Managing Hazards and Risk

Connected with Repair and

Maintenance in RMX Plants
Ian Pughsley
Country Head of Health & Safety
Tuesday 31st May 2016
 Who is affected when an accident occurs;

Work Supervisor
mate and
Family Management

ACCIDENT
(To insert Local
accident Community
Emergency
photo)
Service

Therefore, what should our aim be;

“everyone returns home after a day‟s work unharmed”
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 What are the costs associated with an accident?

Cost of accidents
in Malaysia
 Direct Cost
RM
Medical treatment/response, YEAR
(billion)
repair/replace equipment and/or
building’s, ruined product, fines, 2010 1.7
legal fees, insurance premiums,
sick pay. 2011 1.7
 Indirect Cost
Loss of production, loss of 2012 2
staff/recruiting new/training,
2013 2.2
investigation and report writing
costs, family support, penalty
2014 2.5
clauses on delivery, loss of good
will. Source: SOCSO Annual Report
2014
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 Incident analysis and where we should be focusing
Fatality
(1) • Accidents already
Serious happened
Injuries
(30) • Outside our control

Minor Injuries • Investigation - „Pain‟

(300)
• REACTIVE

Near Miss (3000)

Unsafe Act (300,000)
GAPS IN PEOPLE‟S
KNOWLEDGE & AWARENESS
OF DANGER
• Potential Incidents
• Within our control
• Intervention – „Pleasure‟
• PROACTIVE

96% of accidents caused by people behavior (ILO Statistic)

When are workers most at risk?

 Repair and Maintenance of plant

and equipment.

 Delivery of product – transport.

 Customer site activity.

andconditions
Today‟s presentation focuses on
the repair and maintenance of plant
and equipment as well as how to
keep workers safe

The RMX business is a direct customer facing one so the risks

increase with “unplanned” maintenance!
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 How do we address Unsafe Behavior
Supervision

1
Personal
Risk
Assessment
2
7
Planning
Training
Work

Risk
Supervision Assessment Supervision
3
6 Addressing
Visibility Killer
Hazards

5 4
Communication
Change
Management

Supervision
 Examples of accidents during maintenance of plant &
equipment

• Contractor worker lost three fingers during a chevron belt  Finger injury during mixer maintenance
conveyor replacement job. activity
• Fingers on his right hand trapped in the head drive v-belts.  Middle finger pinched between mixer
blade and wall liner

• Employee suffered hairline

fractures to his right wrist and
ribs after falling to ground from
3.35 m height.
• Injured person attempted to
replace a worn out return roller
on a raw material conveyor

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 Identifying and managing hazards - Risk Assessment?

 General hazards - Personal Risk Assessment (PRA)

This concerns 5 principal behaviors
 Be aware of hazards around you (Assess Area)
 Keep eyes on paths
Individual
 Keep eyes on hands
responsibility
 Staying out of the line of fire
 Working within body limits
 Killer hazards - Job Task Risk Assessment (JTRA)
 Planning work , knowing the hazards, controls
Team
 Following safe work procedure and reviewing hazards supervision &
 Completion of job – tidying up, making area safe discussion

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Personal Risk Assessment (PRA) to prevent self harm and
lead by example

Assess area around you Eyes on path

Personal Risk Assessment (PRA) to prevent self harm
and lead by example

Assess
Eyes onarea
hands EyesLine
on Path
of fire
Personal Risk Assessment (PRA) to prevent self harm
and lead by example

Eyes on
Assess area Line
Eyes
of on
Fire
Path
Hands Body limits – manual handling
Job Task Risk Assessment - Managing Killer Hazards.

 Job Planning

 Discussion among workers about job steps, hazards and what

could seriously injure or kill during the task

 Workers behaving safely – following steps of the job and avoiding the

hazards by safe working

 Completion of job – tidying up, making area safe for operational

workers (post job housekeeping)

Supervision, visibility on site and conversation are important

factors in addressing people behavior deficiency - remember,
96% of accidents are caused by human behavior.
Managing Killer Hazards – Life Saving Talk (LST)

 A copy of Preventing Killer Hazard template on this

page
Supervisors Review Log – Job Task

LH and Workers‟ supervisors

document when they review
the job

Rear of the life saving talk form

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Managing Killer Hazards – Job Planning Tool (JPT)

 A copy of Job Planning Tool on this slide

Managing Potential Killer Hazards – critical risks.

Confined space, welding, working at height, energy

sources, working with electricity
 Implementing Safe Working Procedures in Practice – who does what?
For Contractor Managed Jobs - assumes applicable LOTOTO applied
Job Supervisor decides if
Follow flow chart the job is Routine or Non-
for each of the Routine prior to handover to E.g. Major mixer
the contractor supervisor repairs,
classified jobs… E.g. Replace a changing
large motor or hopper liners
gear box etc.
Routine Non-Routine
GWP

Non-High Hazard High Hazard

HH Permit
E.g. Changing
conveyor rollers,
mixer cleaning
Non-Complex Complex Non-Complex Complex
• Contractor RA • Contractor RA
• JPT • JPT

All workers:
All workers:
• Conduct
• Participate in
PRA
a LST Transfer killer hazards to the LST
• Start work
E.g. Light bulb
E.g. Replace a replacement at
small motor height.
Routine
Jobs for which workers are trained in a Work Instruction / SWMS or have the relevant trade certificate and experience (Roller replacement)
Complex
Jobs that require advance methodology planning (E.g. Gearbox removal)
High Hazard
Jobs requiring permits (Confined Space, Hot Work, Working @ Heights etc.)
 Conclusion
 People are our most prized asset and therefore we must invest time and
money in keeping them safe.
 Plan repair and maintenance activities to avoid an environment where people
are rushing and taking short cuts.
 Business efficiency and productivity is enhanced by a strong safety culture -
driven by the top leadership in the organization.
 Safe ways of working e.g. using Risk Assessment in the form of Personal as
well as Job Task – identify and control less severe as well as killer hazards.
 Apart from our moral duty to provide a safe working environment for workers,
as management we also have legal responsibility;
OSHA Act 1994, Section 15 “It shall be the responsibility of every employer and self employed
person to ensure, so far as is practicable, the safety, health and welfare at work of all it
employees”

If everyone returns home to their family each day unharmed, this will
make business and family life more enjoyable and sustainable

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