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WCM Safety Tools

Risk Analysis
Overview
Safety Emergency Work Order (SEWO)
HOW?

3G OF INJURY SITE

INTERVIEW OF
OPERATOR

5W + 1H IS COMPLETED

SKETCH THE
PHENOMENON

JSRA IS UPDATED AND


COMMUNICATED TO
OPERATORS

INJURY OCCURS
(*NON-EMERGENCY)

SEWO IS INITIATED

WHY?
LONG TERM
COUNTERMEASURE IS
IDENTIFIED

ROOT CAUSE OF INJURY


IS DETERMINED

EMPLOYEE RECEIVES
MEDICAL ATTENTION

IMMEDIATE
COUNTERMEASURE IS
IMPLEMENTED

SEWO REVIEWED BY
LEADERSHIP BASED ON
SEVERITY

LONG TERM
COUNTERMEASURE IS
IMPLEMENTED

CHECK FOR
EFFECTIVENESS FOR
90 DAYS

READ ACROSS FORM IS


COMPLETED AND
SHARED

* Non-emergency incidents

Safety Emergency Work Order (SEWO)

INJURY OCCURS
(EMERGENCY)

EMPLOYEE RECEIVES
MEDICAL ATTENTION

3G OF INJURY SITE

SEWO IS INITIATED

INTERVIEW OF
OPERATOR

HOW?
WHY?
LONG TERM
COUNTERMEASURE IS
IDENTIFIED

ROOT CAUSE OF INJURY


IS DETERMINED

IMMEDIATE
COUNTERMEASURE IS
IMPLEMENTED

SKETCH THE
PHENOMENON

SEWO REVIEWED BY
LEADERSHIP BASED ON
SEVERITY

LONG TERM
COUNTERMEASURE IS
IMPLEMENTED

CHECK FOR
EFFECTIVENESS FOR
90 DAYS

READ ACROSS FORM IS


COMPLETED AND
SHARED

* Emergency incidents

5W + 1H IS COMPLETED

JSRA IS UPDATED AND


COMMUNICATED TO
OPERATORS

Job Safety Risk Assessment (JSRA)

SELECT A TEAM

PROVIDE TRAINING

REVIEW SOP / SWI

OBTAIN OPERATOR
INPUT

ANALYZE THE RISKS


IDENTIFIED

SEVERITY
+ PROBABILITY
+ CONTROL

UPDATE PROJECT
TRACKER WITH
COUNTERMEASURES

STRATIFY TOP RISKS


IDENTIFIED

ENTER SCORES INTO


THE TRACKING MATRIX

DETERMINE RISK
SCORE

CONSIDER ALL FACTORS

IMPLEMENT THE
COUNTERMEASURE

CHECK FOR
EFFECTIVENESS /
EVALUATE NEW RISK
LEVEL

UPDATE THE JSRA AND


COMMUNICATE RISKS
TO OPERATOR

EXPAND TO OTHER
AREAS

Green
Room

ASSIGN RESPONSIBILITY
TO PROJECTS IN GREEN
ROOM

Job Safety Risk Prediction (JSRP)

SELECT A TEAM

IDENTIFY TOP STATION


WITH TOP RESIDUAL
RISK

REVIEW PREVIOUS JSRA


& UNDERSTAND RISKS

OBTAIN A VIDEO OF
THE WORKSTATION
FOR ANALYSIS

LIST ALL TASKS FROM


THE SOP / SWI

EVALUATE VIDEO FOR


OTHER MOVEMENTS /
RISKS NOT IDENTIFIED

IDENTIFY ANY UNSAFE


ACTS THAT CAN LEAD TO
THE RISKS IDENTIFED

SCORE EACH
MOVEMENT BASED ON
THE RISK IDENTIFIED

IDENTIFY PREVIOUS
INJURIES AND RISKS TO
ASSESS MOVEMENTS

IDENTIFY ALL
MOVEMENTS WITHIN
EACH TASK

IDENTIFY
COUNTERMEASURES TO
ATTACK EACH RISK

IMPLEMENT
COUNTERMEASURES

CHECK FOR
EFFECTIVENESS

UPDATE THE JSRA AND


COMMUNICATE RISKS
TO OPERATOR

EXPAND TO OTHER
AREAS

Non-Routine Risk Assessments


PLANT ACTIVITIES

NON-ROUTINE ACTIVITIES:

ROUTINE ACTIVITIES:

Implementation of
Countermeasures

Analysed
by Risk
Analysis

Execution
of activity

Yes

Step 4

Did we achieve
ZERO Injuries
OR Reduce All
High Risks?

Continuous
monitoring

No
Risk analysis &
implementation of SOP / SMP

Risk Prediction

Non-Routine Risk Assessments

IDENTIFY HIGH
FREQUENCY TASKS
FROM TMS

SELECT A TEAM

REVIEW SMP / WORK


ORDER FOR TASK

OBTAIN SKILLED TRADE


/ OPERATOR INPUT

ANALYZE THE RISKS


IDENTIFIED

SEVERITY
+ PROBABILITY
+ CONTROL

IDENTIFY THE LONG


TERM
COUNTERMEASURES

STRATIFY TOP RISKS


IDENTIFIED

ENTER SCORES INTO THE


TRACKING MATRIX
LISTING EACH TASK

DETERMINE RISK
SCORE

CONSIDER ALL FACTORS

MPI

IMPLEMENT
COUNTERMEASURES

CHECK FOR
EFFECTIVENESS /
EVALUATE NEW RISK
LEVEL

ADD RISKS AND PPE


REQUIRED TO TMS
WORK ORDER / SMP

UPDATE THE JSRA AND


COMMUNICATE RISKS
VISUALLY AT SITE

GENERATE MPI AND


EXPAND

Safety Management Audit Training (SMAT)

SELECT STATION TO
REVIEW

REVIEW SOP TO
UNDERSTAND THE
WORK ASSIGNMENT

REVIEW JSRA AND


NOTE ALL RISKS

REVIEW PREVIOUS
SMAT AUDIT ON
STATION

OBSERVE THE
OPERATOR

UNSAFE CONDITIONS
UNSAFE ACTS
SAFE ACTS

ASK OPERATOR FOR


SUGGESTIONS TO
IMPROVE

PERFORM A TWTTP IF AN
UNSAFE ACT IS
OBSERVED

COACH OPERATOR ON
UNSAFE FINDINGS AND
RECOGNIZE SAFE ACTS

INTERVIEW THE
OPERATOR IN A QUIET
SETTING

NOTE ALL UNSAFE


CONDITIONS AND ACTS

ADDRESS UNSAFE
CONDITIONS FOUND

LOG UNSAFE
CONDITIONS AND
UPDATE SMAT MATRIX

UPDATE THE JSRA IF


NEW RISKS ARE NOTED

SUBMIT SUGGESTIONS
TO PEOPLE
DEVELOPMENT

EXPAND TO OTHER
AREAS

Near Miss Analysis and Classification


HOW?

SEWO IS INITIATED

3G / 5G OF NEAR MISS
LOCATION SITE

NEAR MISS IS CLASSIFIED

NEAR MISS OCCURS

NEAR MISS
INFORMATION IS
ADDED TO TRACKING
DATABASE

INTERVIEW OF
PERSONNEL INVOLVED

5W + 1H IS COMPLETED
WITH SKETCHES

WHY?

