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SAFETY AUDIT A KEY HAZARD IDENTIFICATION TECHNIQUE

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SAFETY AUDIT A KEY HAZARD IDENTIFICATION TECHNIQUE A presentation by Subbarao Cholamandalam AXA Risk Services What is Safety Audit Verifying the existence and ... – PowerPoint PPT presentation

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Title: SAFETY AUDIT A KEY HAZARD IDENTIFICATION TECHNIQUE


1
SAFETY AUDIT A KEY HAZARD IDENTIFICATION
TECHNIQUE
  • A presentation by
  • Subbarao
  • Cholamandalam AXA Risk Services

2
What is Safety Audit
  • Verifying the existence and implementation of
    elements of occupational safety and health system
    and for verifying the systems ability to achieve
    defined safety objectives
  • IS-14489-1998

3
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

4
SAFE AND SOUND
  • A study of top companies in the world indicated
    that
  • Safety and Loss Prevention Programmes
    were essential for a companys
    prosperity and accepted as part of
    good Business'.

5
Why do organizations have to bother about Safety
  • Corporate Strategy
  • Finance
  • Human Resources
  • Marketing, Product Design and Product Liability
  • Manufacturing and operating policy
  • Information Management and systems
  • Societal Concerns

6
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

7
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8
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9
  • Demand for full information and for public
    involvement
  • A willingness to challenge and complain

10
Corporate Strategy
  • Business Mission, Philosophy and codes of ethics
  • Company image in the community
  • Environment impact
  • Management Professionalism

11
Finance
  • Loss Control and cost reduction strategies
  • Product liability, Legal liability, Property
    damage
  • Risk retention or transfer
  • Investment decisions concerning business
    acquisitions

12
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13
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14
Human Resources
  • Work and job structuring
  • Morale and retaining people
  • Positive health structure

15
Marketing, product design and product liability
  • Specification of product and service
  • Legal requirement
  • International requirement
  • Consumer protection act

16
Manufacturing and operating policy
  • Design/selection/construction/maintenance of
    premises, plant, equipment and substances
  • Quality management
  • Environment management and waste disposal

17
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.

18
Organizations carry out
  • Safety Audit
  • Safety Survey
  • Safety Inspection
  • Safety Tour
  • Safety Sampling
  • HAZOP

19
  • 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 examination-hazards are
    removed-standards are removed

20
  • 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.

21
SAFETY AUDIT
  • MONITORING
  • COMPARE ACTUAL PERFORMANCE -STANDARDS
  • COMPREHENSIVE
  • CONTINUOS
  • AUDIT
  • NOT DONE BY INSIDER
  • NOT COMPREHENSIVE-DEPENDS ON SCOPE
  • PERIODIC

22
DIFFERENT TYPES OF AUDIT
  • Electrical Audit
  • Fire Safety Audit
  • Pressure vessels Audit
  • Lifting Tackles Audit
  • Statutory Regulations Compliance Audit
  • Emergency Communication Audit
  • Pipe lines Audit

23
Safety Depends on
  • Accident and incident analysis
  • Work permit

Hardware
  • Engineering

Software
  • Emergency
  • Procurement

Humanware
  • Maintenance
  • Leadership
  • PPE
  • Health and Hygiene
  • Task observation

24
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.

25
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.

26
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 PROCEDURES-DEGRADED WITH
    TIME
  • TRAINING, PREPAREDNESS FOR HANDLING EMERGENCIES.

27
SCOPE OF AUDIT
  • FIRE AND EXPLOSION PREVENTION, PROTECTION AND
    EMERGENCY MANAGEMENT.
  • WORK INJURY PREVENTION.
  • HEALTH HAZARDS CONTROL.
  • CONSEQUENCES OF EMERGENCIES.
  • ON SITE EMERGENCY CONTROL

28
Elements of Occupational Safety and Health
System-IS14489
  • Occupational Health and Safety Policy
  • OSH organizational set up
  • Education and Training
  • Employees participation in OSH Management
  • Motivational and Promotional measures for OSH
  • Safety Manual and Rules
  • Compliance with Statutory Requirements
  • New Equipment review and inspection

29
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

30
Elements contd..
  • 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

31
Elements contd..
  • Transportation of hazardous substances
  • Hazardous waste treatment and disposal
  • Safety in storage and warehousing
  • Contractor safety systems
  • Safety for customers(including MSDS)

32
Records to be examined during Audit
  • OSH 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

33
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

34
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,
    Transportation of Hazardous substances

35
TOPICS ON WHICH INFORMATION IS COLLECTED
  • SAFETY ORGANIZATION.
  • CONTRACTOR EMPLOYEE ACTIVITIES.
  • MATERIAL SAFETY DATA.
  • OCCUPANCY.
  • SAFETY AND HEALTH POLICY.
  • OPERATION AND MAINTENANCE OF SAFETY MANUAL.

36
  • EXPANSION MODIFICATION -AUTHORIZATION PROCEDURES.
  • SAFETY EDUCATION , TRAINING.
  • STATUTORY STANDARDS, SAFETY IF
  • JOB SAFETY ANALYSIS.
  • JOB SAFETY INSTRUCTIONS

37
.TOPICS CONTD.
  • SAFETY INSPECTION.
  • SAFETY OBSERVATIONS.
  • WORK PERMIT SYSTEM.
  • FIRE PROTECTION ARRANGEMENTS
  • FIRE EMERGENCY CONTROL PROCEDURES.
  • WORK ENVIRONMENT MONITORING.

38
  • 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.

39
  • EMERGENCY COMMUNICATION FACILITIES.
  • EVACUATION FACILITIES.
  • PRODUCT/SERVICE-LIABILITY

40
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

41
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 important-Facilitator rather
    than an inspector.

42
Are you a good auditor?
  • FINISHED FILES ARE THE RESULT OF YEARS OF
    SCIENTIFIC STUDY COMBINED WITH THE EXPERIENCE OF
    YEARS

43
Safety Leadership is key to success
Survey by Linkage, inc., 1999
44
Safety Culture
  • Liveware
  • Safety Culture
  • Hardware Software

Acts-Practice-Habit-Behavior-Culture
45
Coincident or Not ?
If, A B C D E F G H I J K L M N O P Q
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 both ON and OFF the job
46
Safety and Incident Prevention
  • Depends how much on ATTITUDE ?

A T T I T U D E

1 20 20 9 20 21 4 5
100
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