11th_WCM_ Safety Presentation 2016 updated 070416

A part of your world

A part of your business

A part of your passion

A part of your future

Gunasegaran

Safety ALMY-PE

SAF Pillar Leader

Penang, MALAYSIA

11-15th April 2016

WORLD CLASS MANUFACTURING Automotive Lighting

Penang Malaysia, April 2016 2/142

Shimmer And Shine Let Silver Be Mine



© Copyright by Automotive Lighting

WCM Structure

Co

st D

eplo

ymen

t

World Class Manufacturing

Safe

ty

Focu

sed

Imp

rove

men

t

Pro

fess

ion

al M

ain

ten

ance

Qu

alit

y

Logi

stic

s

Commitment, Involvement, Communication, Understanding, Measurement, Deployment, Implementation, Evaluation, Standardization with Visibility, Documentation

Au

ton

om

ou

s A

ctiv

itie

s (A

M &

WO

)

Earl

y P

rod

uct

/ E

qu

ipm

ent

Man

agem

ent

Peo

ple

Dev

elo

pm

ent

Envi

ron

men

t




Safety Information for Visitors

You Are

Here




Safety Training Room



© Copyright by Automotive Lighting Safety shoes

or over shoes

Safety helmet

+

Safety vest

Ear Plugs

Safety Information for Visitors

Safety Information Safety Questionnaire Safety Pass




Area PPE Example

Pre-prod

Assembly

Tool shop

Area PPE Example

Maintenance

LOG

warehouse

Chemical

Waste Store

Plant wide

Worker’s Safety Rules – Plant Wide

http://images.mysafetylabels.com/img/lg/L/Wear-Face-Shield-Safety-Label-LB-0464.gif




DEPARTMENTS IN CHARGE

ALL

DEPTS

Study of the law to

be applied

Introduction to Web-

base updating

System

Notification and

information to those

involved

Application

and control

EHS

EHS

Sources for data

collection EHS

Facilities

Non

Compliance

Local

Government

Agencies

Corporate

Legal Register

List

Monitoring

report

Web-base

tracking

EHS

Facilities

Legal Compliance

EVERY YEAR

FULL REVIEW

EVERY YEAR

FULL REVIEW

Compliance with laws and regulations




Occupational & Safety Policy

Our mission of Environmental

Health & Safety is to promote

fun, harmonize and providing

a safe and healthful workplace

for our employees, contractors,

and communities

Positive Safety Culture

Strong Safety

Leadership

Effective Communication

Employees Involvement

& Participation

Learning Organization

Just Culture




Agenda

I. Introduction

– Vision, Needs, Objectives, Targets

– Pillar Team

– Activity Organization

– KPI/KAI

– Route Map

– Last Audit Comments

– 7 Steps Status

II. Seven Steps Approach

– Step 1

– Step 2

– Step 3

– Step 4

– Step 5

III. Health Initiatives

IV. Plant Results

– KPI Plant

– SWOT Analysis




Vision,Needs Objectives,Targets

VISION

NEEDS

OBJECTIVES

To cultivate a zero harm safety culture at all levels.

Everyone is responsible for safety.

To give to all personnel a best safety and healthy working environment.

We will not compromise on safety and expect all employees to contribute to our

safety journey and to take responsibility for their own safety.

•Zero accidents:

Reducing risks at source

Growing safety culture

TARGETS

2016

KPI 2008 2009 2010 2011 2012 2013 2014 2015 2016

Actual

2016

Target

FI For

Injury(LTI) 0.45 0 0 0 0 0 0.06 0 0 0

FI for first

aid 0.59 1.67 0.97 0.45 0.48 0 0.06 0 0 0




Low Soon Lan / PD

Izuwan / EN

Norlia / LOG Amir / LOG

Pillar Team

Guna / SA

Mohd Hardiha / EN

Nadarajan / WO

Pillar Leader

Core team

Team Members

Pillar Leader

Core Team




SAFETY PILLAR LEADER - BACKGROUND

Bachelor Degree

Electronic &

Electrical

Engineering

Year 1994

Professional Role

- Industrial

Assistant

Engineer

WCM Role

NA

Year 1998

Professional Role

-Industrial

Engineer

- OHSAS 18001

Internal Auditor

- ISO 14001

Internal Auditor

WCM Role

- Safety Committee

member

Year 2000-2008 Professional Role

- Process Engineer

- Industrial Engineer

- OHSAS 18001

Internal Auditor

- ISO 14001

Internal Auditor

WCM Role

Safety Working

Committee Member

- Environment

Working Committee

Member

Year 2009

Professional Role

EHS Manager

WCM Role

SAF Pillar Leader

Year 2014-2016




Radar Chart Pillar Leader

Training: • Trained by WCM Expert Fiat -

Roberto Castellano

• Trained by WCM expert APAC –

Dieter Voigt

• Training by MM central team

• Participation to Prof. Yamashina’s

Audit in ALMY 2012

LUTI : • 5W1H

• 7 WCM tools

• 7 steps of problem solving

• Problem, phenomena & root

cause

• S- EWO

Benchmarking Turkey in

2014

Risk Assessment

Benchmarking ALCN & AL

Spain in 2015

New Risk Analysis format-

Legal Compliance, Risk

Assessment & Risk

Prediction & Risk analysis

for Non-Routine




Team Radar Charts

SAF

PD

Mohd Hardiha

Izuwan Kamal

LowSLAngLM

AmirSahilaZamani Nadarajan

Norlia

TEAM RADAR CHART

0

1

2

3

4

55G

5W+1H, 5 WHY

7 WCM TOOLS

THE PRINCIPLE OF HEINRICHPYRAMID

SAFETY MATRIX

PPE

MANAGEMENT INITIATED SAFETY

BASIC SAFETY STANDARDS

EMERGENCY PLAN

STEP1: ACCIDENT ANALYSIS ANDCOUNTERMEASURE

GATHER NEAR MISSES ANDUNSAFE CONDITION

STEP2: COUNTERMEASURES ANDHORIZONTAL EXPANSION

SAFETY STANDARDS GAPANALYSIS

SAFETY RESPONSIBITY MATRIX

SAFETY COMMUNICATION SYSTEMINCIDENT TREND ANALYSIS

RISK ASSESSMENT

RISK PREDICTION

ERGONOMICS RISK ANALYSIS

STEP3: DEFINITION OF SAFETYSTANDARDS AND MANDATORY…

SAFETY RCA

TWTTP TO FIND ROOT CAUSES OFACCIDENTS

SMAT MANAGEMENT

STEP4: GENERAL INSPECTION FORSAFETY

STEP5: AUTONOMUS INSPECTION

EFFECTIVE REPORTING

OCCUPATIONAL HEALTH CHECKUP

STEP6: AUTONOMUS SAFETYSTANDARD

SAFETY + TWTTP + HUMAN ERRORIDENTIFICATION

SYSTEM TO CREATE MOTIVATION

PROACTIVE WCM KNOWLEDGE

PREVENTIVE REACTIVE




Step 1 Step 2

Step 3 Step 4

Step 5 Step 6

Step 7

KAI KAI

KAI

KAI

KAI KAI

KAI

Accident & FAI

Analyzed by

S-EWO

Percentage

of

Expansion

of

countermea

sures

Percentage

of Covered

Area by Risk

Assessment

N° of OPL

N° of SOP

N°of S-card

N°of UC

N°of UA

N° of

Suggestion

N°of OPL by

workers

N° of SOP

by workers

N° of NC in

OHSAS18001 audit

Percentage of

Employees

participated into

Health Advice Prog.

