risk assessment context - ria - robotics online · 2017. 6. 27. · en 954 categories b,1,2,3 &...

Michael Douglas ([email protected])Global Safety and Industrial HygieneSenior Manager Global Manufacturing Safety Design and Standards

The World’s Best Vehicles

Risk Assessment context

What we will cover todayHow to navigate real world situations “Dynamics” and “Continuums”

How the 2-Stage Approach transformed the hierarchy of Controls

Risk Assessment Worksheet “RAW”

Examples Robots, Ped Welder, your examples

Mapping RAW to All Risk Assessment Standards International, National, and Local

Influencer Kerry Patterson et.al.

Time

Axiom #1 - Risk Assessment is a convergence of Philosophy, Sociology, Culture, and Technology

3

Gate 1

Gate 2

Gate 3Gate 4

To Area 6 of Cake Chart

Project/ Program Design Targets

PossibleVariables

To Target

Where you want to go

Expected Unexpected

Events

Preoccupation with Failure

Sensitivity to Operations

Reluctance to Simplify

Commitment to Resilience

Deference to ExpertiseDeferring

Downward• Ability to absorb

strain and preserve functions

• Ability to recover• Learn and grow

Think Mitigation“Stage 2”

Think Elimination “Stage 1”

Managing the UnexpectedResilient Performance in an Age of Uncertainty

Karl Weick and Kathleen Sutcliffe

Anticipation Containment

Evolution of Safety Culture

What is Safety?

Legal Compliance

Cost of Injuries

Safety is a Top Priority

Safety is a Value/Instinctive

Discipline/Compliance Focus

Self Assessment – Data Focus

Culture Focus

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5

Safety Performance

Where is you Company ?

Returning People Home Safely Every Job. Every Level. Everyday.

Dealing With

Dynamics!

G-DHS Regional ImplementationGroup Dynamics Project / Program Timing

Leadership Risk

Management

Global Engineering

CentersCommon

Execution Teams & Suppliers

Manufacturing Facility

(Plant Floor)

G-S21

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

G-S21

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

GDHS

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

GDHS

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

GDHS

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

G-S21

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

G-S21

Gate 1

Gate 4

Gate 3Gate 2

4

Time

Convergence of Design Variables as Timing Increases

3

Gate 1

Gate 2

Gate 3Gate 4



PossibleVariables

To Target

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

GDHS

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

G-S21

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

G-S21

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

G-S21

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

G-S21

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

GDHS

Axiom #2 Continuums are how

to work with variability

• William Arthur Ward:

–Pessimists complain about the wind

–Optimists expect it to change

–Realists adjust their sails

Risk Assessment leaders frame or of mind

The Continuums

Enablers of Confidence and Creditability

The Continuums

The Continuums create a Visual Image

Help your “dialogue(s)” to be more:

• fluid

• effortless

• spontaneous

The Continuums

The Continuums

What’s in it for them

SpecificDetails

GeneralPrinciples

Specificity Continuum

‘

What is Safety

Legal Compliance

Cost of Injuries

Safety is a Top Priority

Safety is a Value

Discipline / Compliance Focus

Self Assessment Data Focus

Cultural Focus

Perception of Safety

GainsLosses

NI = (Sp – Vc)#U – FC

Net Income = 0

Contribution Margin < 0 Contribution Margin > 0

Impact Continuum

Bottom Line Results

NI = (Sp – Vc)#U – FCApplying new technologies

reduces Manufacturing costs (Capital investment,

Maintenance techniquesetc…)

NI – Net IncomeSp – Selling PriceVc – Variable CostU – UnitsFC - Fixed Cost

Analyzing Details of Safety Productivity”

