DRH, 05/09/03, Slide 1 Methodology for applying HF analysis or A Human Factors Toolkit Debby Hallett, Ciba Specialty Chemicals

DRH, 05/09/03, Slide 2 Introduction… Purpose of presentation: –Share experiences of developing and using the “Human Factors Toolkit” Contents: –Ciba Specialty Chemicals & it’s requirements –Overview of methodology –Examples of applying the method –Problems encountered (& overcome)

DRH, 05/09/03, Slide 3 Ciba Specialty Chemicals & it’s requirements

DRH, 05/09/03, Slide 4 Ciba Specialty Chemicals… Globally: –20,000 employees –64 production sites –25 countries Bradford, UK site: –1,200 employees –Top tier COMAH site Human Factors at Ciba Specialty Chemicals: –Wide range of projects involve HF –3 year history of specific HF work

DRH, 05/09/03, Slide 5 Ciba Human Factors “History”… 2000: submitted COMAH Safety Report –Considered Technical control measures –Improvement plan on Human Factors agreed 2000 – 2001: Various individual assessments on lone working, manloading and Human Factors DNV 2001: Developed HF assessment technique:Ciba/DNV 2002: Pilot assessment – Grimsby siteCiba/DNV 2002: Assessment – Bead, Bradford siteCiba/DNV 2003: Assessment – MaintenanceCiba 2003: Assessment – R2000 Control roomCiba/DNV 2003: Assessment – Project DiamondCiba

DRH, 05/09/03, Slide 6 Ciba’s objectives: COMAH (Seveso) compliance…demonstration of: –Evaluation of potential human error –Effectiveness of human interventions required to maintain control Establish awareness of human factors: –Line Management –Engineering design Technology transfer: –Develop internal HF assessment methodology –Apply to all types of activities on site –Suitable for use by non-HF professionals –Complement other risk assessment techniques

DRH, 05/09/03, Slide 7 Overview of Methodology

DRH, 05/09/03, Slide 8 Incorporate relevant results into Safety Report Major Accident Hazard scenarios identified from COMAH Safety Report Task inventory & criticality assessment Observational data Identify critical tasks Error analysis Task analysis (HTA & concurrent) Qualitatively assess critical tasks and potential errors Staffing assessment Alarm & Procedure checklists Evaluate the safeguards Identify risk control strategies Before Assessment Assessment After Assessment Human Factors Method to Support COMAH

DRH, 05/09/03, Slide 9 Examples of applying the method

DRH, 05/09/03, Slide 10 1) Maintenance activities Manual task: –Breaking and making gasketted joints Toolkit worked well: –Easy to identify task steps, errors & consequences –Easy to generate recommendations Example - handover incomplete job to next shift –Error: fail to communicate task status –Consequence: Gaskets missing/untightened - leak of hazardous substance –Recommendations: Maintenance operatives handover job personally Use job sheet to record status

DRH, 05/09/03, Slide 11 2) Automated continuous plant General control room duties difficult to assess Selected a manual task, and looked at links to control room activities –e.g., communications, data entry & decision making Example – taking sample of reactor contents –Error: fail to circulation valve on sample cooler –Consequence: Unrepresentative sample taken - status of reactor unknown Potential runaway reaction –Recommendations: Ensure all operators understand importance of sampling Improve labelling of valves Investigate linking valves to sample point

DRH, 05/09/03, Slide 12 3) Design phase of new plant Multi-disciplinary team established during design phase Applied methodology to proposed design: –Identified how plant will operate –Identified design problems before too late –Identified manning levels –Most importantly…ensured employee involvement Example – connect road tanker to off-load point –Error: driver connects to wrong point –Consequence: Incompatible substance into storage tank - exothermic reaction –Recommendations: Tanker drivers not allowed on site unaccompanied 2 x paperwork checks Off-load points locked

DRH, 05/09/03, Slide 13 Problems encountered (& overcome)

DRH, 05/09/03, Slide 14 Key learning points… Consultants requirements  Ciba’s: –Unused data removed from process –Role of Task Inventory? –Training modified: less academic, more pragmatic Select the right assessment team: –Key people = experienced operators –Manager/supervisor also required (reality check) –Must be available for whole assessment Time intensive process: –Moved some steps outside assessment timetable –Ensure assessment scope is realistic –Facilitator observe task(s) before assessment –Smarter recording (reduce time to ‘write-up’)

DRH, 05/09/03, Slide 15 Key learning points (cont)… Costs involved: –Move to Ciba Specialty Chemicals led assessments –DNV provide support as required Staffing assessment: –Diagrams told us what we suspected – not specific enough –Concurrent task analysis = more useful

DRH, 05/09/03, Slide 16 Conclusions… 1) Methodology meets Ciba’s requirements: COMAH Compliance: –“Reality check” on current practice –Identifies deficiencies/opportunities Raised HF awareness within Ciba Specialty Chemicals Technology Transfer: –Simple method (but time consuming) –Suitable for wide variety of activities –Compliments other RA techniques 2) Most important parts of process: –Team selection –Setting scope –Concurrent task analysis –Smart recording

DRH, 05/09/03, Slide 17 Continue assessment programme: –Incorporate into design process –Roll-out to remaining production areas Development of best practice document –Continue Technology Transfer to other Ciba Specialty Chemicals EHS professionals Link to other business initiatives e.g. quality Way forward…