Target % 100

N°of SMAT

No of UC

No of UA

KPI

KAI

No Accident

No First Aid

No Unsafe Condition

No Unsafe Act

No Near Miss

KPI & KAI




Activity Organization – Follow Up

DAILY WEEKLY MONTHLY

• IMPROVEMENT

MEETING AND

FOLLOW UP ON

SAFETY UC & UA &

6’S ( DAILY 10.30 AM )

• EHS AUDIT THE SHOP

FLOOR

• CONFERENCE CALL

WITH EHS & WCM

CENTRAL TEAM

PILLAR AND WITH

OTHER PLANTS

• REVIEW EHS KPI &

ACTIVITY WITH TOP

MANAGEMENT

• REVIEW S-EWO AND

STATUS OF UC & UA

WITH TOP

MANAGEMENT

• INVOLVEMENT OF

TOP MANAGEMENT IN

SMAT & EMAT

• PILLAR REVIEW WITH

TOP MANAGEMENT

• SAF STEERING

COMMITEE

• EHS REPORT TO

DEPARTMENT OF

OCCUPATIONAL

SAFETY AND HEALTH

(LOCAL AUTHORITY)

• REVIEW LOCAL

LEGAL REGISTERY




SAFETY ROUTE MAP

0

.... Autonomous Safety System

TWTTP applied up to UA

Operator SMAT

SMAT Audits & 6’S Audits

NM & UC& UA Analysis

Self Check System

Methodology

Development

Score

KPIs

0.43

Risk Analysis (Risk Assessment & Risk

Prediction)

LTA & FAI Analysis by

S-EWO

Horizontal Expansion of

Countermeasures

OPL & SOP

0 0.09

137 17

203 42

0

0

105

1147

0

0

58

1362

0

0

45

1410

0.06

295

342

0

208

346

IF

IG

UC

UA

Expansion 40% 33% 56% 56% 100% 100% 100%

0.04 0

0

67

115

100%

0

S1 S2 S3 S4 S5 S6 S7

L1 L2 L3 L4 L5 L6 L7

S1 S2 S3 S4 S5 S6 S7

L1 L2 L3 L4 L5 L6 L7

S1 S2 S3 S4

S6 S7

L1 L2 L3 L4

L6 L7

S1 S2 S3 S4 S5

S7

L1 L2 L3 L4 L5 L6 L7

S1 S2 S3 S4

S6 S7

L1 L2 L3 L4

L6 L7

S1 S2 S3 S4 S5

S7

L1 L2 L3 L4 L5

L7

Steps &

Levels

Time

S1 S2 S3 S4 S5 S6 S7

L1 L2 L3 L4 L5 L6 L7

L3 L4

L5 L5

S1 S2 S3 S4 S5

S7

L1 L2 L3 L4 L5

L7 L6 L6

Detailed Analysis of UAs

Implemented of Safety

Captain

Health Checks

Other Proactive Safety

Tools & Methods

S1 S2 S3 S4 S5

S7

L1 L2 L3 L4 L5

L7 L6

S1 S2 S3 S4 S5

S7

L1 L2 L3 L4 L5

L7

0

0

0

0

100% 100%

#

#

#

#

S1 S2 S3 S4 S5

S7

L1 L2 L3 L4 L5

L7

0

0

#

#

100%

S6 L6 S6 S6 L6 L6




Implemented Actions Auditor: Mr. Vendange

Christian Date

Actual

Score

Oct. 2015 3

Target

Score

Mar. 2016 3

Comments:

• Good visual management.

• Detailed risk analysis and risk prediction, good

example shown. In assessment take don't mix

action to reduce occurrence with action to

reduce gravity.

• Best practice of 6S audit with good tracking of

issues. Try to make correlation of the results

with the findings of SMAT and heinrich

pyramid by sector.

• Tune the check list to be always effective

Last Audit Comments

What we have done:

• Separate the action taken to reduce the

occurrence with gravity in the risk

assessment.

• Related the results of the 6S & SMAT audit

finding at heinrich pyramid.

• Update the 6’s checklist to be more

effective.




Agenda

I. Introduction


– Pillar Team


– KPI/KAI

– Route Map


– 7 Steps Status


– Step 1

– Step 2

– Step 3

– Step 4

– Step 5


IV. Plant Results

– KPI Plant

– SWOT Analysis




7 Steps Approach

Step 6

Management initiated Self-initiated

Team initiated

Step 4

Step 5

Step 7

A AREAS

C AREAS

AA AREA

Step 3

Step 2

Step 1

B AREAS

Accidents analysis of causes

Preventive measures and horizontal deployment

Tentatives to establish safety standards (list of all the safety related problems)

General safety control, training and education to instruct the employees how to take care the safety

Autonomous control (countermeasures undertaken in case of safety problems)

Autonomus Safety standard

Full implementation of safety system

Reactive Preventive Proactive




Plant Wide Heinrich’s Pyramid

2011 2012 2013 2014 2015

0 0 0 0 0

0 0 0 1 0

0 0 0 0 0

5 3 0 1 0

9 13 8 3 3

58 45 168 295 208

1362 1410 132 342 346

Transferring

to new plant Jan ‘16

Feb ’16

Mar ‘16

0 0 0

0 0 0

0

0

0

0 0 0

0 0 0

26 16 25

47 24 44

Fatality

LTI > 30 days

LTI < 30 days

First Aids

Near Misses

Unsafe Conditions

Unsafe Acts




X DOA (Delagation of Authority person)

X make the plan (scheduler)

X put into practice (practitioner)

X assist the process (partner)

Safety Responsibility Matrix




S-Matrix 2008

Area Localization

Injured

Part

Heinrich

Pyramid

Type of

Injury

Root

Cause

Counter

measures

Injuried Organ

N° of ACC,FA & NM(Heinrich Pyramid)

Type of Injury

Root Causes (UC or UA)