2 Trucks Every 5 hours

4 Trucks / day times 5 Plants times Contribution Margin

= 3.8 Million $ per year

Migrate based on dynamics of culture

DifficultEasy

Comprehension Continuum

Migrate or “Balance” based on dynamics of the

Marketplace

QuantitativeQualitative

Outcome Continuum

Migrate or “Balance” based on dynamics who will benefit

Complete Responsibility

No Responsibility

Responsibility Continuum

Combative Competitive Cooperative Collaborative

Reality Continuum

Program Interaction

Competitive

Combative

Collaborative

Cooperative

AUG SEP OCT NOV DEC JAN FEB MAR APR MAY

Issues

TaskBasedRisk

Assessment

With outTasksBased

RiskAssessment

BuildInstallRun

Equipment

Retrofits

$$$

DetermineSolutions

Safety Process

UnresolvedIssues

The Future of Safety and Health in an Evolving Workplace

Face to Face Voice Text Web

Platform Continuum

Averse Apathetic Open Savvy

Manual Checklist Excel ToolPower Point

The Technology (Tech) Continuum

The Standards Hierarchy

“Balance”Movement along the continuum

Type of Standards

“A” Level

“B” Level

“C” LevelHierarchy of Controls

Hierarchy of Controls

Eliminate SubstituteEngineering

Controls Training

Personnel Protective Equipment

Safe Operating

ProceduresAwareness

Devices

Goal ResultAction Steps

The 2-Stage Approach (An iterative application approach of the Hierarchy of Health & Safety Controls)

Eliminate

A combination of actions

within these five categories

reduces risks to a safe and

acceptable level

Stage 1

Stage 2


within these two categories

eliminates hazards

• Engineering Controls

• Awareness (Warnings, signs & devices, Placards, etc…

• Safe Operating Procedures

• Substitution of Materials

• Change Task, function, location, layout etc...

• Personnel Protective Equipment

• Training (operator, Maintenance, etc…

Balance

Action Combination # 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 27 28 29 30 31 32 33 34Elimination by Change X XElimination by Substitution X X

Engineering Controls X X X X X X X X X X X X X X X XAwareness Devices X X X X X X X X X X X X X X X XSafe Operating Procedures X X X X X X X X X X X X X X X XTraining X X X X X X X X X X X X X X X XPersonnel Protective Equipment X X X X X X X X X X X X X X X X

Possible "Action Combinations" to Achieve Safe and Acceptable Risks - 34 total "Action Combinations" or Choices Stage 1 Stage 2

“Eliminate” Actions in 2 categories

to remove risks

“Balance” actions in the5 categories to reduce risks to a safe level

“Results” You have 1 to 34

Possible“Action Combinations” to achieve these two results

Eliminate SubstituteEngineering

Controls Training

Personnel Protective Equipment

Safe Operating

ProceduresAwareness

Devices

Combinations of these are the outcomes of the mitigation part of a Risk Assessment

Elimination part of aRisk Assessment


En 954CategoriesB,1,2,3 & 4

ANSI B11.26Currently TR-6

Circuit ExamplesCircuit Analysis Tables

NFPA 79NFPA 70E

IEC 60204-113849-1

Performance Levels Hardware

13849-2Performance

Validation

1996F I R M

MPS

2006SCS

2011

Engineering Controls

1. How the hierarchy of Controls was transformed into a quick visual or icon of 2-Stage approach,

2. The key features of Stage 1,

3. The key features of Stage 2,

4. How a matrix is created from the two stages,

5. How to Eliminate the problem of passing safety issues down the line.

What we will learn:

Objectives Module 1

UAW-GM Annual Health & Safety Conference

March‘06

From an (SPQRC) Discussions with Asia Pacific Region

October ‘05

Hierarchy of Health & Safety Controls

Eliminate or Substitute

Engineering Controls

Warnings

Training

PPE

November ‘05

December ‘05

How the “2-Stage 7-Step Approach” was created at GM

January ‘06

Eliminate

Balance

Stage 1

Stage 2

1. Engineering Controls

2. Awareness (Warnings, signs & devices, Placards, etc…

3. Safe Operating Procedures

4. Personnel Protective Equipment

5. Training (operator, Maintenance, etc…

2. Substitution of Materials

1. Change Task, function, location etc...

Hierarchy of Controls• Circa 1934 the Industrial Hygiene community

created the Hierarchy of Controls.

• Later Safety Professionals integrated this hierarchy into their discipline.

• Eliminate or substitute• Engineering Controls• Administrative Controls (Awareness devices, signage etc..)

• Training & Procedures• Personal Protective Equipment


• Eliminate or substitute• Engineering Controls• Administrative Controls (Awareness devices, signage etc..)

• Training & Procedures• Personal Protective Equipment

The 2-Stage ApproachVisual or Icon

Stage 1

Stage 2








“Balance”

Eliminate

Determining “Action

Combinations”or

Choices

Optimize


Combinations”or

Choices

“Eliminate”



Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance

2-Stage Approach• Notice that the “Hierarchy of Controls” is still visible

within the 2-Stage Approach icon.

