OH

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OHS Plant Regulations makeGood Business Sense

• Robert Enchelmaier
• Capability By Design

Peter Kohler
Robert Enchelmaier
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OHS Plant Regulations
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• Are in place for a reason
• Represent good engineering practice
• Make good business sense

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OHS Plant Regulations - in place for a reason

• What are OHS Plant Regulations
• What is Plant
• Why did the Regulations come about
• When did they come into effect
• How do they work
• How do I find out more about them
• What are they designed to achieve

?
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What are OHS Plant Regulations?

• National Standard for Plant NOHSC1010 (1994)
• Uniform code for the use of plant
• Performance-based (not prescriptive)
• Responsibilities of designers through to
  employees
• Process requiring demonstrable outcomes
• Signing of a Safe To Use Certificate
• Associated State Acts and Regulations
• Variations in licensing
• Some States altered the responsibilities
• Referenced Standards

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What is Plant?

• Machinery
• Equipment
• Appliances
• Implements
• Tools
• Furniture

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Why did the Regulations come about?

• Over 200 plant-related fatalities each year
• 65,000 - 70,000 plant-related compensation claims
  each year
• 350 million in compensation payments
• Growth in OHS regulation in OECD countries
• Need for a national standard

Source WorkSafe Australia, Economic Impact
Analysis on the National Standard for Plant,
February 1996
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OHS Plant Regulations in effect
1994
2000 ?
1996
1994
1995
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How do the Regulations work?

• Workplace OHS responsibility structure
• Plant Designers, Manufacturers, Importers,
  Suppliers, Installers, Plant Users (Owners) and
  OHS regulators
• Outcomes
• Hazard identification and risk assessment
• Risk control
• Training
• Record keeping

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How do I find out more about the Regulations?

• www.worksafe.gov.au
• www.workcover.vic.gov.au
• www.workcover.nsw.gov.au
• www1.safetyline.wa.gov.au
• www.workcover.sa.gov.au
• www.detir.qld.gov.au/hs/hs.htm
• www.wsa.tas.gov.au
• www.nt.gov.au/wha
• www.act.gov.au

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What are the Regulations designed to achieve?

• A demonstrably safe work environment
• 24 reduction in fatalities accidents
• 900 million reduction in compensation payouts
• Improved business efficiency
• Indirect savings of 7.8b over 10 years

Source WorkSafe Australia, Economic Impact
Analysis on the National Standard for Plant,
February 1996
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OHS Plant Regulations - good engineering practice

• What do the regulations require?
• How do these requirements differ from good
  engineering practice?

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What do the Regulations require?

• Hazard identification and risk assessment
• Risk control
• Training
• Record keeping

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Hazard Identification and Risk Assessment

• Process
• What plant do you have
• What do you want it to do
• What was it designed to do
• What is failure
• How critical is failure
• Likelihood
• Consequences

• Standards
• National Standard for Plant NOHSC1010 (1994)
• AS/NZS 3931 Risk Analysis of Technological
  Systems - Application Guide
• AS/NZS 4360 Risk Management
• IEC 61078 Failure Mode Effect Analysis
• US Military Std 882B System Safety Programme
  Requirements
• AS/NZS 3907 Guidelines for Configuration
  Management

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Risk control

• Eliminate the hazard
• Minimise the risk
• Substitute with something safer
• Modify the design
• Isolate the plant
• Engineering controls (cut-outs, guards)
• Back-up controls
• Administrative controls (Safe work practices,
  signs)
• Personal protective equipment

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Training

• What, Why How
• Plant
• Intended and actual use
• Hazards and risks
• Safe work practices
• Personal protective equipment
• Pre-work safety checks

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Record keeping

• Need for Systems

• List of Plant
• Designed Use
• Actual Use
• Hazards associated with use
• Risk control measures
• Maintenance, testing, alterations
• A Safe to Use certificate signed by the owner

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List of Plant
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Plant Details
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Plant Regulation Requirements
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Designed and Actual Use
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HAZARD Analysis Risk Assessment
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How does this differ from good engineering?

• Risk management
• Maintenance engineering analysis
• Pre-work safety

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Risk Management

• AS/NZS 4360 Risk Management
• Define the Context
• Specify probability and consequence criteria
• Identify and prioritise hazards
• Develop risk mitigation strategies and tasks
• Implement
• Review and monitor

• US MIL-STD 882C System Safety
• Define the Context
• Specify probability and consequence criteria
• Prioritize the hazards using a hazard matrix
• Develop risk mitigation strategies and tasks
• Implement
• Review and monitor

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Maintenance engineering analysis

• IEC 61078 Failure Mode Effect Analysis
• Focus is on what assets do or their intended
  use
• Failure is defined in terms of what the business
  wants each asset to do
• Maintenance tasks are developed by understanding
• What the business wants each asset to do
• The hazards associated with each asset in the
  delivery of what it does
• The likelihood of the occurrence of each hazard
• The consequences to the business of each hazard
• What needs to be done to reduce the likelihood
  and/or consequence of each hazard

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OHS Maintenance
Capability Assurance

• Health Safety

• Efficient Plant Operation

Hazard Analysis Risk Assessment Risk Control
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Good engineering practice
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• One approach that delivers
• OHS requirements
• Plant maintenance requirements
• Operating tasks (start, run, stop and emergency)
• Plant instrumentation requirements
• Simple
• Integrated
• Consistent
• Complete

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Plant, Operations and Maintenance
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OHS Plant Regulations - good business sense

• Costs
• Benefits
• Opportunities

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OHS Plant Regulations - the cost

• Employers Costs over 10 years
• Hazard Identification 303M
• Risk Control 3,358M
• Training 903M
• Record Keeping 123M
• Other parties costs not available

Source WorkSafe Australia, Economic Impact
Analysis on the National Standard for Plant,
February 1996
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OHS Plant Regulations - the benefits

• Reduction in fatalities and injuries associated
  with plant
• Lower operating costs from nationally uniform
  regulations
• Situation specific, not global responses from
  performance-based regulations

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OHS Plant Regulations - the opportunities

• Significant efficiencies with one approach, one
  system
• OHS Plant Regulations
• Plant maintenance
• Consistency across all plant people issues
• Safe to Use
• Efficient operation
• Involvement of stakeholders
• Common language
• hazards, risks, likelihood, consequences, control

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Introducing Assure
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• OHS Plant Regulations
• Maintenance Planning
• Analysis Compliance demonstration
• Single- and Multi-User
• Windows 95, 98, NT
• Office 97, 2000
• Audit, Premium Professional versions
• Integration with commercial Maintenance
  Management Systems
• In use in major projects

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Introducing Assure
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• Audit against selected Standards
• Hazard Analysis
• Task Specification
• Maintenance
• Operations
• Testing
• Training
• Packaging of Standard Activities
• Pre-work safety check (Job Safety Analysis)
• Production of Technical Manuals
• Data libraries

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OHS Plant Regulations
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• Are in place for a reason
• Represent good engineering practice
• Make good business sense
• Thankyou

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Contacting CBD

• Phone [phone]
• Fax [phone]
• Email kohler_at_tpg.com.au
• Post PO Box 125 Granville NSW 2142

Peter Kohler
Robert Enchelmaier