Countermeasures

For each year, we collected the data about safety incident on the S-MATRIX

AA A B C




Area Classification

Step 1&2

Step 3

Step 4

Step 5

Office

Warehouse

TPM

BMC

AO

AF

Office

Metalizing HC BA

Kanban

Utilities

AF-Anti fog

HC-Hard Coating

BA-Bezel Assy

Parking Area

AA

A

A

C

B

B B

B

C

A B B

Step 6




No. EQUIPMENT DEFINITION

2014 2015 2016 2017

Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q! Q2 Q3 Q4 Q1 Q2

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun

1 TPM

SAF STEP 4 STEP 5 STEP 6

> > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > >

2 BMC

SAF STEP 4 STEP 5 STEP 6

> > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > >

3 AO

SAF STEP 1 STEP 2 STEP 3 STEP 4 STEP 5

> > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > >

4 WARE HOUSE


> > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > >

5 AF


> > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > >

6 HC


> > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > >

7 BA


> > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > >

8 METALIZING


> > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > >

9 OFFICE


> > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > >

10 UTILITIES


> > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > >

11 KANBAN


> > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > >

12 PARKING

AREA

SAF

STEP 1 STEP 2 STEP 3 STEP 4

STEP 5

> > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > >

SAFETY Master Plan




Step 3

Step 4

Step 5

Step 6

Step 7

Setting tentative standards for safety (Listing all safety problems)

General inspection for safety (Train and grow people in such a way that they care for safety)

Autonomous inspection (Predictive countermeasures against safety problems)

Fully implemented safety management

Step 1

Analysis of accidents (Analysis of causes)

Countermeasures and horizontal expansion (Countermeasures at the similar areas)

Autonomous safety standards (*Overall inspection of safety levels *Re-evaluation if safety control)


Step 2

Step 1 & Step 2




TRAINING TO ALL THE

MANAGEMENT and

SUPERVISORS ON THE RIGHT

PROCEDURE FOR

REPORTING ALL THE EVENTS

EHS SUPERVISOR/

DEPT MANAGER

Before HR

Plant Manager

MM Reporting System (Score card and SAD System)

EMPLOYEE

HOW TO BE SURE THAT WE ARE

REPORTING ALL THE EVENTS

SUPERVISOR/ DEPT MANAGER

SAFETY

CAMPAIGN

SKETCH SAF

CAMPAIGN

EHS SUPERVISOR/

DEPT MANAGER

After

HR

Plant Manager

AL TOP MANAGEMENT & MM Reporting System

EMPLOYEE

KEYS AT THE

GUARD’S LODGE

HOW TO IMPROVE OUR DATA COLLECTION




Step 1&2: Logic

Using S-EWO for root cause analysis

Implement countermeasures

Effective check for 3 months

Horizontal expansion

Fatality

Major

Minor

First Aids

P

D

C

A

Countermeasures




Step 1

Analysis of accidents

Root cause of accidents




Incident Analysis

Provide necessary first aid treatment by OHN

Reported to E-accident report

Using S-EWO for root cause analysis

Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 1

Fatality

LTI > days

LTI < 30 days

First Aids

Step 0

Root Cause Analysis

S-EWO P

P

P

Incident

reported




Incident Analysis at Model Area

Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 0 Step 1

2

1

1

1

1

2008

TPM Model Area




Implementation of countermeasures in the model

area

Horizontal expansion on similar areas

KAI step 2

Safety responsibility matrix

Step 2




Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X

Picture or sketch Picture or sketch

Status updateREVIEW RESP. OBJECT

INSTALLATION

COST (C.D) ERGONOMICS /W.O COSTRUCTION OPERATIVE CHECK

1

Machine component

IMPACT / PILLAR

QUALITY (Q.C) AFFIDABILITY (P.M)

Project Information

Priority Kaizen code or name

WORKING(A.M) SAFETY PROJECT DETAIL FINAL CHECK

2

After - Avoid finger/hand from stuck/hit by machine

CHECK FUNCTIONAL

PROBLEM DESCRIPTION SOLUTION DESCRIPTION

ENVIRONMENT PRELIMINARY PROJECT

MACHINE

Line Work Station Machine code

STATUS

PLANNING

DescriptionMachine name

MANTENANCE (P.M)

Suzuki YV7 HL

12B Stn.1, 2, 3, 4, 5, 9 Housing Assy. H and Cap Assy. Headlamp Assy.

MFE/Zamzam

Penang Process Final Assembly EEM

Maintenance Prevention Information

Plant Unit Pillar

SAF

EEM


Effectiveness Check

We have no similar accidents

Countermeasures

Countermeasure – Example Accident

Phenomena

Replace normal hot water valve to safety lock

water valve. Technician need to use 2 hand to

turn on or off the valve.

Fatality

LTI > 30 days

LTI < 30 days

First Aids

Left hand was

burned by hot

water

Problem

INJURY EXPANSION

Hot water purged

out while technician

accidentally

touched the water

valve

Root Cause:

No Safety Lock

valve

Unsafe

Condition:

Tools

/Equipment -

Weakness of

design

Horizontal Expansion





Countermeasures

Effectiveness Check

We have no similar first aid

PPE Defined (Kevlar

Armguard)

Countermeasure – Example First Aid

Fatality

LTI > 30 days

LTI < 30 days

First Aids

Problem

Left forearm was

burned by hot

barrel

Phenomena

While dismantling

screw barrel,

unintentionally

touched hot barrel

without protection

Root Cause:

No SOP

Unsafe

Condition:

Insufficient

Procedures

PPE

inadequate


EXPANSION INJURY




• Lever was pulled

while standing in

the wrong

position to

unscrew mold

clamp

• No safety helmet.

Phenomena


Countermeasures

Effectiveness Check

We have no similar first aid


Countermeasure – Example First Aid

EXPANSION INJURY

Train the operator proper way to tighten mold

using lever and proper PPE (Safety Helmet).

Fatality

LTI > 30 days

LTI < 30 days

First Aids

Problem

Head was injured

by metal pipe

Root Cause:

Wrong method

used

Unsafe Act:

Competence/

Knowledge




KAI Formula Period Target

Accident Investigation N° of S-EWO applied for Accident Monthly 100 %

FAI Investigation N° of S-EWO applied for First-aids Monthly 100 %

100% of Accident and First Aids were analyzed by S-EWO and

Root Causes were detected.