• However, the 2-Stage Approach drives a two step process (Stage 1), elimination and (Stage 2) reducing the risks by considering all associated actions required to reduce the remaining hazards to a safe and acceptable level.

• The 2-Stage Approach promotes team collaboration at any point in time, to reach the desired goal in each stage.

Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance

2-Stage Approach• From the 2-Stage visual or icon we can:

– Build a matrix to select actions– Track progress toward those actions

• This Matrix will consist of three parts:1. Stage 1 “blue area”

Two categories (3 ways work can be done)

2. Stage 2 “yellow area”Five Categories (31 ways work can be done)

3. A communication line for quick reference “white area”

Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance

Concept behind the Due Diligence Matrix• Before “Where’s the Beef” there was an ad campaign at

Wendy’s hamburgers from the mid ‘70’s – We fix Hamburgers - 256 ways

1. Mayo 5. Tomato2. Cheese 6. Ketchup3. Mustard 7. Lettuce4. Pickle 8. Onion

Stage 1

Elimination by Change X XElimination by Substitution X X

Section 1 of the Matrix show as “Stage 1”

The two categories in Stage 1 are from the top partof the 2-Stage icon

There are three possible action combinations or choices of the two categories identified by the (X). In other words the team can work in the “elimination/change” category, the “Elimination/Substitution” category or both.

Section 1 - of the “Action Combination” Matrix

EliminateStage 1



eliminates hazards






acceptable level

Stage 2






Balance

Stage 2


Section 2 - of the Action Combination Matrix

Section 2 of the Matrix shows Stage 2

The five categories in Stage 2

The 31 possible action combinations or choices within the five categories identified by the (X)




acceptable level

Stage 2






Balance

EliminateStage 1



eliminates hazards



Action Combination # 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 27 28 29 30 31 32 33 34

Possible "Action Combinations" to Achieve Safe and Acceptable Risks - 34 total "Action Combinations" or Choices

Section 3 - of the Action Combination Matrix

“Action Combinations or Choices” row is used for quick identification and communications

The 34 “Action Combination or Choices” (1-34) above, identifies what needs categories to be worked on to achieve elimination (Stage 1), or reducing remaining risks to a safe level (Stage 2)



Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance




Relationship to the 2-Stage Approach icon to the Action Choice Matrix

“Eliminate” Actions in 2 categories

to remove risks

“Balance” actions in the5 categories to reduce risks to a safe level

“Results” You have 1 to 34

Possible“Action Combinations”

to achieve these two results




Use a “Scott Air Pac”Modify the Operators procedureProvide skilled trade tool-box talkMove the cell entrance gates flush with the fence line Use a safety control system (SCS or MPS) for routine

operator and maintenance tasks.Create an SCS or MPS placard.Create a lockout placard

_______________________________________________________________________________

Action choice or Combination # Assignment or Action

Group Exercise

197111

4

5

27

12 16

5 Or 7

EliminateStage 1

Stage 2








Balance

CrushPinch

2-Stage Application Example

1. Slip from Hand – Crush hazard

2. Placing weights on bar or stand can lead to a pinch hazard of the fingers

Issue:




The Complete Action Combination MatrixAdding numbers to the action combinations row shows progression toward your solution

2 3

Numbers 1 through 3 above could have happened during one meeting, or over the phone, or over a period of time.

Example: Truck Driver unloading small parts from a truck to a portable carrier located on the dock.

1

Fill in the Blanks

Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards

• E__________ C______

• A__________ (Warnings, signs & devices, Placards, etc…

• Safe Operating ____________


• C_____ Task, function, location, layout etc...

• _________ ________ Equipment

• T_______ (operator, Maintenance, etc…

Balance

Summary Module 1• The “Hierarchy of Safety Controls” was divided

into two stages.

• A visual was created for the hierarchy.

• “Stage 1” reminds users to consider the categories of elimination and substitution.

• If Elimination is not possible then we need to consider “Stage 2” or actions in the remaining hierarchical categories until a safe level has been achieved.

Objectives Module 2

1. The five parts of the new Risk Assessment Worksheet

How the old TaBRA tool fitsHow to fill out the five parts

2. And how to perform on-the-floor risk assessments

3. How to assign responsibility and track actions4. How to report progress or roadblocks in

meetings (Skilled Trades Safety Team Meeting, Team Meetings, PSRB, etc…)

What we will learn:

Contextual Risk Assessment

1. Helps you deal with the “dynamics” inherent in all types of situations.

2. Is a 5 step problem solving toolYou can start at any step and proceed to the other four in any order.

3. Can be used in any conversation, meeting, dialogue, etc…

ObservationsIssues

These two terms allow this new risk assessment the flexibility to be applied in any situation and across all

disciplines and technologies.

