safety-first - anzen daiichi - eng v1.3

1 Factory Management Institute - www.factorymanagementinstitute.com. CC4 2017 This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by-nc-nd/4.0/.

SAFETY FIRST Eduardo L. Garcia. CC4 2017 V1.3. SAFETY FIRST (Jp. 安全第一, ‘ANZEN'-Safety ‘DAIICHI'-First)

is one of the foundations of the Factory Management System as TPS: Total Preventive Safety. ‘Safety-First' is developed by all workers in Gemba through some tools and daily uses, even some of the most renowned tools of LEAN-Kaizen, like 5S or TPM. Master Koichi Kimura shows us the way in which some more tools are used daily: KIKEN-YOCHI TRAINING(KYT) and KIYARI-HATTO (HH).

WHERE THE ACCIDENTS ACTUALLY COME

A.- HEINRICH’S 300, 29, 1 PRINCIPLE

300,29,1 HEINRICH'S Model is an attempt for Approximate

the reallity oh business accidentes at 1931, Same. SAME

300,29,1 Principle is used Nowadays in Health and safety

(H&S) In regard to accidents, Machinery or Facilities

Maintenance-Fails and Job-Mistakes to show up an

approximate proportion between major, minor and near misses

fails and their consequences.

B.- 3K KITSUI + KITANAI = KIKEN

Jp. きつい,’KITSUI’-Hard Work. 汚い,‘KITANAI’-Dirty Work.

危険,‘KIKEN’-Danger. Also known as the 3Ds, is an American

neologism derived from the Japanese concept, and refers to

certain kinds of labor often performed by unionized blue-collar

workers. 3D means are also: Dirty, Dangerous and Demeaning

or Dirty, Dangerous and Difficult.

WORK · (HARD + DIRTY ) = DANGER

SAFETY KAIZEN

SAFETY KAIZEN ACTIVITY is

an improvement front-line

workers activity in Gemba

where a group of workers, even

supervisors, and safety

coordinators, discuss about one

or some dangerous events

occurred or detected through

one or more daily tools widely

known by workers through on-

the-job training, just in the same

events held: Hiyari-Hatto

or/and Kiken-Yochi

KAIZEN CYCLE

KAIZEN CYCLE is widely used

in these events. PCDA + A3, on a

template, in the same place has

happened the danger or hazard,

are commonly the method

deployed in theses preventive or

corrective events. Furthermore,

Quick Response Kaizen Activity

(QRKA) is the right way when

Near misses (HIYARI-HATTO),

Minor or even Mayor Accident

occurs.

Just when some disruption to

work occurs is time to QRKA in

the way of ‘HIMADESHO', Jp.

暇でしょ: 'free time or probably

lost' taken to recover the normal

condition of the process.


C.- 90% OF ACCIDENTS IS HUMAN ERROR

INDUCED

The properties of human behavior such as confusion (illusion) and

carelessness are called "human characteristics," and errors caused by

these properties are "human error".

KIKEN-YOCHI TRAINING (KYT)

Hazard prediction training (KYT) Jp. 危険 KIKEN-hazard, 予知

YOCHI-Prediction. Using illustrations showing the workplace and

work conditions, or while supervising or demonstrating work in real

situations on site, discuss in small groups hazardous factors in the

workplace and in work conditions. Discuss, think about, and

understand the type of accidents that may arise from such factors, and

determine the danger points and the kind of action to take, confirming

these with pointing and calling, and pointing and saying out louder

together. Conduct this training so that you can take steps on a

preemptive action for safety before you act.

The hazard prediction training based on the KYT Basic 4-Round

Method and short meetings includes the following elements:

1. Operational Direction STK Training on a supervisory level (S:

sagyo (work), T: team, K: kiken-yochi);

2. KY by asking questions;

3. One-point KY on a team level;

4. SKYT (Short-time KYT) before start any work;

5. KYT by answering a self-questioning and answering card;

6. KYT through shift start or end meetings;

7. KYT by studying past disasters.

The KYT Basic 4-Round Method forms the foundation for all these

elements. Workers openly discuss the hidden hazards depicted in the

illustrations of the workplace and work conditions and solve problems

by proceeding through the four rounds step by step.

Round 1: What are the hidden hazards? (Understanding the actual

situation)

Round 2: These are the danger points. (Investigating the reality)

Round 3: What would you do? (Establishing countermeasures)

Round 4: These are the danger points. (Setting targets)

New Standard of Job Safety Analysis Assesment (JSA) and Standard

Operation Procedure or Instruction (SOP/SOI) have to be the result of

all countermeasures and actions delivered by KYT.

Source JNIOSH: Zero-accident Total Participation Campaign.

An accident occurs due to:

UNSAFE ACT

1. Not wearing

appropriate PPE’s.

2. Not following safety

standards (Wearing

sandals/long sleeves).

3. Wearing gloves while

operating drilling

machine.

4. Improper use of

machine, device, tools.

5. Cleaning, lubricating,

repairing or checking

machine while it is in

operation.