KAI -TPM (Model Area)

Re

po

rte

d

Re

po

rte

d

An

aly

ze

d

An

aly

ze

d


6 of S-EWO

Step 2





Expansion to other Areas






KAI Formula Period Target

Countermeasures Expansion Monthly 100 % # of Expansion Completed

# of Possible/Similar Expansion Point

0

1

2

3

4

5

6

7

8

Expansion Point 2009 Expansion Completed2009



© Copyright by Automotive Lighting CREATE KNOWLEDGE AND

CONSOLIDATE (TEACH and

INSPECT)

KNOWLEGE ON HOW TO

PERFORM INCIDENT

ANALYSIS (LEARN and

CREATE a DOCUMENT, and

USE)

12 Managers trained

5 Supervisor

5 Operators of the Model Area

CONSOLIDATE ZERO

INJURIES and FIRST AIDS

Step1 & Step 2 Result




Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Setting tentative standards for safety (Listing all safety problems)

General inspection for safety (Train and grow people in such a way that they care for safety)

Autonomous inspection (Predictive countermeasures against safety problems)

Fully implemented safety management

Step 1

Analysis of accidents (Analysis of causes)

Countermeasures and horizontal expansion (Countermeasures at the similar areas)

Autonomous safety standards (*Overall inspection of safety levels *Re-evaluation if safety control)


Step 3




Risk analysis

Setting standards

KPI step 1-3

Step 3




Applicable to the

WORKING PLACE and to

ALL TASKS and ACTIVITIES

EVALUATE LEGAL REQUIREMENTS REGULATIONS, LEGISLATIONS ENGINEERING

CONTROL

Ris

k A

ss

es

sm

en

t

INVESTIGATION COUNTERMEASURES APPLICATION

LEGAL

COMPLIANCE NOK OK

LEGAL COMPLIANCE

EVALUATION

Applicable to the


ALL TASKS and

ACTIVITIES

FOCUS ON UNSAFE CONDITIONS ENGINEERING

CONTROL

To reduce the level of the Risk


ENGINEERING CONTROL

PROCEDURES

TRAINING

VISUAL MANAGEMENT


RISK LEVEL MEDIUM –

HIGH LOW

EVALUATION

LEVEL OF RISK

-PHYSICAL FACTORS

- EQUIPMENT FACTORS

- EXPOSURES

DATA AGGIORNAMENTO DATA AGGIORNAMENTO 10/10/2014

WORKING STATION Mechanical Risks 2 3 4 5 MACHINE Mechanical Risks 7 8 TOOLS Mechanical risks 10 11 12 13 CHEMICAL SUBASTANCES and MATERIALS Risks 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

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Line Events (Injury/ First

Aid) Recorded

Operation/

Activity

Task

numberTask Description P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R

OP

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l

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iza

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ok

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e

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du

re

s

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ize

n

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itio

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ize

n

Countermeasure Description

UPS07 M1 1 Prelevare da contenitore 1 riflettore mtz 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 1 2 2 NA NA NA NA NA NA 1 2 2 1 1 1 1 1 1 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 55 600 647 X XQK prelievo componenti +QK fermo rulliere + QK corretta inclinazione rulliere per

ergonomia

M1 2 evacuare foglio pe 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA 1 1 1 1 2 2 1 1 1 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 55 -8% X X QK evacuatore pelure

M1 3 posizionare riflettore su posaggio avvitatura 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 1 2 2 NA NA NA NA NA NA 1 2 2 1 1 1 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 54 X

M1 4 Prelevare da contenitore 1 basetta led 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 1 2 2 NA NA NA NA NA NA 1 2 2 1 1 1 1 1 1 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 55 X XQK prelievo componenti +QK fermo rulliere + QK corretta inclinazione rulliere per

ergonomia

M1 5 orientare e posizionare 2 basette laterali 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA 1 2 2 1 1 1 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 52 X

M1 6 orientare e posizionare 4 basette centrali 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA 1 2 2 1 1 1 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 52 X

M1 7 sistemazione cavetti 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 51 X

Infortunio 04/2010 (UA) M1 8 avvitatura di n. 4 viti 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 NA NA NA NA NA NA 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 NA NA NA NA NA NA 1 1 1 1 2 2 NA NA NA NA NA NA 1 2 2 1 1 1 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 63 X X XQK caricatore avvitatore a bussola + QK deposito avvitatore + Controllo periodico

avvitatori + visite mediche periodiche + campionamenti vibrazioni periodici

M1 9 deporre su mensola 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 51 X

M1 10 Scaricare contenitore riflettore mtz 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 1 2 2 NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 56 X X QK Scarico automatico rulliere + Controllo integrità imballi/cassette

M1 11 Scaricare contenitore basette 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 1 2 2 NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 56 X X QK Scarico automatico rulliere + Controllo integrità imballi/cassette

M1ATTIVITA' EXTRA

CICLOPulizia Linea 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 51 X

M1ATTIVITA' EXTRA

CICLOLucidatura 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA 1 3 3 NA NA NA NA NA NA 1 1 1 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 56 X

M1ATTIVITA' EXTRA

CICLO1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 51 X

M1ATTIVITA' NON

ROUTINARIESblocco cassetta rulliera 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 55 X

Overall total

level risk for

activity

Risk Assessment UPS 07 Before

Legal requirements

Overall total

level risk for

task (A)

Overall total

level risk for

activity

NOTE: Il rischio derivante da incendio ed altre emergenze è gestito mediante dispositivi, impianti e procedure previsti dal piano emergenza.

Il personale viene formato e periodicamente testato sulle procedure. L'accesso ai dispositivi di risposta in caso di emergenza è verificato

continuamente ed eventuali anomalie risolte immediatamente

Risk Level S=1 S=2 S=3 S=4

P=1 1 2 3 4

P=2 2 4 6 8

P=3 3 6 9 12

P=4 4 8 12 16

Did you have

INJ or FA Caused

by UA? NO YES

Monitor and update in case of

layout/process changes

For Model

Areas

Applicable to


also in relation with the

WORKINGPLACE and

Environmental conditions

Potential Unsafe Act Description

Tri

p

Inci

amp

o

Slip

Sciv

ola

me

nto

Bu

rial

Sep

pe

llim

en

to

Stre

ctch

Stir

ame

nto

mu

sco

lare

Ob

iect

s fa

ll fr

om

he

igh

t

Cad

uta

ogg

ett

i dal

l'alt

o

Fall

fro

m h

eig

ht

Cad

uta

dal

l'alt

o

Stri

ke

Urt

i - C

olp

i

Co

llisi

on

Co

llisi

on

e /

Inve

stim

en

to

Cru

shin

g

Sch

iacc

iam

en

to

She

ar

Ce

soia

me

nto

Cu

t -

Nip

Tag

lio -

Gra

ffio

Pie

rcin

g

Pe

rfo

razi

on

e

Bu

rn

Ust

ion

e

Exp

losi

on

Esp

losi

on

e

Ele

ctri

c -

dir

ect

co

nta

ct

Ele

ttro

cuzi

on

e p

er

con

tatt

o d

ire

tto

Flu

id, d

ust

, su

bst

ance

s p

roje

ctio

n

Pro

iezi

on

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i liq

uid

i, p

olv

eri

, mat

eri

ali

Max

Le

vel o

f R

isk

Inad

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ate

tra

inin

g

Litt

le o

r n

o e

xpe

rie

nce

in s

pe

cifi

c jo

b

Ne

glig

en

ce

Inco

rre

ct u

se o

f P

PE

No

re

gard

of

safe

ty r

ule

s

Wo

rk c

ycle

ou

t o

f se

qu

en

ce

Lack

of

use

of

PP

E

Lack

of

trai

nin

g

PP

E n

ot

avai

lab

le

Mai

nte

nn

ce n

ot

pe

rfo

rme

d

Cle

nin

g cy

cle

no

t p

erf

orm

ed

No

re

gard

of

pro

ced

ure

s n

d r

egu

lati

on

s

(in

clu

din

g 5

S)