Contextual Risk Assessment“RAW”

ScalabilityFlexibilityPortabilityTransparency

Emergence of the Risk Assessment Worksheet

"Risk" does not exist "out there", independent of our minds and culture, waiting to be measured.

Humans have invented the concept of "risk" to help us understand and cope with the dangers and uncertainties of life.

Although these dangers are real, there is no such thing as "real risk" or "objective risk"

The ubiquitous variations of Risk Assessment Continuum

Kahnman Thinking Fast, Thinking Slow, Chapter 13 “Risk”

Science behind the smile• All disciplines have distinct but intersecting interests

– Psychologists look for “how people feel”

– Economists want to know “what people value”

– Neuroscientists want to know “how people respond”

• Risk assessments have five comment elements even when viewed through this intersecting lens.

1. Observations

2. Issues

3. Evaluation

4. Impact

5. Elimination/Mitigation

HBR January 2012

Science behind the smile

• Measuring subjective experiences is easier that most people think

– It’s what your eye Doctor does when she fits you for glasses

• She puts lenses in front of you and ask you to report your experience.

• She will use these reports as data

• Then designs a lens for perfect vision – all on the basis of your reports of your subjective experience.

HBR January 2012

Science behind the smile

• People’s real-time reports are very good approximation of their experiences.

• These experiences make it possible to see the world through their eyes

– This is what “task based” did back in the mid ‘90’s for risk assessment applications.

• Must talk to the people who do the work.

HBR January 2012

A Leader’s Framework for Decision MakingWise executives tailor their approach to fit the complexity of the circumstances they face.

by David J. Snowden and Mary E. Boone

Harvard Business Review November 2007 Reprint R0711C

http://harvardbusinessonline.hbsp.harvard.edu/hbrol/en/includes/sasearch.jhtml?author=David+J.+Snowden

http://harvardbusinessonline.hbsp.harvard.edu/hbrol/en/includes/sasearch.jhtml?author=Mary+E.+Boone

A Leader’s Framework for Decision Making

• Simple Context (Domain of Best Practice)– Clear Cause and effect– Realm of “know known's”– Sense / Categorize / Respond

• Complicated Context (Domain of Experts)– Main Contain Multiple right answers “at least one right answer”– Realm of “known unknowns”– Sense / Analyze / Respond– Often requires expertise

• Complex Context (Domain of Emergence) the Next Practice– The whole of the system is greater than the sum of its parts.– Realm of “unknowns, unknowns”– Patterns emerge– Probe / Sense / Respond

• Chaotic– Realm of Unknowns– Act / Sense / Respond

(Cynefin, pronounced ku-nev-in, is a Welsh word that signifies the multiple factors in our environment and our experience that influence us.

Used by DARPA (Defense Advanced Research Projects Agency)


The ubiquitous variationsof

“Risk Assessment”


“...the world is not Task-based…”

T a B R A


“Risk Assessment”1996

2000


T a B R A 1996

‘05



All Risk Assessments can be condensed into 5 categories and can be captured in any order.

1

2

4

5

3

ObservationsIssuesEvaluationImpact Actions

(accountability Info)


TaB

RA

T a B R A 1996

‘07

’08

‘05

Risk Assessment Worksheet (“RAW”)







TaB

RA

T a B R A 1996

‘07

’08

‘05





Narrow Framework

Broader Framework(e.g. System, Subsystem, Equipment, Device, Component, Primary Task, Related Task, thought experiment, etc….)




TaB

RA

T a B R A



‘05

‘07


2000


’08

This is a five step problem solving / tracking tool




TaB

RA

T a B R A

Discussionor

Questions?



‘05

‘07


2000


’08

This is a five step problem solving / tracking tool

What

How

Back side of sheet

Details




TaB

RA

T a B R A



‘05

‘07


2000


’08

What

How

Back side of sheet

Details



Risk Evaluation Risk Reduction

Issues

Observations1

3

2

5

Impact

(Hazards, etc...)

Include Severity, Frequency, Monitoring, and Possibility of

Avoidance, or other risk matrices as required.

