Job Hazard Analysis
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Job Hazard Analysis A Guide for Voluntary Compliance and Beyond This page intentionally left blank Job Hazard Analysis A Guide for Voluntary Compliance and Beyond From Hazard to Risk: Transforming the JHA from a Tool to a Process James E. Roughton Nathan Crutchfield AMSTERDAM • BOSTON • HEIDELBERG • LONDON NEW YORK • OXFORD • PARIS • SAN DIEGO SAN FRANCISCO • SINGAPORE • SYDNEY • TOKYO Butterworth-Heinemann is an imprint of Elsevier Butterworth-Heinemann is an imprint of Elsevier 30 Corporate Drive, Suite 400, Burlington, MA 01803, USA Linacre House, Jordan Hill, Oxford OX2 8DP, UK Copyright © 2008, Elsevier Inc. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. Permissions may be sought directly from Elsevier’s Science & Technology Rights Department in Oxford, UK: phone: (+44) 1865 843830, fax: (+44) 1865 853333, E-mail: [email protected]. You may also complete your request online via the Elsevier homepage (http://elsevier.com), by selecting “Support & Contact” then “Copyright and Permission” and then “Obtaining Permissions.” Recognizing the importance of preserving what has been written, Elsevier prints its books on acid-free paper whenever possible. Library of Congress Cataloging-in-Publication Data Roughton, James E. Job hazard analysis : a guide for voluntary compliance and beyond / James Roughton and Nathan Crutchfield. p. cm. Includes bibliographical references and index. ISBN 978-0-7506-8346-3 (hardback : alk. paper) 1. Industrial safety. I. Crutchfield, Nathan. II. Title. T55.R693 2007 658.38–dc22 2007033646 British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library. ISBN: 978-0-7506-8346-3 For information on all Butterworth-Heinemann publications visit our Web site at www.books.elsevier.com Printed in the United States of America 07080910111210987654321 Working together to grow libraries in developing countries www.elsevier.com | www.bookaid.org | www.sabre.org To my wife, my friend and my lifelong partner of 37 years and counting, who has always been patient with me in my passion for safety. She has always given me the freedom to pursue my dreams of promoting safety. Thanks to the many reviewers of this book: Neal Lettre, my Six Sigma Black Belt friend who reviewed the chapter on Six Sigma; Jeff Swire, safety professional who reviewed the chapter on behaviors; several of my students (Roy McConnell, Brian Wood, Karen Barkley) who reviewed the entire book and provided constructive feedback. Thanks to Nathan Crutchfield, my co-author for added his experience in risk assessment to this book. Thanks to other professionals such as Jim Mercurio, a good friend of mine and co-author of Developing an Effective Safety Culture: A Leadership Approach, who provided some insight into this project. Last but not least, thanks to other safety professionals who I have made contact with over the last several years and to the many OSHA public domain websites, all of which provide a vast amount of resources used in the book. James E. Roughton My efforts for this book are dedicated to my wife, Bonnie, who brings a loving presence to my life, and to Brian, a wonderful son who will achieve much in life. I owe much to the many colleagues and clients that have assisted me over the years. Their friendship, insights, encouragement, criticism and professionalism have meant so much to me. I am grateful to have learned and benefited from them all. Special thanks to James Roughton for allowing me to participate in this project, an important element in an overall safety process. Nathan Crutchfield This page intentionally left blank Contents About the Authors ............................................ xvii Foreword...................................................... xix Preface........................................................ xxi Introduction ................................................... xxix Acronyms .....................................................xxxvii Part 1 Developing a Toolkit for Identifying Workplace Hazards and Associated Risk....... ...1 1 Preparing for the Hazard Analysis and Risk Assessment . 