1. IE 419 1 Work Design: Productivity and Safety Dr. Andris Freivalds Class #21

2. IE 419 2 Basics of Accident Prevention (Heinrich, Petersen, Roos – Industrial Accident Prevention) Accident Prevention – direct control of workers, machines, environment to prevent accidents Safety Management - long range planning, education, training to prevent accidents

3. IE 419 3 Accident Prevention Process Identify Problem Collect Data Analyze Data Select Remedy Apply Remedy Monitor

4. IE 419 4 Domino Theory (Identify Problem)

5. IE 419 5 Ex. #1 - Domino Theory Sparks from grinder ignite nearby gasoline causing operator to be burned. Lack of Control Basic Causes Immediate Causes Accident Injury Multiple causation!

6. IE 419 6 Accident Causation Unsafe ActsUnsafe Conditions

7. IE 419 7 Accident “Iceberg”

8. IE 419 8 3 E’s of Accident Prevention Engineering – redesign of job/workplace Education – training Enforcement – discipline, rules Accident Causation Models →

9. IE 419 9 Life Change Unit Theory Accident probability is situational Overload taxes person’s capacity Leads to accidents (or illness) >300 → 79% in 2 yrs >200 → 51% in 2 yrs >150 → 37% in 2 yrs RankLife EventUnits 1 Death of spouse 100 2 Divorce 73 4 Jail term 63 6 Injury 53 27 End school 26 41 Vacation 13

10. IE 419 10 Motivation-Reward Satisfaction Model (Identify Problem)

11. IE 419 11 Behavioral Based Training ABC approach A – antecedents B – behavior C - consequences

12. IE 419 12 Collect Data – Analyze Data Systematic approach Who, what, where, when, how, why Inspection –Job/methods analysis –Worksite analysis –Job Safety Analysis (JSA) –(Look beyond direct causes!!)

13. IE 419 13 Job Safety Analysis (JSA) (Job Hazard Analysis, Methods Safety Analysis, Critical Incident Technique, Failure Mode and Effects Analysis (FMEA), Hazard and Operability Study (HAZOP)) 1)Break down job into elements 2)List them in sequential order 3)Examine them critically 4)Focus on: Worker Method Machine Material

14. IE 419 14

15. IE 419 15 Ex. #2 - JSA Scenario: Two inspectors smashed their toes when a stack of armor plate (36x24x⅜ in), standing on end against workbench, slid to the floor. They were stacked there because of insufficient room to leave them on delivery pallet, towed from Receiving. Since each piece needed to Rockwell tested, the inspectors stacked the plates on end rather than laying them flat on the floor, which would require later lifting (NIOSH!!). Similar accidents had occurred earlier, but without injuries. Typical Solution :

16. IE 419 16 Ex. #2 – JSA con’t (Old Method)

17. IE 419 17 Ex. #2 – JSA con’t (New Method) Recommendation: Adjustable, powered transporter (two)

18. IE 419 18 Advantages of JSA Maps out all details Quick, simple, objective Compares old & new methods Examines effects on production Analyze safety before accident occurs Leads into Fault Tree Analysis

19. IE 419 19 Select Remedy Decision-Making Tools - Hazard Action Table Conditions

20. IE 419 20 Ex. # 3 - Value Engineering

21. IE 419 21 Value Engineering - Safety Define Factors: –Effect on safety –Cost –Morale –Social/environment Choose Alternatives – depends Determine Weights – judgmental Rate each alternative by factor - relative Resulting Value (sum of products) selects proper alternative

22. IE 419 22 Risk Analysis – Basics Basic premise/approach –All risks can not be eliminated –However, can reduce potential loss –Go for max cost effectiveness Risk of loss increases with: –↑ probability that hazard will occur –↑ exposure to the hazard –↑ consequences of hazardous event

23. IE 419 23 Risk Analysis - Procedure Assign numerical values to factors Multiply factors → overall risk score Risk score is a numerical value Good for relative comparison (not absolute)

24. IE 419 24 LikelihoodValues Expected10 Possible6 Unusual3 Remote1 ~ Conceivable0.5 ~ Impossible0.1 ExposureValues Continuous10 Daily6 Weekly3 Monthly2 Few/year1 Yearly0.5 Factor Values

25. IE 419 25 Possible Consequences Value Catastrophe (many fatalities, $10 8 damage)100 Disaster (few fatalities, $10 7 damage)40 Very serious (fatality?, $10 6 damage)15 Serious (serious injuries, $10 5 damage)7 Important (injuries, $10 4 damage)3 Noticeable (first aid, $10 3 damage)1 Possible Consequences

26. IE 419 26 Risk Situation Value Very high risk, discontinue operations400 High risk, immediate correction200-400 Substantial risk, correction needed70-200 Possible risk, attention needed20-70 Risk?, perhaps acceptable< 20 Risk Score

27. IE 419 27 Ex. #4 - Risk Calculation

28. IE 419 28 Ex. #5 - Risk and Cost Effectiveness

29. IE 419 29 Apply Remedy and Monitor Who applies remedy –Safety specialist/engineer –Line supervisors –Workers Monitor effectiveness of accident prevention –Close the feedback loop –Variety of statistical approaches Identify Problem Collect Data Analyze Data Select Remedy Apply Remedy Monitor

30. IE 419 30 Accident and Injury Statistics Incidence (frequency) rate IR = # incidents x 200,000 # hrs exposure Severity rate SR = # days lost x 200,000 # hrs exposure

31. IE 419 31 Chi-Square Analysis χ 2 = ∑ (E i – O i ) 2 / E i E i = H i xO T /H T M = # areas E i = expected O i = observed O T = Total observed H i = hours worked in area i H T = total hours worked ν = m -1

32. IE 419 32 Ex. #6 - Chi-Square Analysis χ 2 = ∑ (E i – O i ) 2 / E i Dept.# CTD# HoursIREiEi A22900,000 B4600,0001.37.4 C101,400,0001.417.4 Total362,900,0002.536

33. IE 419 33 Red Flagging – Control Chart

34. IE 419 34 Red Flagging - Monitor