4 Quality, Responsiveness, Cost, Environmental, Other

Describe details on page 2 for

Action and Follow-up( ) ( )

Process Motion:

Other

System, Sub-system, Equipment, Device, Primary Task, Related Tasks, etc…( ) ( )



Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance

Stored Energy: Electrical

Electric ShockFalls > 6 ft (1.8m)

Repetitive Motion (Ergo)Strains/SprainsCrushingPinch PointsFalls < 6 ft (1.8m)

Stored Energy: PneumaticStored Energy: HydraulicStored Energy: MechanicalLive Energy: ElectricalLive Energy: PneumaticLive Energy: HydraulicLaser or other RadiationSlips/Trips

Lighting: ShadowsLighting: HeatLighting: LocationMobile Equipment: Fork TruckMobile Equipment: TuggerMobile Equipment: DolliesEnvironmental Facility: Air (VOC impact)Environmental Facility: Water (SPPCC impact)Environmental Facility: Waste (Treatment impact)

Gravity

Lighting: IntensityConfined Space

Chemical ExposureThermal (extreme Hot or Cold)Pressurized Paint/SolventChemical Mist (Inhalation)Electrostatic High Voltage

Sharp EdgesNoiseVentilation Flow Path (Fumes/Dusts/etc.)ExplosionsFireBurnsHead ObstructionEye Hazard

System ID_________________ Team___________________ Date: _________________

Process Motion (Hazard Zone):

Other:

A

B

C

D

E

F

G

Has a Safe and Acceptable Risk been Achieved? Assessment Complete

No

Yes

Step 2-Stage DetailsList of Actions Required to Eliminate or Mitigate Risks

Action Combination # ______

Responsibility Est. Date

5 Risk Assessment Worksheet

Rev. E

Revise Action List Requirements

Due Diligence Matrix – To assure that all possible “Hierarchy of Control” combinations have been considered.


TaB

RA

T a B R A



‘05

‘07


2000


’08

What

How

Back side of sheet

Details




Issues

Observations1

3

2

5

Impact

(Hazards, etc...)






Process Motion:

Other




Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance






Gravity






Other:

A

B

C

D

E

F

G


No

Yes





Rev. E




Due Diligence

TaB

RA

T a B R A



‘05

‘07


2000


’08




C1

Technical ExpertsTechnical

ExpertsTechnical Experts

Action Validation

Technical Experts

Operations Support

A

D

C

B

E

B1 Task & Hazard IdentificationAnalysis Methods(Risk Estimation)

EliminateStage 1

Stage 2








Balance

B2

Risk elimination or Reduction (2-Stage Approach) Action

Inputs based on System Limits,and Intended use

or Application

Quick Response

Emergence

Expertise

Best Practice

What

Front side of sheet

What

HowDetails



What is it?

What are the issues (hazards)?

What is the affect (harm)?

What is the impact (business, process , environment etc….)?

How to Fix (“2-Stage Approach”).

What

How

1

2

3

4

5

1

2

3

4

5

Risk Assessment WorksheetFront side of sheet


Issues

Observations1

3

2

5

Impact

(Hazards, etc...)

Include Severity, Frequency, Monitoring, and Possibility of Avoidance, or other risk matrices as required.


Describe details on page 2 for Action and Follow-up( ) ( )

Process Motion:

Other




Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance






Gravity





Details

Front side of sheet

Back side of sheet

(Action, Responsibility and Timing )


Issues

Observations1

3

2

5

Impact

(Hazards, etc...)






Process Motion:

Other




Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance






Gravity






Other:

AB

CDEFG

Has a Safe and Acceptable Risk been Achieved?

Assessment Complete

No

Yes





Rev. E



What is it?

What are the issues (hazards)?

What is the affect (harm)?

What is the impact (business, process , environment etc….)?

How to Fix (“2-Stage Approach”).

What

How

1

2

3

4

5

1

2

3

4

5

Risk Assessment WorksheetFront side of sheet


Issues

Observations1

3

2

5

Impact

(Hazards, etc...)




