ohs ah 18001 overview
TRANSCRIPT
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The World Leader in High Performance Signal Processing Solutions
OHSAS 18001 Overview
Ron Scholtz- REA, CHMM
Manager- Environmental/SafetyAnalog Devices, Inc.
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Background
ADIs Silicon Valley semiconductor manufacturing operations totalaround 900 employees.
This operation had a very high accident and lost work day ratearound 10 years ago.
As many as 70 OSHA recordable accidents per year (130 plus total
claims per year) with workers compensation costs over $400,000per year.
Twice as many workers compensation claims as another ADImanufacturing 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
Accident rates 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 AssessmentSeries (OHSAS).
Developed by the British Standards Institute.
Voluntary standard for developing an occupational health andsafety management system (HSMS).
Enables an organization to more proactively control healthand safety risks and improve performance.
Developed in response to demands for a recognizable OHSmanagement 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
Management Review4.6Management Review4.6
Internal AuditAudit
Control of RecordsRecords and Record Management
Evaluation of Compliance,
Corrective Action and Preventative Action
Accidents, Incidents, Non-Conformances
And Corrective and Preventative Action
Monitoring and MeasurementPerformance Measurement and Monitoring
Checking and Corrective Action4.5Checking and Corrective Action4.5Emergency Preparedness and ResponseEmergency Preparedness and Response
Operational ControlOperational Control
Control of DocumentsDocument and Data Control
DocumentationDocumentation
CommunicationConsultation and Communication
Competence, Training, AwarenessTraining, Awareness, Competence
Resources, Roles, Responsibility, AuthorityStructure and ResponsibilityImplementation and Operation4.4Implementation and Operation4.4
Environmental Management ProgramsOH&S Management Programs
Objectives, Targets, and ProgramsObjectives
Legal and Other RequirementsLegal and Other Requirements
Environmental AspectsHazard Identification and Risk Assessment
Planning4.3Planning4.3
Environmental Policy4.2OH&S Policy4.2
ISO 14001:2004OHSAS 18001:1999
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Policy Statement
Includes a commitment to continual improvement
Includes a commitment to at least comply with current OH&Slegislation
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 toprotecting the environment and the health & safetyof fellowemployees, customers, and the public
by endeavoring to adhere to stringent regulatory andindustry standards across all our facilities, encouraging
pollution prevention, and striving towards continualimprovement. Analog seeks to go beyond compliance withregulatory standards in order to achieve a standard of
excellence in environmental, health and safety managementpractices, as an integral part of its total quality managementsystem.
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Hazard Identification and Risk Assessment
A risk assessment process needs to be developed andimplemented.
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 JHAs are completed, they will be revisited andrevised 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
Task?
How
Often?
Production Equipment
Used?
Types of
Che micals/Gases Used?
List Hazards
Involved
Other/Comments
YESNO
YESNO
YESNO
YES
NO
YESNO
YES
NO
Page ___ of ___
See separate presentation for other JHA forms
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Legal and Other Requirements
Develop a comprehensive list of legislation and regulationsthat 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 StandardsOHSAS 18001ANSI Industry BenchmarkingVPP
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Objectives and Targets
Goals that result in continuous improvement in the Healthand Safety Management System.
Consider the following factors:Legal and Other Requirements
Hazards and RisksViews 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: ExampleObjective: Ensure compliance with EH&S and Other Requirements Target: Maintain 100% compliance with EH&S permit and
operating requirementsResult 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% AIs addressed)
Owner: Environmental/Safety
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Targets and Objectives: ExampleObjective: 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
TrainingOHSAS 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 ControlsOperations 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 MonitoringObjectives 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
Internal audit program to ensure the HSMS meets OHSAS 18001Conducted 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 predeterminedintervals (example: quarterly)
Excellent way for getting top management feedback andsupport 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:Meeting minutes 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 havemultiple sites
Increased regulatory compliance
Potential cost savings- workers compensation, manufacturingdisruptions
Systematically plan, control, and monitor operations throughoperational controls
Top management involvement
Increased employee awareness and involvementPositive image with customers
Positive image with stakeholders (stockholders)
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Why Bother With Registration?
Its really up to top management just how far they want to gowith a HSMSValue added
Bare minimum
Take beyond OHSAS 18001Why 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 furtherHSMS improvement
Registration certificate satisfies many customer surveys
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OHSAS 18001 Registration Process
Apply for 18001With Registrar
Perform GapAnalysis
vs. Standard
CloseGaps
Identified
Pre-AssessmentAudit ByRegistrar
AddressPre-AssessmentAudit Findings
RegistrationAudit
AddressRegistration
Audit Findings
Yes
No
Yes
No
Project Monitor:Are All Gaps
Addressed?
Reschedule
Pre-AssessmentAudit
Project Monitor:Major
Findings?
RescheduleRegistration Audit
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Example Implementation Schedule
8/25/048/24/047. Pre-Assessment audit with Eagle
9/7/048/25/048. Address findings from Pre-Assessment Audit
9/10/049/8/049. Registration audit with Eagle
5/28/044/26/046. 18001 Awareness training
4/26/044/12/045. Finalize Objectives and Targets
8/23/044/12/044. Internal Auditing of all 18001 elements
8/23/044/5/043. Address other deficiencies from gap analysis
8/23/044/5/042. Implement Job Hazard Analysis
3/31/043/1/041. Perform gap analysisFinishStartTask
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Some Lessons Learned
If your facility is already ISO 9001 certified, many of theneeded elements are already in place
If you can implement ISO 14001 and OHSAS 18001 at thesame time, some redundant work can be avoided
Policy statementOperational controls
Combined EMS and HSMS manuals
Use your Injury and Illness Prevention Plan (IIPP) as yourHealth 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!
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#OSHAACCIDENTS
OSHA Accidents 30 37 23 19 7 6
FY2000 FY2001 FY2002 FY2003 FY2004 FY2005
Zero lost work days in FY 2005!
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The World Leader in High Performance Signal Processing Solutions
QUESTIONS?
Thank You!