SAFETY AUDIT A KEY HAZARD IDENTIFICATION TECHNIQUE

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SAFETY AUDIT A KEY HAZARD IDENTIFICATION
TECHNIQUE

• A presentation by
• Subbarao
• Cholamandalam AXA Risk Services

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What is Safety Audit

• Verifying the existence and implementation of
  elements of occupational safety and health system
  and for verifying the systems ability to achieve
  defined safety objectives
• IS-14489-1998

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CONCERNS OF MANAGEMENT

• QUANTITY PRODUCED IN RELATION TO PRODUCTION
  SCHEDULE AND MARKET REQUIREMENT
• PRODUCT QUALITY
• PRODUCTION COSTS
• INTEGRATING THE STAKEHOLDERS
• CONCERNS

• Is Safety Important? Not always

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SAFE AND SOUND

• A study of top companies in the world indicated
  that
• Safety and Loss Prevention Programmes
  were essential for a companys
  prosperity and accepted as part of
  good Business'.

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Why do organizations have to bother about Safety

• Corporate Strategy
• Finance
• Human Resources
• Marketing, Product Design and Product Liability
• Manufacturing and operating policy
• Information Management and systems
• Societal Concerns

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Societal Concerns

• Increased concern about the impact on the public
  not just the workforce concerned
• Public intolerance of risks which do not have
  clear benefits to those affected
• Readiness to press for retribution on those who
  cause harm and to seek compensation
• Demand for increased transparency

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• Demand for full information and for public
  involvement
• A willingness to challenge and complain

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Corporate Strategy

• Business Mission, Philosophy and codes of ethics
• Company image in the community
• Environment impact
• Management Professionalism

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Finance

• Loss Control and cost reduction strategies
• Product liability, Legal liability, Property
  damage
• Risk retention or transfer
• Investment decisions concerning business
  acquisitions

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Human Resources

• Work and job structuring
• Morale and retaining people
• Positive health structure

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Marketing, product design and product liability

• Specification of product and service
• Legal requirement
• International requirement
• Consumer protection act

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Manufacturing and operating policy

• Design/selection/construction/maintenance of
  premises, plant, equipment and substances
• Quality management
• Environment management and waste disposal

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Information management and systems

• Identification of data critical to the management
  of health and safety
• Selection of appropriate performance indicators
• Use of information technology in the collection
  and analysis of essential data.

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Organizations carry out

• Safety Audit
• Safety Survey
• Safety Inspection
• Safety Tour
• Safety Sampling
• HAZOP

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• Safety Survey Detailed examination of a narrower
  field of activity-e.g.- key areas revealed by
  safety audits
• Safety Inspection Routine inspection-work is
  being carried in accordance with procedures etc.
• Safety Tour Unscheduled examination-hazards are
  removed-standards are removed

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• Safety Sampling Trained observers record the
  number of safety defects seen while touring
  specified locations by a prescribed route.
  Typically tours last for 15 min. and are
  conducted at weekly intervals. The unweighted
  count of defects is used to portray trends in the
  safety situation.

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SAFETY AUDIT

• MONITORING
• COMPARE ACTUAL PERFORMANCE -STANDARDS
• COMPREHENSIVE
• CONTINUOS

• AUDIT
• NOT DONE BY INSIDER
• NOT COMPREHENSIVE-DEPENDS ON SCOPE
• PERIODIC

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DIFFERENT TYPES OF AUDIT

• Electrical Audit
• Fire Safety Audit
• Pressure vessels Audit
• Lifting Tackles Audit
• Statutory Regulations Compliance Audit
• Emergency Communication Audit
• Pipe lines Audit

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Safety Depends on

• Accident and incident analysis

• Work permit

Hardware

• Engineering

Software

• Emergency

• Procurement

Humanware

• Maintenance

• Leadership

• PPE

• Health and Hygiene

• Task observation

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SAFETY AUDIT

• OCCUPIERS ARE REQUIRED TO DEMONSTRATE THEIR
  CAPABILITY TO DESIGN LOCATE OPERATE AND MAINTAIN
  THEIR FACILITIES TO STANDARDS ACCEPTABLE TO THE
  GOVT. AND PUBLIC.

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AUDIT

• AN AUDIT IS A SYSTEMATIC INDEPENDENT REVIEW TO
  VERIFY CONFORMANCE WITH ESTABLISHED GUIDE LINES
  OR STANDARDS. IT EMPLOYS WELL DEFINED REVIEW
  PROCESS TO ENSURE CONSISTENCE AND TO ALLOW THE
  AUDITOR TO REACH DEFENSIBLE CONCLUSIONS.

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OBJECTIVES OF THE SAFETY AUDIT

• DESIGN DEFICIENCIES AND ALSO WEAKNESSES WHICH
  MIGHT HAVE CROPPED UP DURING MODIFICATIONS
  /ADDITIONS.
• FIRE PROTECTION ARRANGEMENTS AND SAFETY SYSTEMS.
• OPERATING /MAINTENANCE PROCEDURES-DEGRADED WITH
  TIME
• TRAINING, PREPAREDNESS FOR HANDLING EMERGENCIES.

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SCOPE OF AUDIT

• FIRE AND EXPLOSION PREVENTION, PROTECTION AND
  EMERGENCY MANAGEMENT.
• WORK INJURY PREVENTION.
• HEALTH HAZARDS CONTROL.
• CONSEQUENCES OF EMERGENCIES.
• ON SITE EMERGENCY CONTROL

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Elements of Occupational Safety and Health
System-IS14489

• Occupational Health and Safety Policy
• OSH organizational set up
• Education and Training
• Employees participation in OSH Management
• Motivational and Promotional measures for OSH
• Safety Manual and Rules
• Compliance with Statutory Requirements
• New Equipment review and inspection

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Elements contd..