UNSAFE CONDITION

1. Press machines

without safety devices

(two hand switches,

Light sensors etc.)

2. Grinder without

protector.

3. Live electric wires (No

proper insulation).

4. No proper 5S followed

5. Bad maintenance of

machines.

Source: Kaizen Institute

Consulting Group, Hiyari-

Hatto, enhance employees

hazard-perception

capabilities Part - I

UNSAFE ACT &

UNSAFE CONDITION

https://www.jniosh.go.jp/

https://in.kaizen.com/blog/post/2016/01/15/hiyari-hatto-enhance-employees-hazard-perception-capabilities-part---i.html





HIYARI-HATO (HH)

Jp. ヒヤリ ‘HIYARI’ ハット’HATTO’ – Incident / Close-Call / Near-

miss & narrow-scape. Experience of Almost Accident situation, and as

Master Koichi Kimura says: ‘Swett of Fear’. Expression in spanish is

‘Salvado or los pelos’ when sailors were rescued from drowning,

grabbing her hairs.

HiyariHatto (or Hatto-Hiyari) activity has been organized to

encourage company employees to make report to their superiors on

the HiyariHatto-Page or A3 designed for the purpose, which are

detected or even eliminated during the work by countermeasures.

Eventually The Team Member makes its presentation in monthly

safetty meeting.

Worker should report in the way of HIMADESHO:

1. Any situation or prevailing conditions on equipment/work area,

which has potential to create accident.

2. Any operation difficult to do/carry out.

3. Any operations which enhances the safety of equipment or work

area

4. Any modification in standard operating procedures/operating

control procedures which contributes towards accident prevention.

暇でしょ – HIMADESHO*

In Japanese it means 'free time or probably lost'. It is the

time taken to recover the normal condition of the process.

HH MEMO FIELDS:

1. Name of observer.

2. When? (date & time).

3. Where? (location).

4. Who was with you?.

5. What has created the HH? (Reason).

6. What are you and your colleagues doing?

7. Graphic of the HH if possible.

8. Countermeasure/s.

9. Graphic of the Countermeasure if possible.

10. Supervisor signature.

11. Shop safety coordinator signature and comments.

12. Plant Safety coordinator signature and comments.

13. Observer signature and comments.

14. Follow up and control, as every other action or problem.

HIYARI HATTO FLOWCHART


EXAMPLE OF HIYARI-HATTO MEMO


SAFETY WEEK CELEBRATION

First of all, SAFETY is a relevant part of 5s deployment. Therefore,

House-Keeping or Tidy a Wharehouse Up prevent some of the hazards

or danger situations may induce an accident.

In point of fact, activities of Safety Week may celebrate at time with

5s+TPM, if time is tight.

It is relevant celebrate a safety week in order to maintain

Safety week is an involvement-by-all event, even managers, supervisors,

office-clerk, engineers, front-line-workers. That is to say: Both, Blue &

White collar workers.

Here is an agenda for a Safety Week Celebration:

Day 1:

1. Flag raising ceremony in a common area: Self-Apparent Flag

2. Brief all safety coordinators about H&S work and take a round of

plant, office, changing rooms and bathrooms, area around plant,

parking, access and shortcuts, etc.

3. Checking of PPE’s and check workers awareness.

4. Monthly safety coordinators meeting and Hiyari-Hatto

presentation.

Day 2:

1. Checking of electrical, chemical & mechanical hazard and take

necessary actions using HH-Memo.

2. Annual (or even Quarter…) emergency mock drill: Signals, time,

evacuation routes, meeting-points, equipment & volunteers, etc.

Day 3:

1. Checking of safety check sheet of all equipment.

2. Brief session along with practical demonstration of the fighting

equipment and rescue operation for all.

Day 4:

1. 5S and safety round of plant.

2. Awareness session for the nominated staff of every department on

shop safety fire-fighting & emergency preparedness

Day 5:

1. Checking safety action plan of all shops and its implementation.

2. Closing ceremony.

KPIs

1. No. Accidents in presence

of supervisor.

2. N0. Accidents in absence

of supervisor.

3. N0. Accidents which

causes sick leave (1).

4. N0. Accidents which does

not causes sick leave (2).

5. Time lost by Accidents (1

& 2) and Cost.

6. N0. Hiyari-Hatto memos

by the team member.

7. N0. Hiyary-Hatto

memos by supervisor.

8. No Hiyari-Hatto Memo

involves actions.

9. N0 H&S-Training Hours

to the team member.

10.No. H&S-Training Hours

to supervisors.

11. No. of KYT Events

celebrated, time and

attending.

12.Mock drill successful

actions

PARETO CAUSES &

COMPLEMENTAL DATA

1. Years of service for the

injured team member.

2. Age and other personal

characteristics of

injured team member.

3. Team member fitness.

4. 5W+H (What, Where,

When, Who, Why, How)

5. 5S Status.

6. Fault-Tree Analysis.

SAFETY INDICATORS

VISUAL CONTROL

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