Lack

of

atte

nti

on

Op

era

tio

ns

no

t sc

he

du

led

OP

L

Tra

inin

g

Tra

inin

g o

n t

he

job

usi

ng

spe

cifi

c p

ost

er

Vis

ual

man

age

me

nt

Wo

rkp

lace

Org

aniz

atio

n

Po

ka Y

oke

Pro

ced

ure

s

Te

chn

ical

co

un

term

eas

ure

s

PP

E

SOP

Vid

eo

Tra

inin

g

Re

de

fin

itio

n o

f e

ngi

ne

eri

ng

pro

cess

Wo

rk c

on

dit

ion

s im

pro

vem

en

t

(illu

min

atio

n, n

ois

e, e

rgo

no

mic

s, …

)

Pla

nn

ed

Clo

sed

Re

spo

nsi

ble

Overall total

level risk for

taskBEFORE

Tra

inin

g In

ade

guat

o

asse

nte

/lim

itat

a

esp

eri

en

za

Ne

glig

en

za

Inco

rre

tto

uso

de

i DP

I

No

n r

isp

ett

o d

elle

pro

ced

ure

di s

icu

rezz

a

No

n r

isp

ett

o d

el c

iclo

Man

cato

uso

de

i DP

I

Man

can

za d

i tra

inin

g

DP

I no

n d

isp

on

ibili

Cic

lo d

i man

ute

nzi

on

e

no

n r

isp

ett

ato

Cic

lo d

i pu

lizia

no

n

risp

ett

ato

No

n r

isp

ett

o d

i

rego

lam

en

ti e

pro

ced

ure

(in

clu

so 5

S)

Man

can

za d

i

atte

nzi

on

e

Op

era

zio

ne

no

n

pre

vist

a

2885

Line

Events

(Injury/

First Aid)

Recorded

Operation/Activity Task number Task Description P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R

Tra

inin

g In

ade

guat

o

asse

nte

/lim

itat

a

esp

eri

en

za

Ne

glig

en

za

Inco

rre

tto

uso

de

i DP

I

No

n r

isp

ett

o d

elle

pro

ced

ure

di s

icu

rezz

a

No

n r

isp

ett

o d

el c

iclo

Man

cato

uso

de

i DP

I

Man

can

za d

i tra

inin

g

DP

I no

n d

isp

on

ibili

Cic

lo d

i man

ute

nzi

on

e

no

n r

isp

ett

ato

Cic

lo d

i pu

lizia

no

n

risp

ett

ato

No

n r

isp

ett

o d

i

rego

lam

en

ti e

pro

ced

ure

(in

clu

so 5

S)

Man

can

za d

i

atte

nzi

on

e

Op

era

zio

ne

no

n

pre

vist

a

1454

M1 1 Prelevare da contenitore 1 riflettore mtzMancato o incorretto uso DPI e non rispetto

5S1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 NA NA NA 2 2 4 NA NA NA 1 1 1 NA NA NA 2 2 4 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA 4 X X X X X X X

Training + OPL uso DPI + OPL201300124(5S) + Visual Uso DPI tabellone + OPL201400122(uso guanti)

+ OPL201200020 controllo e sostituzione di cassette rovinate X 15

M1 2 evacuare foglio pelureMancato o incorretto uso DPI e non rispetto

5S2 1 2 1 1 1 NA NA NA 1 1 1 1 2 2 NA NA NA 1 2 2 NA NA NA 1 1 1 NA NA NA 1 1 1 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA 2 X 11

M1 3 posizionare riflettore su posaggio avvitaturaMancato uso/Uso errato di DPI + Mancato

rispetto 5S 1 1 1 1 1 1 NA NA NA 1 2 2 1 2 2 NA NA NA 2 2 4 NA NA NA 1 1 1 NA NA NA 1 1 1 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA 4 X X X X X X X OPL201300124(5S) + Calendario WO + Posaggi secondo guidelines EEM + Video trainin Safety X 13

M1 4 Prelevare da contenitore 1 basetta ledMancato o incorretto uso DPI e non rispetto




M1 5 orientare e posizionare 2 basette lateraliMancato uso/Uso errato di DPI + Mancato

rispetto 5S + Non rispetto del ciclo1 1 1 1 1 1 NA NA NA 1 2 2 1 2 2 NA NA NA 2 2 4 NA NA NA 2 1 2 NA NA NA 2 2 4 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 4 X X X X X X X Training + OPL uso DPI + OPL201300124(5S) + Visual Uso DPI tabellone + OPL201400122(uso guanti) X 18

M1 6 orientare e posizionare 4 basette centraliMancato uso/Uso errato di DPI + Mancato


M1 7 sistemazione cavettiMancato uso/Uso errato di DPI + Mancato


Infortunio 04/2010

(UA)M1 8 avvitatura di n. 4 viti

Mancato o incorretto uso DPI, non rispetto

5S, non rispetto della procedura di lavoro1 3 3 1 1 1 NA NA NA 1 3 3 1 2 2 NA NA NA 2 2 4 NA NA NA 1 1 1 NA NA NA 1 3 3 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 4 X X X X X X X X X X

Training posizione corretta in fase di avvitatura + OPL uso DPI + OPL201300124(5S) + Visual Uso DPI

tabellone + OPL201400122(uso guanti) + Video trainin Safety 5S + OPL201100048 (posizione dita in

avvitatura) + OPL201200162 (deposito avvitatore in alloggiamento) X 19

M1 9 deporre su mensolaMancato o incorretto uso DPI e non rispetto

5S1 2 2 1 2 2 NA NA NA 1 1 1 1 2 2 NA NA NA 2 2 4 NA NA NA 1 1 1 NA NA NA 1 1 1 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA 4 X X X X X X X X X OPL201400122(uso guanti) + OPL201300124(5S) + Calendario WO X 14