• Accident reporting analysis investigation and
  implementation and recommendations
• Risk Assessment including hazard identification
• Safety inspections
• Health and safety improvement plan/targets
• First aid facilities-Occupational health center
• Personal Protective Equipment
• Good housekeeping
• Machine and general area guarding
• Material handling equipment

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Elements contd..

• Electrical and Personal safeguarding
• Ventilation, illumination and noise
• Work environment monitoring system
• Prevention of occupational diseases including
  periodic medical examination
• Safe operating procedures
• Work Permit systems
• Fire Prevention, Protection and fighting systems
• Emergency Preparedness plans(onsite/offsite)
• Process Plant modification procedure

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Elements contd..

• Transportation of hazardous substances
• Hazardous waste treatment and disposal
• Safety in storage and warehousing
• Contractor safety systems
• Safety for customers(including MSDS)

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Records to be examined during Audit

• OSH Policy
• Safety organization chart
• Training Records on safety, fire and first aid
• Accident investigation reports
• Accidents and dangerous occurrences-Statistics
  and analysis
• Records of tests and examination of equipment and
  structures
• Safe operating procedures for various operations
• Record of work permits
• Record of montioring of flammable and explosives

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Records- Contd..

• Maintenance and testing records of fire detection
  and fire fighting equipment
• Medical records of employees
• Records of industrial hygiene surveys(noise,
  ventilation, illumination levels, airborne and
  toxic substances, explosive gases)
• MSDS
• Onsite emergency plans and record of mockdrills
• Records of waste disposal
• Records of effluent discharge to the environment
• Housekeeping inspection records

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Records contd..

• Minutes of Safety committee meetings
• Approval of layouts and other approvals from
  statutory authorities
• Records of any modifications carried out in plant
  and process
• Maintenance procedure records
• Calibration and testing records
• Shutdown maintenance procedures
• In service inspection manuals, records including
  that of material handling
• Safety Budget
• Statutory Records, Previous audit reports,
  Transportation of Hazardous substances

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TOPICS ON WHICH INFORMATION IS COLLECTED

• SAFETY ORGANIZATION.
• CONTRACTOR EMPLOYEE ACTIVITIES.
• MATERIAL SAFETY DATA.
• OCCUPANCY.
• SAFETY AND HEALTH POLICY.
• OPERATION AND MAINTENANCE OF SAFETY MANUAL.

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• EXPANSION MODIFICATION -AUTHORIZATION PROCEDURES.
• SAFETY EDUCATION , TRAINING.
• STATUTORY STANDARDS, SAFETY IF
• JOB SAFETY ANALYSIS.
• JOB SAFETY INSTRUCTIONS

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.TOPICS CONTD.

• SAFETY INSPECTION.
• SAFETY OBSERVATIONS.
• WORK PERMIT SYSTEM.
• FIRE PROTECTION ARRANGEMENTS
• FIRE EMERGENCY CONTROL PROCEDURES.
• WORK ENVIRONMENT MONITORING.

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• PERSONAL PROTECTIVE EQUIPMENT.
• MEDICAL/AMBULANCE FACILITIES.
• ACCIDENT/INCIDENT -REPORTING INVESTIGATION
  ANALYSIS.
• IDENTIFICATION OF CRITICAL EQUIPMENT AND PREUSE
  INSPECTION OF CRITICAL EQUIPMENT
• OFF THE JOB -SAFETY.
• STATISTICAL INF. ON LOSSES INJURIES.

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• EMERGENCY COMMUNICATION FACILITIES.
• EVACUATION FACILITIES.
• PRODUCT/SERVICE-LIABILITY

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Manufacture, Storage and import of Hazardous
Chemicals Rules, 1989

• Safety Audit is required to be carried out by by
  the occupiers of both the new and the existing
  industrial activities with the help of an expert
  not associated with such industrial activities.
• This is required under Rule No.10-subrule (4)
• This has come into effect from 3/10/94

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Traits of an auditor

• Dispel the myth that it is policing on behalf of
  management
• Is questionnaire useful?
• Knowledge in the area being visited
• Blinkered view?
• Discussion is more important-Facilitator rather
  than an inspector.

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Are you a good auditor?

• FINISHED FILES ARE THE RESULT OF YEARS OF
  SCIENTIFIC STUDY COMBINED WITH THE EXPERIENCE OF
  YEARS

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Safety Leadership is key to success
Survey by Linkage, inc., 1999
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Safety Culture

• Liveware
• Safety Culture
• Hardware Software

Acts-Practice-Habit-Behavior-Culture
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Coincident or Not ?
If, A B C D E F G H I J K L M N O P Q
R S T U V W X Y Z Equals, 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 Then, K N O W L E D
G E 11 14 15 23 12 5 4 7 5
96 H A R D W O R K 8
1 18 4 23 15 18 11 98
Both are important, but the total falls just
short of 100 But, A T T I T U
D E 1 20 20 9 20 21 4 5
100
Safety really is about attitude. Make 100 Safe
Behavior your choice both ON and OFF the job
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Safety and Incident Prevention

• Depends how much on ATTITUDE ?

A T T I T U D E

1 20 20 9 20 21 4 5
100