LONG TERM
COUNTERMEASURE IS
IMPLEMENTED

CHECK FOR
EFFECTIVENESS FOR
90 DAYS

LONG TERM
COUNTERMEASURE IS
IDENTIFIED

ROOT CAUSE OF NEAR


MISS IS DETERMINED

JSRA IS UPDATED AND


COMMUNICATED TO
OPERATORS

READ ACROSS FORM IS


COMPLETED AND
SHARED

Green Room

ANALYSIS OF ISSUES

RISK ASSESSMENTS

KAIZEN DEVELOPMENT

RESULTS
Green
Room

GREEN ROOM REVIEW


COMPLETE JSRAs BASED
ON MTS

STRATIFY TOP RISKS


IDENTIFIED

SEVERITY

SEWO INVESTIGATIONS

LOW
RISK

11

10

ASSIGN PROJECTS TO
UNIT LEADERS

PROJECT AGAINST
INJURY LOSSES

WIRBM PROJECT
REVIEW
PROJECT CREATION

IFI / FAI

IF POOR PROJECT ALIGNMENT


EXISTS, REVISIT JSRA ANALYSIS

PROBABILITY

PRIORITIZE RISK SCORES

REACTIVE

PREVENTIVE

RESULTS

SHARE

Green Room Review


1

Green
Room

What: Increasing the Know-How


Who: Plant Manager, Center / Manufacturing
Manager, Safety Pillar Team, Team Leader /
Team Member
Why: Transfer of knowledge to team,
accountability, buy in of all team members
Lessons Learned: Successful safety programs
involve all levels of the organization; invite
others to join into the discussion
4

Top
Projects

What: What are the main issues/gaps that exist


in your data?
Who: Center / Manufacturing Manager, Business
Unit Leader, Safety Pillar Team
Why: Green Room is designed to highlight gaps
and develop action items against top injuries
Lessons Learned: Room documentation should
have evidence of activity
(writing on charts) as problems are uncovered

What: What are your most significant projects


currently being worked on that will close the
gap on those issues?
Who: Center / Manufacturing Manager,
Business Unit Leader, Safety Pillar Team
Why: Alignment of projects / activities to top
injury losses or risks is critical; historical
trends will provide guidance to emerging
issues

6
This is a perfect
project for John to
attack .....

What: What is the top issue you are NOT


attacking?
Who: Center / Manufacturing Manager,
Business Unit Leader, Safety Pillar Team
Why: Understanding emerging issues that
require significant resource allocation or
investment must be escalated to ensure
appropriate resolution
Lessons Learned: Some risks identified may be
difficult to resolve due to current product or
facility constraints but must be carried forward
to future design (EEM / EPM)

What: Has each management employee been


assigned high risk projects that align with top
injury losses to meet the target?
Who: Center / Manufacturing Manager,
Business Unit Leader
Why: All personnel are responsible to
contribute to the overall improvements in the
safety program
Lessons Learned: Ensure the project owner
has the knowledge or skills to complete their
assigned project(s)

What: Are the trends of the top 3 injury losses


improving?
Who: Center / Manufacturing Manager,
Business Unit Leader, Safety Pillar Team
Why: If there is no improvement to your injury
trends, either the total number of projects
completed is insufficient or the current projects
are not effective
Lessons Learned: The quality of
projects is always more important
than quantity

Test Your Knowledge


6/21/13

TEST YOUR KNOWLEDGE - SEWO


Define the Non-Emergency SEWO process? Place the magnets over the numbers.

10

11

12

13

14

15

TEST YOUR KNOWLEDGE - SEWO


Define the Emergency SEWO process? Place the magnets over the numbers.

10

11

12

13

14

15

TEST YOUR KNOWLEDGE - JSRA


Define the current Job Safety Risk Assessment process? Place the magnets over the numbers.

10

11

12

13

14

15

TEST YOUR KNOWLEDGE - JSRP


Define the Job Safety Risk Prediction process? Place the magnets over the numbers.

10

11

12

13

14

15

TEST YOUR KNOWLEDGE NON-ROUTINE


Define the Non-Routine Risk Assessment process? Place the magnets over the numbers.

10

11

12

13

14

15

TEST YOUR KNOWLEDGE SMAT


Define the Safety Management Audit Training process? Place the magnets over the numbers.

10

11

12

13

14

15

TEST YOUR KNOWLEDGE NEAR MISS


Define the Near Miss Analysis process? Place the magnets over the numbers.

8
9

10

11

12

13