HU151: Industrial Safety Prof. Dr. Abdelsamie Moet Fall 2012/13 Pharos University in Alexandria Faculty of Engineering Lecture 2: Overview

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3 Industrial Safety Contextual definitions

HU151, Lect2, Overview4 Industrial Safety Occupational Safety Environmental Safety Product Safety

HU151, Lect2, Overview5 Includes, but not limited to: SAFETY MANAGEMENT PLANT LAYOUT MATERIALS HANDLING OCCUPATIONAL HEALTH FIRE PREVENTION AND CONTROL HAZARD ANALYSIS ELECTRICAL SAFETY ERGONOMICS Industrial Safety

HU151, Lect2, Overview6 Safety Defined U.S. National Safety Council – "Safety" is the control of hazards to attain an acceptable level of risk.

HU151, Lect2, Overview7 "Safety" is the control of hazards to attain an acceptable level of risk.

HU151, Lect2, Overview8 "Safety" Hazard Acceptable Risk the control of hazards to attain an acceptable level of risk

HU151, Lect2, Overview9 Hazard Hazard are defined as the "potential for harm or damage to people, property, or the environment" and are the "source of risk". Hazards include: - the characteristics of things -"actions" or "inactions" of people. As such, they are the "base" of all safety concerns

HU151, Lect2, Overview10 HAZARDS “Events or physical conditions that have the potential to cause fatalities, injuries, property damage, infrastructure damage, damage to the environment, interruption of business, or other types of harm or loss.” - FEMA, 1997 FEMA Multi Hazard Identification and Assessment. FEMA. Washington, D.C.

HU151, Lect2, Overview11 Hazard Categories 1.Biological - bacteria, viruses, insects, plants, birds and animals, etc., 2.Chemical - depends on the physical, chemical and toxic properties of the chemical. 3.Ergonomic - repetitive movements, improper set up of workstation, etc., 4.Psychosocial - stress, violence, etc., 5.Physical (Mechanical, Electrical) - slipping/tripping, - inappropriate machine guarding, equipment malfunctions or breakdowns. - radiation, magnetic fields, pressure extremes (high pressure or vacuum), noise, etc,

HU151, Lect2, Overview12 Common Hazards in the Workplace StressorType ChemicalCorrosiveFire Explosion Toxic ElectricalShockShort Circuit Fire-Static MechanicalMoving Parts FailureNoise Pressure ErgonomicStrainHuman Error Fatigue

HU151, Lect2, Overview13 Common Hazards in the Workplace StressorType RadiationIonizingNon Ionizing ContactStruck ByStruck Against Caught In EnvironmentTemp.VisibilityWeather Misc.SlipsTripsFalls

HU151, Lect2, Overview14 Risk* "A measure of the probability and severity of adverse effects" * Of acceptable risk: science and the determination of safety, William W. Lowrance,1976, W. Kaufmann (Los Altos, Calif)

HU151, Lect2, Overview15 Hazard

HU151, Lect2, Overview16 Deliverables of RM Process ProcessDeliverable Risk IdentificationRisk Register Risk AssessmentRisk Assessment Matrix Risk Response PlanningRisk Response Plan Risk Monitoring and ReviewUpdated Risk Register

HU151, Lect2, Overview17 Risk Matrix

HU151, Lect2, Overview18 Tools of Risk Analysis Cause-Consequence Analysis Reliability Centered Maintenance Hazard and Operability Studies (HAZOP) Bow-tie Analysis Brainstorming Structured interviews Delphi Check-lists Primary Hazard Analysis Hazard Analysis and Critical Control Points (HACCP) Environmental Risk Assessment Structure (SWIFT) Scenario Analysis Business Impact Analysis Root Cause Analysis Fault Tree Analysis Event Tree Analysis Cause and Effect Analysis Layer Protection Analysis (LOPA) Decision Tree Human Reliability Analysis Sneak Circuit Analysis Markov Analysis Monte Carlo Simulation Bayesian Statistics and Bayes Nets FN Curves Risk Indices Consequence/Probability Matrix Cost/Benefit Analysis Multi-criteria Decision Analysis (MCDA) Failure Mode Effect Analysis