Process Motion:

Other




Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance






Gravity





Details

Front side of sheet

Back side of sheet

(Action, Responsibility and Timing )

Time

Convergence of Design Variables as Timing Increases

3

Gate 1

Gate 2

Gate 3Gate 4



PossibleVariables

To Target

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

GDHS

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

G-S21

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

G-S21

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

G-S21

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

G-S21

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

GDHS

C1



Action Validation

Technical Experts

Operations Support

A

D

C

B

E

B1Task & Hazard Identification

Analysis Methods(Risk Estimation)

EliminateStage 1

Stage 2








Balance

B2


Inputs based on Machine Limits,and Intended use

or Application

Five main Areas of a Risk Assessment Flow Chart

Risk Assessment Worksheet

Gate 3C1



Inputs based on Machine Limits,and Intended use

or Application

Action Validation

Technical Experts

Operations Support

A

D

C

B

E

B1 Analysis Method s(Risk Estimation)

EliminateStage 1

Stage 2








Balance

B2

Risk elimination or Reduction

(2-Stage Approach) Action

Assistance

Gate 1

Gate 2

Gate 4

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

G-S21

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

G-S21

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

G-S21

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

G-S21

Leadership Risk

Management

Global Engineering

CentersCommon



(Plant Floor)

G-S21

Risk Assessment Documentation


No

Yes

Step 2-Stage Details

Describe action details of Safety BalanceAction Combination # ____

Describe details of EliminationAction Combination # ___



5

Stag

e 1

Stag

e 2



Possible "Action Combinations" to Achieve Safe and Acceptable Risks - 34 total "Action Combinations" possibleStage 1 Stage 2

11


Issues

Observations1

3

2

5

Impact

(Hazards, etc...)




Stored Energy: ElectricalStored Energy: PneumaticStored Energy: HydraulicStored Energy: MechanicalLive Energy: ElectricalLive Energy: PneumaticLive Energy: HydraulicLaser or other RadiationSlips/TripsRepetitive Motion (Ergo)Strains/SprainsCrushingPinch PointsFalls < 6 ftFalls > 6 ftElectric Shock

GravitySharp EdgesNoiseThermal (extreme temperature Hot or Cold)ExplosionsFireBurnsHead ObstructionEye HazardChemical ExposureInadequate VentilationPressurized Paint/SolventChemical Mist (Inhalation)Electrostatic High VoltageConfined SpaceLighting: Intensity


Process Motion:

Other




Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance

10

Communication Paths


Issues

Observations1

3

2

5

Impact

(Hazards, etc...)






Process Motion:

Other




Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance






Gravity






Other:

A

B

C

D

E

F

G


No

Yes





Rev. E




Issues

Observations1

3

2

5

Impact

(Hazards, etc...)




Process Motion:

Other




Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance






Gravity






How

Front side of sheet

Back side of sheet

Details

What


No

Yes

Step 2-Stage DetailsDescribe Action Details to Eliminate or Mitigate Risks



5





Rev. B

Re-evaluate or Modify

Due Diligence MatrixHierarchy of Health &

Safety Controls

Action Combination #

Robot Examples


Issues

Observations1

3

2

5

Impact

(Hazards, etc...)




Process Motion:

Other




Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance






Gravity





Jeff Fryman’s Risk Assessment Example from his class

How Risk Assessments look for Mature Safety Control Designs

1997, 1999, 2004, 2006

Rotating Turn Table Exampleusing

ISO 13849-1


Issues

Observations1

3

2

5

Impact

(Hazards, etc...)




Process Motion:

Other




Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance






Gravity





Removing Power from Turntable

Operator becoming entangled with rotating table is the stop circuit failed


Issues

Observations1

3

2

5

Impact

(Hazards, etc...)






Process Motion:

Other




Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance






Gravity






Other:

PED Welder Examplegroup - Discussion

Think of your examples at your site - Discussion


Issues

Observations1

3

2

5

Impact

(Hazards, etc...)






Process Motion:

Other




Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance






Gravity






Other:


No

Yes

Step 2-Stage DetailsDescribe Action Details to Eliminate or Mitigate Risks



5





Rev. B

Re-evaluate or Modify

Due Diligence MatrixHierarchy of Health &

Safety Controls

Action Combination #


• Easy to use & portable (quick data capture on-the-floor)

• Scalable seven different levels (System, Sub-system, Equipment, Device, Component, Primary Task, Related Task)

• Captures Savings (capital, responsiveness, thru-put, quality, etc …)

• Shows all risk elimination / reduction options(where you’ve been, where you are, where you could go)

• Identifies Actions, Responsibilities & Dates

Benefits:

What is needed - “Flexibility”The Contextual Risk Assessment is a tool that provides you with the flexibility to perform due diligence based on a defined scope.

The Risk Assessment Worksheet:

• Allows you to identify the issues as they relate to what your are observing.

