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

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

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

4. Domino Theory (Identify Problem) 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 IE 419 Multiple causation!

6. Accident Causation IE 419

7. Accident “Iceberg” IE 419

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

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

11. Behavioral Based Training • ABC approach • A – antecedents • B – behavior • C - consequences 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!!) 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)) • Break down job into elements • List them in sequential order • Examine them critically • Focus on: • Worker • Method • Machine • Material IE 419

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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: IE 419

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

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

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

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

24. Factor Values IE 419

25. Possible Consequences IE 419

26. Risk Score IE 419

27. Ex. #4 - Risk Calculation IE 419

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

29. Identify Problem Collect Data Monitor Analyze Data Apply Remedy Select Remedy 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 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 IE 419

31. Chi-Square Analysis • χ2 = ∑ (Ei – Oi)2/ Ei Ei = HixOT/HT • M = # areas Ei = expected • Oi = observed OT = Total observed • Hi = hours worked in area i • HT = total hours worked ν= m -1 IE 419

32. Ex. #6 - Chi-Square Analysis χ2 = ∑ (Ei – Oi)2/ Ei IE 419

33. Red Flagging – Control Chart IE 419

34. Red Flagging - Monitor IE 419