HU151, Lect2, Overview19 Cause-and-Effect Diagram The Cause-and-Effect Diagram was created by Dr. Kaoru Ishikawa, an engineer and professor in Japan. The Cause-and-Effect Diagram is also referred to as a "Fishbone" diagram, getting the name from its resemblance to a fish skeleton when created. The main purpose of this diagram is to define a problem, identify a possible cause, isolate the cause, and then develop a solution.

HU151, Lect2, Overview20 Fishbone Analysis: 5ME 1.MAN - Does the operator have the proper training, experience, and ability to perform the function? 2.METHOD - Are the work instructions available and up-to-date? Do they reflect the best method to perform the task? Are the proper tools available? Are the process parameters specified clearly? 3.MACHINE - Does the machine have the capability to produce the product as specified? Does the machine have the ability to produce the product on a consistent basis? Are there regular routine maintenance and preventative maintenance tasks? Are they performed according to schedule? 4.MATERIAL - Are the correct materials available for the process? What is the quality of the material used in the process? Is there more than one supplier and does quality vary with different suppliers? What types of material problems could exist? 5.MEASUREMENT - Are the measurement instruments adequate for the process? Are they maintained correctly and regularly calibrated? Are the measurement instruments affected by environmental conditions such as temperature, vibration, dirt, etc.? 6.ENVIRONMENT - Is the manufacturing environment affected by temperature, humidity, dust and dirt, power fluctuations or seasonal differences? The real problem becomes which one of the above factors is either totally, mostly, or somewhat responsible for the cause of our problem? Or is it a combination of several causes?

HU151, Lect2, Overview21 Procedure for Fishbone Analysis 1.First, formulate the problem and write it in a box on the right side of the diagram. Everyone must clearly understand the nature of the problem and the process/product being discussed. If everyone is not clear on the purpose of the session, the session will not resolve the problem. 2.Next, draw an arrow from the left side of your chart or board, over to the right side and make and arrowhead point. To the right of the arrowhead, place your "problem" topic. This arrow is called the "EFFECT" arrow. 3.Now place your main "fishbones" in place, the "5 M's" and the "E", laying it out as illustrated. If using a drawing board or flip chart, draw the slanted lines in place and label them, spacing each slanted "bone" apart so as to be able to place smaller "bones" on the main bones. Once your chart is prepared, you are ready to begin the "brain storm" session.

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HU151, Lect2, Overview23 HAZOP software.com/2011/software/hazop/ Hazard and Operability Study

HU151, Lect2, Overview24 Hazard and Operability Study (HAZOP) Hazard and Operability Study (or HAZOP Study) is a risk analysis technique used for new systems or modifications to existing ones. The HAZOP study is a detailed examination, by a group of specialists, of components within a system to determine what would happen if that component were to operate outside its normal design mode. The effects of such behavior is then assessed and noted down on study forms. The categories of information entered on these forms can vary from industry to industry.

HU151, Lect2, Overview25 HAZOP Guide words : NO OR NOT = Complete negation of the design intent MORE = Quantitative increase LESS = Quantitative decrease AS WELL AS = Qualitative modification/increase PART OF = Qualitative modification/decrease REVERSE = Logical opposite of the design intent OTHER THAN = Complete substitution EARLY = Relative to the clock time LATE = Relative to the clock time BEFORE = Relating to order or sequence AFTER = Relating to order or sequence

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HU151, Lect2, Overview28 Components of a Plan Strategy ExecutionResources

HU151, Lect2, Overview29 Risk Response Strategies Four main response strategies for negative risks: 1.Risk avoidance 2.Risk acceptance 3.Risk transference 4.Risk mitigation

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