• Provides an analysis area to evaluate the observation and issues based on the required discipline and the level of expertise needed based on the circumstances.

• Ability to show the impact on the company, project, equipment, quality, responsiveness, etc….

• Allows looking at-a-glance at all the possible safety hierarchical combinationswhere actions can be performed, based on the.

• Facilitates the convergence to the optimal solution and with responsibility, and an estimated completion date.

The Contextual Risk Assessment tool is simple, flexible, and has a great range of applications.

EliminateStage 1

Stage 2








Balance


Issues

Observations1

3

2

5

Impact

(Hazards, etc...)






Process Motion:

Other




Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance






Gravity






Other:

A

B

C

D

E

F

G


No

Yes





Rev. E




Expected Unexpected

Events

Track small Failures

Sensitive to Operations

Resist Oversimplification

Maintain Capabilities

Shifting Locations of

Expertise



• Ability to absorb strain and preserve functions






EliminateDetermining

“Action Combinations”

or Choices







Combinations”or

Choices

Optimize

Decisions are pushed down to the appropriate level for

quick decision making


Issues

Observations1

3

2

5

Impact

(Hazards, etc...)






Process Motion:

Other




Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance






Gravity






Other:

AB

CDEFG

Has a Safe and Acceptable Risk been Achieved?

Assessment Complete

No

Yes





Rev. E



Summary Module 2

• The five sections of the RAW• Identify and document hazardous

situations• Track actions to reach a safe level• Have a high confidence level about

reaching the desired safe state• Use section 5 to share progress or

roadblocks with leadership


Issues

Observations1

3

2

5

Impact

(Hazards, etc...)






Process Motion:

Other




Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance






Gravity






Other:

A

B

C

D

E

F

G


No

Yes





Rev. E






What

How

Back side of sheet

DetailsWhat

How

C1



Action Validation

Technical Experts

Operations Support

A

D

C

B

E


EliminateStage 1

Stage 2








Balance

B2



or Application

Quick Response

Emergence

Expertise

Best Practice



Mapping RAW to ISO Language

• Protective Measures– Inherent Safe Design “Eliminate”– Safeguarding – “The use of safeguards”– Safeguarding

• Guards• Protective Devices (e.g. light screens)

– Complementary Protective Measures

C1



Action Validation

Technical Experts

Operations Support

A

D

C

B

E


EliminateStage 1

Stage 2








Balance

B2



or Application

ISO 31000 & IEC/ISO 31010ANSI B11.0G-Risk Assessment

Designer input

ISO 12100-1 & ISO 12100-2

Inherently Safe Design

Safeguarding

Complementary Protective Measures

The 2-Stage Approach (Mapping ISO - ANSI 12100 and ISO – ANSI 14121 Standards language)


Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance

- Guards- Protective Devices

- Information for use - “As-built”- Hazard awareness - Training

2 – Stage Approach ModelISO 12100 - 1

ISO 2-Stage application in words

Designer input

The 2-Stage Approach (Mapping ISO - ANSI 12100 and ISO – ANSI 14121 Standards language)

2 – Stage Approach ModelISO 12100 – 1 Figure 1


Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance

Designer input

“Step 2”

“Step 3”

“User”

“User” & “Step 3”

“User”

“Step 1”

“Step 1”


Issues

Observations1

3

2

5

Impact

(Hazards, etc...)






Process Motion:

Other




Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance






Gravity






Other:

A

B

C

D

E

F

G


No

Yes





Rev. E



Philosophy, Sociology & Culture

Technological

TR 306

Life Cycle the “Cake Chart”

1. Do we know where you are?

2. Do we know where you are going?

3. Have we considered the best options for new vs. reuse?

4. Can we optimize cost?

5. What is our confidence level that the system is safe?

Helps you with the following questions:

2. Preliminary Design

3. Detailed design

4. Build or Purchase

5. Install / Debug (Commissioning)

6. Production & Related Activities

Design

Supplier

Plant Floor

7. Decommission

Seven AreasThree Phases1. Design Concept

The Machinery and Equipment Life Cycle

Gate 1

Gate 4

Gate 3

Gate 2 Time

2 3 4 5 6Design

ConceptPreliminary

DesignDetailed Design

Build Or Purchase

Commission(Install & Debug)

