Fatality Prevention in the Workplace Forum Effective Risk

Fatality Prevention in the Workplace Forum Effective Risk Assessment Methodologies Breakout Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation

Effective Risk Assessment Methodologies Objectives; capture best practices that address inherent risk in the following areas: Potential impact of ANSI-ASSE Z 590 “Prevention through Design”, ANSI Z 690 “Risk Management, ” and ANSI –ASSE Z 10 “Occupational Health & Safety Management Systems” Identifying human performance aspects or serious injury and fatality prevention, focusing on best practices to manage risk at the operator/group level in the final work planning stages and work execution • Systems-based approach requires the organization to assess and prioritize its occupational health and safety management system (OHSMS) on an on-going basis; • Hazard-based approach begins with the hazardous characteristics of the materials, environment, or worksite considering the possible activities that may affect them, and the consequences; and • Task-based approach begins with a job, breaks the job into specific tasks, identifies the hazards associated with the tasks and then assesses the risks. Common element throughout the best practices was high level of employee involvement in the risk assessment process. Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation

Layers of Protection (LOP) Laurie Shelby, Alcoa, Inc. Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation

Effective Risk Assessment Methodologies Alcoa – Layers of Protection (LOP) Overall fatality prevention process requires location to identify/assess Fatality Risks are tracked and communicated in database as unacceptable, marginal, acceptable/controlled Use simplistic /basic LOP guidelines to move Fatality Hazards to acceptable/controlled level LOP guidelines outline how to use and group engineered controls, safety devices, warning devices, and administrative controls to reduce Fatality Links Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation

Hazard Identification Risk Assessment (HIRA) Process Jeff Dierdorf, U. S. Steel Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation

Effective Risk Assessment Methodologies ➲ United States Steel - Hazard Identification Risk Assessment (HIRA) Process ➯ Applied globally with a defined risk matrix ➯ Support with 8 hour training session for over 2000 leaders ➯ Engages hourly production and maintenance employees with clear, concise data collection and hazard checklist ➯ Empowers supervisors to work with production and maintenance employees to identify the most severe hazards ➯ Drives accountability to identify and eliminate hazards through performance management system Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation 6

Formal Risk Assessment HIRAC – lite Pre-Job Briefing (PJB) Stephen Thompson, Arcelor. Mittal USA Don Westerhoff, Arcelor. Mittal Weirton Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation

Effective Risk Assessment Methodologies ➲ Arcelor. Mittal Task or process area-hazard identification, risk assessment and control (HIRAC) • Formal and quantitative, FMEA based • Risk assessed with and without controls to evaluate effectiveness HIRAC-Lite • Used for non-routine or infrequent tasks • Checklist using red/green/yellow questions to identify hazards and controls • Pocket card designed for jobsite use Pre-Job Briefing (PJB) • Similar to HIRAC-Lite • Incorporates human performance elements and identifies “Stop” events Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation 8

Arcelor. Mittal Risk Assessment Examples 1) Formal Risk Assessment 2) HIRAC – lite 3) Pre-Job Briefing (PJB) Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation

Effective Risk Assessment Methodologies ➲ Arcelor. Mittal Task or process area-hazard identification, risk assessment and control (HIRAC) • Formal and quantitative, FMEA based • Risk assessed with and without controls to evaluate effectiveness HIRAC-Lite • Used for non-routine or infrequent tasks • Checklist using red/green/yellow questions to identify hazards and controls • Pocket card designed for jobsite use Pre-Job Briefing (PJB) • Similar to HIRAC-Lite • Incorporates human performance elements and identifies “Stop” events Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation 1

Arcelor. Mittal Formal Risk Assessment Process Arcelor. Mittal Cleveland - Rail Switching & Securement HIRAC • • • Hazard Identification, Risk Assessment & Control (HIRAC) Formal and Quantitative FMEA based Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation 1

Arcelor. Mittal Formal Risk Assessment Process Task or area risk is assessed using a Risk Assessment Code (RAC) RAC = severity x exposure x probability x number at risk x 10 (if a major risk category) Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation 1

Arcelor. Mittal Formal Risk Assessment Process Example of the controls implemented to reduce collisions & crushing during securement operations at Arcelor. Mittal Cleveland Nine different controls were identified in this situation Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation 1

Arcelor. Mittal Formal Risk Assessment Process Initial risk is assessed assuming no controls are present. Potential risk is assessed assuming all listed controls are in place. The difference between initial risk and potential risk indicates the effectiveness of the risk reduction (this is helpful in communicating the importance of controls to employees and useful as an audit tool for our shop floor audit/layered evaluation process. Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation 1

Arcelor. Mittal HIRAC-lite • Used for non-routine or infrequent tasks • Pocket card designed for jobsite use 20 red (watch-out) boxes available, number of red boxes selected indicated risk profile for the task (note: controls must be identified for each red box selected by the team) Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation 1

Arcelor. Mittal Pre-Job Briefing (PJB) * • Similar to HIRAC-Lite • Incorporates Human Performance elements and identifies “stop” events • PJB based on a form used at Alcoa Davenport Works Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation 1

Arcelor. Mittal Contacts Stephen Thompson, MPH, CSP, CIH Manager Health & Safety Compliance Arcelor. Mittal USA 219. 787. 2605 Stephen. Thompson@Arcelor. Mittal. com Don Westerhoff, CSP Manager Safety Arcelor. Mittal Weirton 304. 797. 3335 Donald. Westerhoff@Arcelor. Mittal. com Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation 1

Catastrophic Potential Incident Review Process Thomas Baldauff, PPG industries, Inc. Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation

Effective Risk Assessment Methodologies PPG - Catastrophic Potential Incident Review Process All OSHA injuries, all fires and all spills meeting a predetermined threshold are evaluated to determine potential for: Significant injury or fatality Significant off-site adverse environmental or health impact Fire or explosion causing significant loss of production or inventory Spreadsheet is generated from our incident database Six member review team Incidents designated a Potentially Catastrophic are further evaluated: Category or Risk or “Incident Precursor” Investigation quality Action item quality Value of EHS Alert to all facilities Top 3 precursors = 60% of incidents (fire/explosion, forklift or industrial truck, motor vehicle accident) Potentially Catastrophic Incidents are Tracked to Closure: All actions have been completed EHS Alert sent, if appropriate Review status is tracked in PPG’s incident database Near misses and minor incidents brought into the process by team members and others, informally, as identified. Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation

Major Incident Studies to Determine Activities With Most Acute Exposure Potential to SIF Ryan Ott, Chevron Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation

Effective Risk Assessment Methodologies Chevron Conducted internal studies to understand what activities in the Chevron Enterprise have most acute exposure potential to SIF Utilized major incident studies across the enterprise to focus on one thematic opportunity • Failure to recognize the hazard or anticipate consequences • Routine work (work done on frequent basis/normal operations) Field Guide intended to be used by front line workers to help them identify hazards and take action Utilize existing internal tools (Hazard Identification Wheel) to reinforce the identification of high-energy sources and barriers to mitigate the hazards. Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation

Effective Risk Assessment Methodologies Gap Identification/Areas for Future Research Organizations in the breakout session recognized most best practices lacked an effective tool for worker / supervisor / planner risk assessment at the critical step level. Systems Hazard Task Critical Step Critical step can be defined as the: • Unrecoverable step in your task, which if it fails results in a SIF These five best practices will be available in detail on the IUP website. Sponsored by Indiana University of Pennsylvania Safety Sciences Department in cooperation with Alcoa Foundation