HU151: Industrial Safety

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

2. HU151, Lect2, Overview

3. Industrial Safety Contextual definitions HU151, Lect2, Overview

4. Industrial Safety Occupational Safety Environmental Safety Product Safety HU151, Lect2, Overview

5. 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, Overview

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

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

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

9. 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, Overview

10. 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 HU151, Lect2, Overview FEMA. 1997. Multi Hazard Identification and Assessment. FEMA. Washington, D.C.

11. Hazard Categories • Biological - bacteria, viruses, insects, plants, birds and animals, etc., • Chemical - depends on the physical, chemical and toxic properties of the chemical. • Ergonomic - repetitive movements, improper set up of workstation, etc., • Psychosocial - stress, violence, etc., • 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, Overview

12. Common Hazards in the Workplace HU151, Lect2, Overview

13. Common Hazards in the Workplace HU151, Lect2, Overview

14. 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, Overview

15. Hazard HU151, Lect2, Overview

16. Deliverables of RM Process HU151, Lect2, Overview

17. Risk Matrix HU151, Lect2, Overview

18. 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 <What if?> (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, Overview

19. 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, Overview

20. Fishbone Analysis: 5ME • MAN - Does the operator have the proper training, experience, and ability to perform the function? • 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? • 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? • 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? • 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.? • 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, Overview

21. Procedure for Fishbone Analysis • 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. • 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. • 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. HU151, Lect2, Overview

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23. HAZOP http://www.isograph-software.com/2011/software/hazop/ Hazard and Operability Study HU151, Lect2, Overview

24. 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, Overview

25. HAZOP Guide words : NO OR NOT = Complete negation of the design intent MORE = Quantitative increase LESS = Quantitative decrease ASWELL AS = Qualitative modification/increase PART OF = Qualitative modification/decrease REVERSE = Logical opposite of the design intent OTHERTHAN = 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 HU151, Lect2, Overview

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28. Components of a Plan Strategy Resources Execution HU151, Lect2, Overview

29. Risk Response Strategies • Four main response strategies for negative risks: • Risk avoidance • Risk acceptance • Risk transference • Risk mitigation HU151, Lect2, Overview

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