M1 10 Scaricare contenitore riflettore mtzMancato o incorretto uso DPI e non rispetto

5S, Manacata segnalazione cassetta rotta1 2 2 1 1 1 NA NA NA 1 1 1 1 2 2 NA NA NA 2 2 4 NA NA NA 2 2 4 NA NA NA 1 1 1 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA 4 X X X X X X X X

Training + OPL uso DPI + OPL201300124(5S) + Visual Uso DPI tabellone + OPL201400122(uso

guanti)+ Scarico automatico rulliere + OPL201100153 (cassette integre con Sketch) + OPL201200020

(gestione cassette rotte)X 16

M1 11 Scaricare contenitore basetteMancato o incorretto uso DPI e non rispetto





M2 1 Prelevare, da ripiano, rifl. Equipaggiato Mancato o incorretto uso DPI e non rispetto




M2 2 posiz su posaggioMancato uso/Uso errato di DPI + Mancato


M2 3 Prelevare G.L. da cont.Mancato o incorretto uso DPI e non rispetto




M2 4 eseguire ctrl estetico Mancato uso/Uso errato di DPI + Mancato

rispetto 5S 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 NA NA NA 1 1 1 NA NA NA 1 1 1 NA NA NA 1 1 1 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA 2 X 9

M2 5 Posizionare G.L. su riflMancato uso/Uso errato di DPI + Mancato


M2 6 Eseguire avvitatura di 1 vite GL su rifl Mancato o incorretto uso DPI, non rispetto





Infortunio

03/2010 (UC)M2 7 Prelevare 1 corpo

Mancato o incorretto uso DPI e non rispetto




M2 8 posizionare corpo su posaggMancato uso/Uso errato di DPI + Mancato


Unsafe Act Potential Root CausePotential Risk Countermeasures

Risk Prediction - Task Level UPS 07 BEFORE

Co

un

term

eas

ure

De

scri

pti

on


P=1 1 2 3 4

P=2 2 4 6 8

P=3 3 6 9 12

P=4 4 8 12 16

RISK LEVEL >6 < 4

LEVEL OF RISK

- MECHANICAL RISKS

- HUMAN FACTORS

- ENVIRONMENTAL

FACTORS

EVALUATION

Ris

k P

red

icti

on

Perform the EVALUATION by

MOVEMENT

FOCUS ON UNSAFE ACT


new UAs found

Extension areas

Risk Analysis L

eg

al C

om

pli

an

ce




How to Carry Out Legal Compliance


Investigate the

causes of

risk/harmfulness

Evaluate risk

Evaluate proper

countermeasures to

reduce risk level

Apply risk

assessment

before work

1. Conformance of national legal requirements 2. Think about past human disaster and accidents 3. Think risk based on types 4. Consider change in condition associated with the operation

1. National legal requirements 2. Risk factors 3. Guideline for Risk Level

4 Statute Laws

24 Regulations

Physical factors

Chemical factors

Psychosocial

factors

Checklist for

assessment safety

condition




Investigation Evaluation

Results

All tasks at TPM had verified below 85 dB(A)

Legal Compliance-TPM (Model Area)

(Noise)


Noise (Legal)




Investigation


Evaluation

Results

13 machines were verified by the authority (DOSH)

Equipments (Legal)

Legal Compliance-TPM (Model Area)

(Equipment)




Investigation


Evaluation

Results

11 Points of Measurements below Legal value by authority

(DOSH)

Ergonomic

Legal Compliance- Ergonomic TPM (Model Area)

11

Ergonomic

Risk have

been assessed





Parameter # of test point Frequency Reference/ Standard

Results

Noise 2 Annually <85 dB(A) 75 dB(A)

Drinking water 3 Annually Malaysia Food Act 1983

Comply to 30 tested parameters

Lighting 5 Annually >50 lux (min) 100 lux

15 % of Legal requirement measured verified OK

Legal Compliance Results TPM (Model Area)

85 % of Legal requirement checks verified OK

185

Total Articles

89

Generel Regulation List

96

Line Regulation List 66

Applicable Articles

30

Not-Applicable Articles

10

Verify by Measurement

56

Verify by Safety Check

Compliance legal

verified by checking

85%

Compliance legal required measurement

15%




Applicable to the




CONTROL

Ris

k A

ss

es

sm

en

t


LEGAL

COMPLIANCE NOK OK

LEGAL

COMPLIANCE

EVALUATION

Applicable to the


ALL TASKS and

ACTIVITIES

FOCUS ON UNSAFE

CONDITIONS

ENGINEERING

CONTROL

To reduce the level of the

Risk

Le

ga

l C

om

pli

an

ce


ENGINEERING CONTROL

PROCEDURES

TRAINING

VISUAL MANAGEMENT



HIGH LOW

EVALUATION

LEVEL OF RISK

-PHYSICAL FACTORS

- EQUIPMENT

FACTORS

- EXPOSURES

Did you have

INJ or FA Caused

by UA? NO YES



For

Model

Areas

Applicable to



WORKINGPLACE and


Potential Unsafe Act Description

Tri

p

Inci

am

po

Slip

Sci

vola

me

nto

Bu

ria

l

Se

pp

elli

me

nto

Str

ect

ch

Sti

ram

en

to m

usc

ola

re

Ob

iect

s fa

ll fr

om

he

igh

t

Ca

du

ta o

gg

ett

i da

ll'a

lto

Fa

ll fr

om

he

igh

t

Ca

du

ta d

all'

alt

o

Str

ike

Urt

i - C

olp

i

Co

llisi

on

Co

llisi

on

e /

In

vest

ime

nto

Cru

shin

g

Sch

iacc

iam

en

to

Sh

ea

r

Ce

soia

me

nto

Cu

t -

Nip

Ta

glio

- G

raff

io

Pie

rcin

g

Pe

rfo

razi

on

e

Bu

rn

Ust

ion

e

Exp

losi

on

Esp

losi

on

e

Ele

ctri

c -

dir

ect

co

nta

ct

Ele

ttro

cuzi

on

e p

er

con

tatt

o d

ire

tto

Flu

id,

du

st,

sub

sta

nce

s p

roje

ctio

n

Pro

iezi

on

e d

i liq

uid

i, p

olv

eri

, m

ate

ria

li

Ma

x Le

vel o

f R

isk

Ina

de

gu

ate

tra

inin

g

Litt

le o

r n

o e

xpe

rie

nce

in s

pe

cifi

c jo

b

Ne

glig

en

ce

Inco

rre

ct u

se o

f P

PE

No

re

ga

rd o

f sa

fety

ru

les

Wo

rk c

ycl

e o

ut

of

seq

ue

nce

Lack

of

use

of

PP

E

Lack

of

tra

inin

g

PP

E n

ot

ava

ilab

le

Ma

inte

nn

ce n

ot

pe

rfo

rme

d

Cle

nin

g c

ycl

e n

ot

pe

rfo

rme

d

No

re

ga

rd o

f p

roce

du

res

nd

re

gu

lati

on

s

(in

clu

din

g 5

S)

