Job Hazard Analysis: A guide for voluntary compliance and beyond

521 Pages·2007·2.53 MB·English

by  James Roughton

Job Hazard Analysis
A Guide for Voluntary
Compliance and Beyond
(cid:84)(cid:104)(cid:105)(cid:115)(cid:32)(cid:112)(cid:97)(cid:103)(cid:101)(cid:32)(cid:105)(cid:110)(cid:116)(cid:101)(cid:110)(cid:116)(cid:105)(cid:111)(cid:110)(cid:97)(cid:108)(cid:108)(cid:121)(cid:32)(cid:108)(cid:101)(cid:102)(cid:116)(cid:32)(cid:98)(cid:108)(cid:97)(cid:110)(cid:107)
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
NEWYORK•OXFORD•PARIS•SANDIEGO
SANFRANCISCO•SINGAPORE•SYDNEY•TOKYO
Butterworth-HeinemannisanimprintofElsevier
Butterworth-HeinemannisanimprintofElsevier
30CorporateDrive,Suite400,Burlington,MA01803,USA
LinacreHouse,JordanHill,OxfordOX28DP,UK
Copyright©2008,ElsevierInc.Allrightsreserved.
Nopartofthispublicationmaybereproduced,storedinaretrievalsystem,
ortransmittedinanyformorbyanymeans,electronic,mechanical,photocopying,
recording,orotherwise,withoutthepriorwrittenpermissionofthepublisher.
PermissionsmaybesoughtdirectlyfromElsevier’sScience&TechnologyRights
DepartmentinOxford,UK:phone:[phone],fax:[phone],
E-mail:[email protected]
viatheElsevierhomepage(http://elsevier.com),byselecting“Support&Contact”
then“CopyrightandPermission”andthen“ObtainingPermissions.”
Recognizingtheimportanceofpreservingwhathasbeenwritten,Elsevier
printsitsbooksonacid-freepaperwheneverpossible.
LibraryofCongressCataloging-in-PublicationData
Roughton,JamesE.
Jobhazardanalysis:aguideforvoluntarycomplianceandbeyond/James
RoughtonandNathanCrutchfield.
p.cm.
Includesbibliographicalreferencesandindex.
ISBN978-0-7506-8346-3(hardback:alk.paper) 1. Industrialsafety.
I. Crutchfield,Nathan. II. Title.
T55.R6932007
658.3(cid:2)8–dc22
2007033646
BritishLibraryCataloguing-in-PublicationData
AcataloguerecordforthisbookisavailablefromtheBritishLibrary.
ISBN:978-0-7506-8346-3
ForinformationonallButterworth-Heinemannpublications
visitourWebsiteatwww.books.elsevier.com
PrintedintheUnitedStatesofAmerica
07 08 09 10 11 12 10 9 8 7 6 5 4 3 2 1
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
hasalwaysbeenpatientwithmeinmypassionforsafety.Shehasalwaysgiven
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.
ThankstoNathanCrutchfield,myco-authorforaddedhisexperienceinrisk
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
Myeffortsforthisbookarededicatedtomywife,Bonnie,whobringsaloving
presencetomylife,andtoBrian,awonderfulsonwhowillachievemuchinlife.
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
(cid:84)(cid:104)(cid:105)(cid:115)(cid:32)(cid:112)(cid:97)(cid:103)(cid:101)(cid:32)(cid:105)(cid:110)(cid:116)(cid:101)(cid:110)(cid:116)(cid:105)(cid:111)(cid:110)(cid:97)(cid:108)(cid:108)(cid:121)(cid:32)(cid:108)(cid:101)(cid:102)(cid:116)(cid:32)(cid:98)(cid:108)(cid:97)(cid:110)(cid:107)
Contents
About the Authors............................................ xvii
Foreword...................................................... xix
Preface........................................................ xxi
Introduction................................................... xxix
Acronyms....................................................x.xxvii
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