Managing Injury Risk at Grain Handling Facilities. Matt Shurtliff Director of Safety and Environmental Issues J.D. Heiskell & Co January 17, 2018

Transcription

1 Managing Injury Risk at Grain Handling Facilities Matt Shurtliff Director of Safety and Environmental Issues J.D. Heiskell & Co January 17,

2 Before We Start If you re unsure of a safe way to do a job There is absolutely no task at any of our locations that is worth getting hurt! 2

3 Agenda Injury Risk Management Principles Policy & Program Development Policy Deployment Continuous Improvement Behaviors Where to Get Help 3

4 Safety Management There s overlap, but they aren t the same thing!

5 Preventing Injuries 5

6 Hazards and Risk Hazard = a situation that has the potential to harm a person Risk = the possibility that the harm (i.e. death, an injury or an illness) might occur when exposed to a hazard.

7 Injury Risk Two elements Severity Likelihood Can be managed To manage it, you have to see it

8 Managing Injury Risk Identify hazards Assess injury risk Reduce risk when you can Manage residual risk that remains

9 Identifying Injury Risk Regularly walk the facility Specifically look for hazards Take pictures Explain to employees WHY something is a hazard Keep one list of hazards identified

10 Identifying Injury Risk Lessons Learned Show that: You want to know about hazards Nobody gets in trouble for bringing them forward Teach your employees HOW to recognize hazards WHAT TO DO when they see them

11 Identifying Risk - Management Commitment For most people hazard = BAD People don t want to look BAD o Reluctance to look for problems o Defensiveness o Worried about getting in trouble

12 Identifying Risk - Management Commitment Make it a GOOD THING to identify hazards Consider incentives Be sure to act quickly and correct the hazards Important

13 Stages of Risk Awareness 1. Doesn t realize injury risk at all 2. Realizes risk after work is done 3. Recognizes risk while performing task and corrects the situation 4. Foresees risk, implements controls, and begins only when safe to proceed This takes TIME, and you have to TEACH

14 Assessing Risk Severity How serious would injury be? Likelihood How likely is is injury to happen? Risk

15 Safety Severity Pyramid 21% of Lower Level Incidents could have been SIFs Fatalities Serious Injuries OSHA Recordable & First Aid Injuries 21% Near-Misses & Property Damage Hazards

16 We Want To Find The 21% These are Uncontrolled High Risks We want to control them before someone gets hurt badly 21%

17 How We Find Them Report near misses and property damage Search for the hazards Supervisors regular safety Inspections Line employees suggestions Investigate with an eye to How bad an injury could have been NOT how bad an incident WAS 17

18 Assessing Risk

19 Risk Management Process Severity = how bad will injury be Likelihood = how likely is it to happen Risk = Severity x Likelihood Risk Threshold

20 Risk Response Plan - SIF Risks Notify GM STOP WORK Immediate temporary CA Develop & install permanent CA Risk Threshold

21 Risk Response Plan Permanent CAs for o Risk > 6 o Severity 4 regardless of likelihood Temporary CAs as Needed Risk Threshold

22 Hierarchy of Controls Eliminate hazard or risk Level 1 Substitute MOST EFFECTIVE Engineering Controls Isolate, Guard, Modify Level 2 USE WITH OTHERS Administrative Controls Behavior SOPs, Best Practices, Rules Training Level 3 LEAST EFFECTIVE PPE

23 Reducing Risk Level 1 Controls MOST Effective First Choice Best Strategy Eliminate or prevent creation of hazard If you can t do that: Substitute (less dangerous, toxic, etc.) Modify/redesign equipment or work process Isolate, contain, separate (includes guards) Reduce (Example: Dust levels)

24 Reducing Risk Level 2 Controls Low Effectiveness More effective in combination with other controls Requires more effort & dollars to maintain/sustain Examples: Signs and labels Policy & procedures Re-Training

25 Why is Level 2 Less Effective? Relying on rules, procedures, and plans Only works if employees know that you re serious ONLY way to show you re serious o Train employees on the rules and procedures o Inspect what you expect frequently o Correct behavior when controls aren t followed 25

