Advanced safety management focusing on Z10 and serious injury prevention

429 Pages·2008·1.405 MB·English

by  Fred A Manuele

ADVANCED SAFETY
MANAGEMENT
FOCUSING ON Z10
AND SERIOUS INJURY
PREVENTION
FRED A. MANUELE, CSP, PE
PRESIDENT,HAZARDSLIMITED
JOHNWILEY&SONS,INC.

ADVANCED SAFETY
MANAGEMENT
FOCUSING ON Z10
AND SERIOUS INJURY
PREVENTION

ADVANCED SAFETY
MANAGEMENT
FOCUSING ON Z10
AND SERIOUS INJURY
PREVENTION
FRED A. MANUELE, CSP, PE
PRESIDENT,HAZARDSLIMITED
JOHNWILEY&SONS,INC.
Copyright2008byJohnWiley&Sons,Inc.Allrightsreserved
PublishedbyJohnWiley&Sons,Inc.,Hoboken,NewJersey.
PublishedsimultaneouslyinCanada
Nopartofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmittedinanyform
orbyanymeans,electronic,mechanical,photocopying,recording,scanning,orotherwise,exceptas
permittedunderSection107or108ofthe1976UnitedStatesCopyrightAct,withouteithertheprior
writtenpermissionofthePublisher,orauthorizationthroughpaymentoftheappropriateper-copyfee
totheCopyrightClearanceCenter,Inc.,222RosewoodDrive,Danvers,MA01923,[phone],
fax[phone],oronthewebatwww.copyright.com.RequeststothePublisherforpermission
shouldbeaddressedtothePermissionsDepartment,JohnWiley&Sons,Inc.,111RiverStreet,
Hoboken,NJ07030,[phone],fax[phone],oronlineat
http://www.wiley.com/go/permission.
LimitofLiability/DisclaimerofWarranty:Whilethepublisherandauthorhaveusedtheirbestefforts
inpreparingthisbook,theymakenorepresentationsorwarrantieswithrespecttotheaccuracyor
completenessofthecontentsofthisbookandspecificallydisclaimanyimpliedwarrantiesof
merchantabilityorfitnessforaparticularpurpose.Nowarrantymaybecreatedorextendedbysales
representativesorwrittensalesmaterials.Theadviceandstrategiescontainedhereinmaynotbe
suitableforyoursituation.Youshouldconsultwithaprofessionalwhereappropriate.Neitherthe
publishernorauthorshallbeliableforanylossofprofitoranyothercommercialdamages,including
butnotlimitedtospecial,incidental,consequential,orotherdamages.
Forgeneralinformationonourotherproductsandservicesorfortechnicalsupport,pleasecontactour
CustomerCareDepartmentwithintheUnitedStatesat(800)762-2974,outsidetheUnitedStatesat
[phone]orfax(317)572-4002.
Wileyalsopublishesitsbooksinavarietyofelectronicformats.Somecontentthatappearsinprint
maynotbeavailableinelectronicformats.FormoreinformationaboutWileyproducts,visitourweb
siteat www.wiley.com.
LibraryofCongressCataloging-in-PublicationData:
Manuele,FredA.
AdvancedsafetymanagementfocusingonZ10andseriousinjuryprevention
/FredA.Manuele.
p.;cm.
Includesbibliographicalreferencesandindex.
ISBN978-0-470-10953-3(cloth)
1.Woundsandinjuries—Prevention.2.Industrialhygiene—Management.
3.Industrialsafety—Management.I.Title.
[DNLM:1.AmericanNationalStandardsInstitute.2.AmericanIndustrial
HygieneAssociation.3.SafetyManagement—standards—UnitedStates.4.
OccupationalHealth—UnitedStates.5.RiskManagement—standards—United
States.6.WoundsandInjuries—prevention&control—UnitedStates.WA
485M2935a2007]
RA645.T73M362007
363.11—dc22
2007017346
PrintedintheUnitedStatesofAmerica
10987654321
CONTENTS
FOREWORD vii
PREFACE ix
INTRODUCTION 1
1 ANOVERVIEWOFANSI/AIHAZ10-2005:THEAMERICAN
NATIONALSTANDARDFOROCCUPATIONALHEALTHAND
SAFETYMANAGEMENTSYSTEMS 7
2 THEPLAN-DO-CHECK-ACTCONCEPT(PDCA) 33
3 SERIOUSINJURYPREVENTION 45
4 HUMANERRORREDUCTION 67
5 MANAGEMENTLEADERSHIPANDEMPLOYEE
PARTICIPATION—SECTION3.0 81
6 ACHIEVINGACCEPTABLERISKLEVELS:
THEOPERATIONALGOAL 97
7 PLANNING—SECTION4.0 107
v
vi CONTENTS
8 APRIMERONHAZARDANALYSISANDRISK
ASSESSMENT—SECTION4.2 111
9 INCLUDINGRISKASSESSMENTPROVISIONSIN
STANDARDSANDGUIDELINES:ATREND 145
10 THREEANDFOURDIMENSIONALNUMERICALRISK
SCORINGSYSTEMS 163
11 IMPLEMENTATIONANDOPERATION—SECTION5.0 199
12 HIERARCHYOFCONTROLS:THESAFETYDECISION
HIERARCHY—SECTION5.1.1 203
13 SAFETYDESIGNREVIEWS—SECTION5.1.2 221
14 LEANCONCEPTS:OPPORTUNITIESFORSAFETY
PROFESSIONALS 255
15 MANAGEMENTOFCHANGE—SECTION5.1.2 271
16 THEPROCUREMENTPROCESS—SECTION5.1.3 289
17 EVALUATIONANDCORRECTIVEACTION—SECTION6.0 337
18 INCIDENTINVESTIGATION—SECTION6.2 341
19 AUDITREQUIREMENTS—SECTION6.3 361
20 MANAGEMENTREVIEW—SECTION7.0 379
21 Z10,OTHERSAFETYSTANDARDSANDGUIDELINES,
ANDVPPCERTIFICATION 383
INDEX 405
FOREWORD
The team that eventually produced the ANSI Z10 standard met for the first time
early in 2001. It may surprise readers to know that the meeting began with a
contentiousdebateastowhetherornotastandardonoccupationalhealthandsafety
managementsystemswasappropriateorevennecessary.Theessentialargumentof
thoseopposedtothedevelopmentofsuchastandardwasthatifwegotit“wrong,”
the consequences would be severe. After some spirited debate, a majority of the
consensus body voted to move forward and set the stage for the five-year effort
that resulted in Z10.
This tumultuous beginning is understandable, given the extraordinary breath of
interestsrepresentedintheconsensusbody.Labor,industry,academia,professional
associations,andgovernmentinterestswereeachrepresentedbyleadingvoiceswith
strongopinionsontheapproachthestandardshouldtake.However,bythetimeof
our second meeting, barely a month after the tragedy of September 11, 2001, the
necessitytoputasideparochialbiaseswasclear.Theteamcoalescedanddedicated
itself to a path of technical rigor.
In this light, the Z10 team produced a standard that was approved by the con-
sensus body with no negative votes and sailed though the final ANSI approval
process in an astonishingly short time. Such unanimous and quick approval is rare
foranystandard,letaloneoneaspotentiallycontroversialasANSIZ10.Thisinitial
acceptance was followed by almost universal support by the technical community
and substantial acceptance by the prospective user community.
While I believe that Z10 is the best tool available for those interested in devel-
oping occupational health and safety management systems, some will view it as
vii