Decommission2 3 4 5 61 7

Machinery and Equipment Lifecycle Areas

Can be displayed horizontally

Areas 1 through 7 above – Depict a Progression from Left to Right

ProductionMaintenance

This concept will appear in TR 306 section 4 and Annex C

Created by GM in December 2007, added to ANSI B11.0 in 2010

2 3 4 5 6

System New

System Reuse

Product Process Changes

4

5

DesignConcept

Preliminary Design

Detailed Design

Build Or Purchase


Decommission

System Retrofit / Rebuild

2 3 4 5 61 7Steps 1 thru 7 = Life Cycle Stages

3

2

1

“Cake Chart” – 35 Steps & 8 Feedback Paths Supporting the 7 Life Cycle Areas


ImpactImpact

Actions

Impact Impact

IssuesIssuesIssues IssuesIssues

ImpactImpact

Actions

Observation

Issues

Observation Observation Observation

Actions Actions Actions

Observation Observation

Actions

Observation

Impact

Actions

Issues

Evaluation Evaluation Evaluation Evaluation Evaluation Evaluation Evaluation

9

10

8

7

6

14

15

13

12

11

24

25

23

22

21

29

30

28

27

26

34

35

33

32

31

19

20

18

17

16

2 3 4 5 6

Scope and Limits, Layout, Information for Use

Observation, Issue and Risk Assessment

Achieving a high “Confidence Level” is based on documented due diligence in steps A through E;

System New

System Reuse

Product Process Changes

D

Concept ScopeReview andApproval

Action Items from R A

Provided to Supplier

Verify or Validate that the Safety Systems perform correctly

Preliminary DesignReview

Detailed Design Review Risk Assessment & Actions Items

Risk Analysis of Current RemediationIssues

Identify possible Hazards

Build Or PurchaseSystem

Identify Tests for evaluatingInstallation at Final Location

Design for Reducing Risks

Notify affectedParties & Follow Local

Requirements

E

Lean and Value PropositionApplication

DesignConcept

Preliminary Design

Detailed Design

Build Or Purchase


Decommission

System Retrofit / Rebuild

Verify actions items from the R/A have been

completed

Identify cost sav-ings by designing for Maintenance and productivity

2 3 4 5 61 7Steps 1 thru 7 = Life Cycle Stages

Proposals to Reduce Risks

Risk Analysis of Observations & Issues

Project or ProgramScope

IdentifyObservations & Issues

Build-site or Supplier

Issues

Concept Scopewithin VP

Limits

Obtain concurrence of VP with

peer reviews

Verify items identified in the R A are

accounted for

Identify Tests for evaluation before delivery

Review Special Disposal & Re-cycling Require-ments

Perform Disposal and Site work per requirements

C

B

A

Verification & Validation of overall system and components

Risk Reduction “2-Stage Approach” Protective Measures Action items

Lean Design 7 Forms of

Waste

Base “C” Level Standards

Risk Assessment

General Safety Requirements

“Cake Chart” – 35 Steps & 8 Feedback Paths Supporting the 7 Life Cycle Areas

EliminateStage 1

Stage 2








Balance

Eliminate








Balance

Eliminate








Balance

Eliminate








Balance








Balance

Eliminate








Balance

Eliminate

VP = Value Proposition

Risk Assessment


Create JES & SOPs for daily Use

RunProductionMaintenance

Perform Continuous Improvements on System

Identify Preventative Maintenance Requirements








Balance

Eliminate


Expected Unexpected

Events

Track small Failures

Sensitive to Operations

Resist Oversimplification

Maintain Capabilities

Shifting Locations of

Expertise



• Ability to absorb strain and preserve functions





Issues

Observations1

3

2

5

Impact

(Hazards, etc...)






Process Motion:

Other




Eliminate




acceptable level

Stage 1

Stage 2



eliminates hazards








Balance






Gravity






Other:



EliminateDetermining

“Action Combinations”

or Choices







Combinations”or

Choices

Optimize


No

Yes

Step 2-Stage Details

Describe action details of Safety BalanceAction Combination # ____

Describe details of EliminationAction Combination # ___



5

Stag

e 1

Stag

e 2


Copyright General Motors Corporation 2008



Possible "Action Combinations" to Achieve Safe and Acceptable Risks - 34 total "Action Combinations" or choicesStage 1 Stage 2

Decisions are pushed down to the appropriate level for

quick decision making

1 2 3 4

5

&

Influencer Kerry Patterson et.al.

Questions Discussion ?

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Risk Assessment context

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