26 Correcting Behavior Correction that follows soon after a behavior means more Silence is considered to be consent If you put a procedure in place and don t regularly check on it you ve wasted your time

27 Reduce Risk Level 3 Least Effective when used by itself. Last resort strategy. Provide PPE & keep in easily accessible location. Requires consistent training & reinforcement. Includes (not limited to): Hearing, vision, skin, respiratory protection Fall protection Other

28 Why is Level 3 LEAST Effective? I can t remove the risk, wear this so you don t get hurt Need to pick the RIGHT equipment for the risk Need to make sure employees o Know HOW to use the PPE o ALWAYS use IT o Know when it needs to be replaced Need to always have it available It s much better to not need PPE at all 28

29 Managing Residual Risk You re never going to eliminate ALL the risk Our SAFETY PROGRAMS are designed to manage residual risk. CRITICAL SAFETY PROGRAMS manage common SIF hazards in our industry 29

30 SAFETY PROGRAMS Manage Residual Risk Engulfment & Explosion Protection (i.e., Grain Handling Industry Standard) Lockout/Tagout Permit Required Confined Spaces Fall Protection Rail Operations Safety Powered Industrial Truck Safety Etc. 30

31 Common Sources of Entanglement Hazards Source:

32 Strategy and Goal Setting Remember these are DIFFERENT THINGS 32

33 How to Get Started Install Safety Programs o ID programs you need o Install ONE program at a time o REPEAT, REPEAT, REPEAT Install a Hazard ID process o Find hazards o Fix them o REPEAT, REPEAT, REPEAT 33

34 Installing a Hazard ID Process Corrective Actions Regularly inspect your sites for hazards Keep track of hazards on a single list, no matter HOW you identify them ASSIGN a corrective action to somebody with a due date Keep checking up until the corrective actions are finished If you do this, you are beginning to reduce RISK 34

35 Program Development 35

36 Safety Programs o Plans for addressing a specific type of RISK o Aligned with OSHA Regulations o Elements: Written program PLAN to manage Risk Procedures HOW you will address Risk while executing work tasks Training COMMUNICATES the Risk and the Procedures Auditing CONFIRMS that the plan is being followed 36

37 How to Get Started There is no magic bullet. Start with adding o One Program o One Procedure o One Training o One Inspection The important thing is to be heading in right direction. It often takes 2-4 years to develop a system and 5-10 years to see the results 37

38 What Safety Programs Do I Need? Bloodborne Pathogens Contractor Safety Electrical Safety Emergency Action Plan Fall Protection Fire Prevention Grain Handling Industry Safety Hazard Communication Hearing Protection Heat Illness Prevention Hot Works Lockout/Tagout Machine Guarding Permit-Required Confined Spaces Personal Protective Equipment Powered Industrial Trucks Rail Operations Respiratory Protection Short answer: You need programs that address the RISKS you have at your facilities 38

39 Major Risks of The Industry 1 Engulfments 2 Falls 3 Electric 4 Entanglement 5 Struck by 6 Dust Explosion Other Respiratory dust exposure Noise Exposure 39

40 California Grain Handling Standard (GHS) Purpose is to PREVENT: o Explosions o Engulfments 40

41 6/1/17

42 1/3/18

43 Written Program Purpose describes your PLAN for how you address this type of RISK This is a document that OSHA will want to review if they inspect Plan needs to o Meet OSHA regulations o Describe what you actually DO 43

44 Tips on Developing Written Programs OSHA requirements vary o Sometimes: written program o Other times very prescriptive Flexibility beyond the OSHA requirement Tip - keep consistent level of detail Consider keeping most of the detail in procedures it makes updating easier 44

45 Programs Need To Contain Objective Of Program Responsibilities o At Facility o Company Wide (sometimes) Subjects the program will cover 45

46 Training Needs To Describe WHO you will train WHAT are the topics you will train HOW OFTEN you will train on the topic 46

47 Recordkeeping Should Identify WHAT written records do you collect HOW they are stored HOW LONG you keep them

48 Tips on Developing Procedure Remember your audience! Easy to understand Make sure they WORK Be specific but not wordy Picture is worth a thousand words Picture describes lockout point better than any words can! 48