3 1.1 THE CENTERPIECE OF A SAFETY PROCESS, 4 1.2 HAZARD RECOGNITION AND CONTROL SYSTEMS, 5 1.2.1 Conducting a Risk Assessment of the Workplace, 5 1.2.2 Prioritizing the Risk Assessment Findings, 6 1.2.3 Developing Solutions to Resolve Risk-Related Issues, 6 1.2.4 Recommending and Implementing Controls, 6 1.2.5 Monitoring the Results, 6 1.3 DEVELOPING A SYSTEM TO IDENTIFY AND REPORT HAZARDS, 10 1.3.1 Company Safety Policy, 11 1.3.2 Involving Employees in the JHA Process, 11 1.3.3 Protecting Employees from Harassment, 12 1.3.4 Identifying Workplace Hazards, 12 1.4 MAINTENANCE WORK ORDERS, 15 1.5 FORMS USED TO REPORT HAZARDS, 16 1.6 ACTION PLANNING, 16 1.7 TRACKING HAZARDS, 17 1.7.1 Tracking by Committee, 17 1.7.2 Follow-up Reviews, 18 1.8 CODES OF SAFE WORK PRACTICES, 18 1.9 SUMMARY, 18 CHAPTER REVIEW QUESTIONS, 19 REFERENCES, 19 vii viii Contents Appendix A......................................................21 A.1 SAMPLE GUIDANCE IN WRITING A POLICY STATEMENT, 21 A.2 CLOSING STATEMENT, 23 A.3 SUMMARY, 26 Appendix B......................................................27 B.1 SAMPLE FORMS FOR EMPLOYEE REPORTING OF HAZARDS, 27 Appendix C......................................................33 C.1 ACTION PLANNING: THREE SAMPLE VERSIONS ARE INCLUDED, 33 Appendix D......................................................37 D.1 CODES OF SAFE WORK PRACTICES, 37 2 Workplace Hazard Analysis and Review of Associated Risk ......................................................... ..39 2.1 ANALYSIS OF THE WORKPLACE, 40 2.2 INSPECTIONS AND AUDITS, 42 2.3 THE CHECKLIST, 42 2.3.1 Consultants and Outside Specialists, 43 2.3.2 Employee Interviews, 44 2.4 TYPES OF INSPECTIONS, 46 2.4.1 General Walk-Around Inspections, 46 2.4.2 Verification Reviews, 47 2.4.3 Focus Reviews, 48 2.4.4 Self-Assessment, 49 2.4.5 Document Review, 49 2.4.6 Written Inspection Reports, 49 2.5 WHO SHOULD REVIEW THE WORKPLACE?, 50 2.5.1 Supervisors, 50 2.5.2 Employees, 51 2.5.3 Safety Professionals, 51 2.6 PREVENTIVE MAINTENANCE PROGRAMS, 52 2.7 OTHER THINGS TO CONSIDER DURING A SITE INSPECTION, 53 2.7.1 Incident Investigations, 53 2.7.2 Trend Analysis, 54 Contents ix 2.8 SUMMARY, 55 CHAPTER REVIEW QUESTIONS, 56 REFERENCES, 56 Appendix E ......................................................57 E.1 SELF-INSPECTION CHECKLIST, 57 3 Developing Systems to Manage Hazards .................. 105 3.1 HIERARCHY OF CONTROLS, 109 3.2 WHY ENGINEERING CONTROLS?, 110 3.3 ADMINISTRATIVE CONTROLS, 112 3.4 PPE, 114 3.4.1 PPE Limitations, 114 3.4.2 PPE Hazard Assessment, 115 3.5 WORK PRACTICES AND SAFETY RULES, 116 3.5.1 General Safety Rules, 116 3.5.2 Limitations of Work Practices and Safety Rules, 117 3.6 CHANGE ANALYSIS, 117 3.6.1 A Change in the Process, 119 3.6.2 Building or Leasing a New Facility, 119 3.6.3 New Equipment Installation, 120 3.6.4 Using New Materials, 121 3.6.5 Employee Changes, 122 3.6.6 Adapting to Change, 123 3.6.7 Other Analytical Tools for Consideration, 123 3.7 SUMMARY, 123 CHAPTER REVIEW QUESTIONS, 124 REFERENCES, 124 Appendix F .................................................... 127 F.1 SAMPLE SAFETY RULES, 127 Appendix G ................................................... 129 G.1 PERSONAL PROTECTIVE EQUIPMENT (PPE) ASSESSMENT, 129 G.2 GUIDELINES FOR COMPLYING WITH PPE REQUIREMENTS, 129 G.3 HAZARD ASSESSMENT FOR PPE, 130 G.4 JOB HAZARD ANALYSIS ASSESSMENT FOR PPE, 137 G.5 EXAMPLE PERSONAL PROTECTIVE EQUIPMENT TRAINING CERTIFICATION FORM, 142 x Contents G.6 EXAMPLE PERSONAL PROTECTIVE EQUIPMENT TRAINING QUIZ, 143 G.7 SAMPLE PPE POLICIES, 144 Appendix H.................................................... 151 H.1 SAFETY REVIEW OF NEW/RELOCATED EQUIPMENT MAJOR MODIFICATION SIGN-OFF FORM, 151 Appendix I..................................................... 153 I.1 OTHER ANALYTICAL TOOLS FOR CONSIDERATION, 153 Part 2 Developing Systems that Support Hazard Recognition ..................................... 159 4 Understanding the Human Role in the Safety Process .... 161 4.1 HOW ARE AT-RISK EVENTS DEVELOPED?, 162 4.2 WHAT CONTRIBUTES TO AN AT-RISK EVENT?, 163 4.3 THE FEEDBACK LOOP, 166 4.4 BEHAVIORAL APPROACH, 168 4.5 CHANGING BEHAVIOR, 168 4.5.1 Understanding Why Employees Put Themselves at Risk, 169 4.6 UNDERSTANDING THE OTHER SIDE OF SAFETY, 171 4.7 BENEFITS OF BEHAVIOR-BASED SAFETY, 174 4.8 BEHAVIOR-BASED SAFETY AND INTEGRATED SAFETY MANAGEMENT FUNCTIONS, 174 4.8.1 Seven Guiding Principles of Integrated Safety Management, 175 4.9 WILL A BEHAVIORAL PROCESS WORK FOR YOU?, 176 4.10 SUMMARY, 176 CHAPTER REVIEW QUESTIONS, 177 REFERENCES, 178 Appendix J .................................................... 179 J.1 SAMPLE BEHAVIOR (AT-RISK EVENTS) LIST, 179 5 Effective Use of Employee Participation ................... 181 5.1 WHY SHOULD EMPLOYEES BE INVOLVED?, 182 5.2 INVOLVING EMPLOYEES IN THE SAFETY MANAGEMENT SYSTEM, 184 Contents xi 5.2.1 Close Contact with Hazards, 185 5.2.2 Improved Support, 185 5.2.3 More Participation, More Awareness, 186 5.3 HAWTHORNE STUDY, 186 5.4 COMMITTEE PARTICIPATION, 188 5.4.1 Getting Employee Participation Started, 188 5.4.2 Form a Committee, 188 5.4.3 How to Use Employees in the Process, 189 5.5 AREAS OF EMPLOYEE PARTICIPATION, 191 5.5.1 Conducting Site Inspections, 191