei Ei = HixOT/HT M = # areas Ei = expected Oi = observed OT = Total observed Hi = hours worked in area i HT = total hours worked = m -1

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Ex. #6 - Chi-Square Analysis

Dept. A B C Total # CTD 22 4 10 36 # Hours 900,000 600,000 1,400,000 2,900,000 IR 1.3 1.4 2.5 Ei 7.4 17.4 36

2 = (Ei Oi)2/ Ei

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Red Flagging Control Chart

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Red Flagging - Monitor

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