49 Training What Are You Trying To Communicate? RISK of injury in our work How we manage that RISK 49

50 Tips on Communicating Risk Make it personal Talk about real situations Make it interactive o Get people sharing their experience o Peer teaching is very effective

51 Tips on Training Citing OSHA regulations and verbiage doesn t help Focus on o How you can get hurt o How to prevent it from happening Mix It Up Look for hands-on opportunities LOTO training handson demonstration 51

52 Auditing Have we done what we said we WOULD DO? If you don t check, you tell people it s not important You want to confirm that: o Your employees UNDERSTAND the risks of injury they face o What they need to DO to manage the risk

53 Tips on Auditing Make Corrections Conduct Audit Identify Corrective Actions Goal of auditing: Determine WHERE YOU ARE and HOW TO GET BETTER! Involve all levels of employees Perform at regular frequencies Track and monitor progress Today s score less important than next score 53

54 Ways You Can Audit Corporate Audits Internal audit team Consistency across company Great teaching opportunity Location Audits Plant audits itself Develops knowledge and skills Establishes line ownership 3 rd Party Audits Someone outside the company Gets you out of your bubble 54

55 Continuous Improvement

56 Reminders for Program Development Don t be overwhelmed You Can t o Implement everything at once o Become perfect overnight Start with adding o One Program o One Procedure o One Training o One Inspection

57 One Approach Get Better Every Month Review ONE Program Per Month Identify 3 things that need to improve. Examples: o Update a procedure o Add hands on demonstration to training o Perform a new inspection Make the improvements Next month move on to another program

58 ABC Behavior Model Antecedent Behavior Consequence

59 ABC Behavior Model A person s attitude (the activator) affects how he behaves Behavior has consequences Consequences either o Reinforce o Deter

60 The Mental Side of Safety An accident, injury or illness is the result of one or both of the following: Unsafe acts (behavior), Or Unsafe conditions

61 Basis for Unsafe Behavior If I do something unsafely (knowingly or unknowingly) and don t get hurt and I get the job done faster or cheaper I will likely do it again

62 Unless? I do get hurt, or I am convinced to stop

63 Feedback Everyone needs it If not given any we create our own Can be difficult to give & receive Not usually a part of our cultures Can be formal or informal Two basic types: opositive ocorrective 63

64 Positive - Catching An Employee Being Safe Recognize and reinforce the employees safe behavior. Show that you re not just looking for problems Ask if there is anything leadership can do to make the workplace safer.

65 Corrective - Speaking Up for Safety Four keys: 1. Stay positive & show concern 2. Be clear about the unsafe behavior and its possible consequences 3. Be specific about the behavior change needed 4. Ask for a commitment to change Goal is a culture win

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67 Summary Correcting Behaviors Watch your people work inspect what you expect Identify safe and unsafe behaviors Provide feedback on what you observed Don t give mixed signals Be consistent don t play favorites 67

68 Impact of YOUR Behavior Everything you say and do is watched and remembered Your attitude and behavior (actions) create the proper atmosphere for safety Supervisors and managers must lead by example

69 You Influence Safety When You Set the example Participate in improving safety Catch others working safely Coach others when you see unsafe actions

70 Getting Help

71 Insurance Company Loss Control Site assessments o Safety o Environmental Hazard Monitoring o Noise o Dust o Thermal Imaging Training on various topics 71

72 National Grain and Feed Association Safety Conferences Regional Safety Seminars Publications o Sweep Auger Operations o Confined Space Entry o Walking/Working Surfaces Training Resources

73 Grain Feed Association of Illinois Have written safety templates for most key programs They work nationwide you do not need to be from Illinois John Lee (217) Kris Richardson (217)

74 GEAPS/KSU University Distance Education Program Currently 24 online courses covering various grain topics. 74

75 Networking Call Others in the Industry There are no secrets in safety

76 Thank You Matt Shurtliff Director of Safety and Environmental Issues J.D. Heiskell & Co. Elkhorn, NE