Lack

of

att

en

tio

n

Op

era

tio

ns

no

t sc

he

du

led

OP

L

Tra

inin

g

Tra

inin

g o

n t

he

jo

b u

sin

g s

pe

cifi

c p

ost

er

Vis

ua

l ma

na

ge

me

nt

Wo

rkp

lace

Org

an

iza

tio

n

Po

ka

Yo

ke

Pro

ced

ure

s

Te

chn

ica

l co

un

term

ea

sure

s

PP

E

SO

P

Vid

eo

Tra

inin

g

Re

de

fin

itio

n o

f e

ng

ine

eri

ng

pro

cess

Wo

rk c

on

dit

ion

s im

pro

vem

en

t

(illu

min

ati

on

, n

ois

e,

erg

on

om

ics,

…)

Pla

nn

ed

Clo

sed

Re

spo

nsi

ble

Overall total

level risk for

taskBEFORE

Tra

inin

g I

na

de

gu

ato

ass

en

te/l

imit

ata

esp

eri

en

za

Ne

glig

en

za

Inco

rre

tto

uso

de

i DP

I

No

n r

isp

ett

o d

elle

pro

ced

ure

di s

icu

rezz

a

No

n r

isp

ett

o d

el c

iclo

Ma

nca

to u

so d

ei D

PI

Ma

nca

nza

di t

rain

ing

DP

I n

on

dis

po

nib

ili

Cic

lo d

i ma

nu

ten

zio

ne

no

n r

isp

ett

ato

Cic

lo d

i pu

lizia

no

n

risp

ett

ato

No

n r

isp

ett

o d

i

reg

ola

me

nti

e

pro

ced

ure

(in

clu

so 5

S)

Ma

nca

nza

di

att

en

zio

ne

Op

era

zio

ne

no

n

pre

vist

a

2885

Line

Events

(Injury/

First Aid)

Recorded

Operation/Activity Task number Task Description P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R

Tra

inin

g I

na

de

gu

ato

ass

en

te/l

imit

ata

esp

eri

en

za

Ne

glig

en

za

Inco

rre

tto

uso

de

i DP

I

No

n r

isp

ett

o d

elle

pro

ced

ure

di s

icu

rezz

a

No

n r

isp

ett

o d

el c

iclo

Ma

nca

to u

so d

ei D

PI

Ma

nca

nza

di t

rain

ing

DP

I n

on

dis

po

nib

ili

Cic

lo d

i ma

nu

ten

zio

ne

no

n r

isp

ett

ato

Cic

lo d

i pu

lizia

no

n

risp

ett

ato

No

n r

isp

ett

o d

i

reg

ola

me

nti

e

pro

ced

ure

(in

clu

so 5

S)

Ma

nca

nza

di

att

en

zio

ne

Op

era

zio

ne

no

n

pre

vist

a

1454

M1 1 Prelevare da contenitore 1 riflettore mtzMancato o incorretto uso DPI e non rispetto




M1 2 evacuare foglio pelureMancato o incorretto uso DPI e non rispetto

5S2 1 2 1 1 1 NA NA NA 1 1 1 1 2 2 NA NA NA 1 2 2 NA NA NA 1 1 1 NA NA NA 1 1 1 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA 2 X 11

M1 3 posizionare riflettore su posaggio avvitaturaMancato uso/Uso errato di DPI + Mancato


M1 4 Prelevare da contenitore 1 basetta ledMancato o incorretto uso DPI e non rispetto




M1 5 orientare e posizionare 2 basette lateraliMancato uso/Uso errato di DPI + Mancato


M1 6 orientare e posizionare 4 basette centraliMancato uso/Uso errato di DPI + Mancato


M1 7 sistemazione cavettiMancato uso/Uso errato di DPI + Mancato


Infortunio 04/2010

(UA)M1 8 avvitatura di n. 4 viti

Mancato o incorretto uso DPI, non rispetto





M1 9 deporre su mensolaMancato o incorretto uso DPI e non rispetto

5S1 2 2 1 2 2 NA NA NA 1 1 1 1 2 2 NA NA NA 2 2 4 NA NA NA 1 1 1 NA NA NA 1 1 1 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA 4 X X X X X X X X X OPL201400122(uso guanti) + OPL201300124(5S) + Calendario WO X 14

M1 10 Scaricare contenitore riflettore mtzMancato o incorretto uso DPI e non rispetto





M1 11 Scaricare contenitore basetteMancato o incorretto uso DPI e non rispetto





M2 1 Prelevare, da ripiano, rifl. Equipaggiato Mancato o incorretto uso DPI e non rispetto




M2 2 posiz su posaggioMancato uso/Uso errato di DPI + Mancato


M2 3 Prelevare G.L. da cont.Mancato o incorretto uso DPI e non rispetto




M2 4 eseguire ctrl estetico Mancato uso/Uso errato di DPI + Mancato

rispetto 5S 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 NA NA NA 1 1 1 NA NA NA 1 1 1 NA NA NA 1 1 1 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA 2 X 9

M2 5 Posizionare G.L. su riflMancato uso/Uso errato di DPI + Mancato


M2 6 Eseguire avvitatura di 1 vite GL su rifl Mancato o incorretto uso DPI, non rispetto





Infortunio

03/2010 (UC)M2 7 Prelevare 1 corpo

Mancato o incorretto uso DPI e non rispetto




M2 8 posizionare corpo su posaggMancato uso/Uso errato di DPI + Mancato


Unsafe Act Potential Root CausePotential Risk Countermeasures

Risk Prediction - Task Level UPS 07 BEFORE

Co

un

term

ea

sure

De

scri

pti

on


P=1 1 2 3 4

P=2 2 4 6 8

P=3 3 6 9 12

P=4 4 8 12 16

RISK LEVEL > 6 < 4

LEVEL OF RISK

- MECHANICAL

RISKS

- HUMAN

FACTORS

- ENVIRONMENTA

L FACTORS

EVALUATION

Ris

k P

red

icti

on


MOVEMENT

FOCUS ON UNSAFE ACT

Monitor and update in

case of new UAs found

Extension areas

Risk Analysis



© Copyright by Automotive Lighting PROBABILITY DESCRIPTION GRAVITY DESCRIPTION

P = 1

Very Low Probability

to Occur: There are

not previous cases

S = 1Slight: potential result

first aid

P = 2

Lower Probability to

Occur: Exist in the

past previous cases

very rare

S = 2

Medium: potential

result injury >1 day & <3

days

P = 3

Probable to Occur:

Exist in the past

previous cases

S = 3

Serious: potential result

injury >3 days & < 30

days

P = 4

Highly Probably to

Occur: Previous

cases are frequent

S =4

Very serious: potential

result injury >30 days, or

Fatal, or Occupational

illness

LEGENDA

PROBABILITY

GRAVITY

RISK MATRIX

Evaluate risk by estimating it risk level Investigate

The causes of risk

PRIORITY OF SAFETY COUNTERMEASURES

Countermeasure to reduce risk level

PAST EVENTS (INJ/FA/NM)

Identifing

hazards

Assessing

risks Appling

controls

Reviewing

effects

• 40 TYPE OF HAZARDS

• 72 DETAILED ANALYSIS

Step 3: Risk Assessment

METHOD




Step 3: Risk Assessment (UC Evaluation)

PROBABILITY DESCRIPTION GRAVITY DESCRIPTION

P = 1

Very Low Probability

to Occur: There are

not previous cases

S = 1Slight: potential result

first aid

P = 2

Lower Probability to

Occur: Exist in the

past previous cases

very rare

S = 2

Medium: potential

result injury >1 day & <3

days

P = 3

Probable to Occur:

Exist in the past

previous cases

S = 3

Serious: potential result

injury >3 days & < 30

days

P = 4

Highly Probably to

Occur: Previous

cases are frequent

S =4

Very serious: potential

result injury >30 days, or

Fatal, or Occupational

illness

LEGENDA

Risk Level G=1 G=2 G=3 G=4

P=1 1 2 3 4

P=2 2 4 6 8

P=3 3 6 9 12

P=4 4 8 12 16





Step 3: Risk Assessment (UC Evaluation)

Hazards / Potential Risks

Machine

Event

recorded

Task

Operation

Countermeasure





CREATE KNOWLEDGE in the TEAM

STRONG KNOWLEGE OF THE TOOL (LEARN and CREATE a DOCUMENT)

2 SAF pillar members

1 PM pillar member

1 AM pillar member

1 line leader

1 Operator of the Model Area

SELECT THE AREA AND APPLY with the SAF- SPECIALISTS

MODEL AREA SELECTED

Step 3: Working to Eliminate Unsafe conditions -

TARGET




0

1

2

3

4

5

6

7

8

9

10

Pareto of Risk Level (Before)

Risk Assessment Pareto

24.36%

HIGH RISK

69.23%

MEDIUM RISK

6.41%

LOW RISK

PRIORITY




Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X



INSTALLATION


1

Machine component

IMPACT / PILLAR


Project Information



2


CHECK FUNCTIONAL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)

Suzuki YV7 HL


MFE/Zamzam



Plant Unit Pillar

SAF

EEM

Risk Assessment Process – Example 1


Fabricate mild steel container to contain

excess extruded hot resin material

EXPANSION

Model Area

Potential Risk /

Hazard:-

Removing the purged

hot and sticky

polymer underneath

the injection unit

using a carton layer –

Risk of getting burn

injury.

G=1 G=2 G=3 G=4

Risk Level

Slight:

potential

result first

aid

Medium:

potential

result

injury >1

day & <3

days

Serious:

potential

result injury

>3 days & <

30 days

Very

serious:

potential

result injury

>30 days

P=1

Very Low

Probability

to Occur1 2 3 4

P=2

Lower

Probability

to Occur2 4 6 8

P=3Probable to

Occur 3 6 9 12

P=4

Highly

Probably to

Occur4 8 12 16

KAIZEN Burns

G=1 G=2 G=3 G=4

Risk Level

Slight:

potential

result first

aid

Medium:

potential

result

injury >1

day & <3

days

Serious:

potential

result injury

>3 days & <

30 days

Very

serious:

potential

result injury

>30 days

P=1

Very Low

Probability

to Occur1 2 3 4

P=2

Lower

Probability

to Occur2 4 6 8

P=3Probable to

Occur 3 6 9 12

P=4

Highly

Probably to

Occur4 8 12 16

Root Cause:

Carton layer is not

a proper container

Unsafe Condition:

Weakness design




G=1 G=2 G=3 G=4

Risk Level

Slight:

potential

result first

aid

Medium:

potential

result

injury >1

day & <3

days

Serious:

potential

result injury

>3 days & <

30 days

Very

serious:

potential

result injury

>30 days

P=1

Very Low

Probability

to Occur1 2 3 4

P=2

Lower

Probability

to Occur2 4 6 8

P=3Probable to

Occur 3 6 9 12

P=4

Highly

Probably to

Occur4 8 12 16

Risk Assessment Process – Example 2


G=1 G=2 G=3 G=4

Risk Level

Slight:

potential

result first

aid

Medium:

potential

result

injury >1

day & <3

days

Serious:

potential

result injury

>3 days & <

30 days

Very

serious:

potential

result injury

>30 days

P=1

Very Low

Probability

to Occur1 2 3 4

P=2

Lower

Probability

to Occur2 4 6 8

P=3Probable to

Occur 3 6 9 12

P=4

Highly

Probably to

Occur4 8 12 16

1°Cutter is changed to

Safety Retracable Cutter

2°Proper PPE defined (Cut

Resistant glove)

3°OPL Prepared

EXPANSION

Model Area

Potential Risk /

Hazard:-

Degating/

deburring

process using

normal penknife

– Risk of getting

cut.

Cut Normal Penknife

Root Cause:

Normal penknife

does not have

safety features

Unsafe Condition:

Weakness of

design




Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X



INSTALLATION


1

Machine component

IMPACT / PILLAR


Project Information



2


CHECK FUNCTIONAL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)

Suzuki YV7 HL


MFE/Zamzam



Plant Unit Pillar

SAF

EEM


Risk Assessment Process - Example 3

The conveyor

completely fenced-up

EXPANSION

Model Area

KAIZEN Potential Risk /

Hazard:-

Robot drop the

molded parts at

the conveyor –

Risk dropping

part hit

operator G=1 G=2 G=3 G=4

Risk Level

Slight:

potential

result first

aid

Medium:

potential

result

injury >1

day & <3

days

Serious:

potential

result injury

>3 days & <

30 days

Very

serious:

potential

result injury

>30 days

P=1

Very Low

Probability

to Occur1 2 3 4

P=2

Lower

Probability

to Occur2 4 6 8

P=3Probable to

Occur 3 6 9 12

P=4

Highly

Probably to

Occur4 8 12 16

Root Cause:

No fencing at

conveyor

Unsafe

Condition:

Weakness

design



© Copyright by Automotive Lighting 0

1

2

3

4

5

6

7

8

9

10


0

2

4

6

8

10

a1

a3

a5

Pareto of Risk Level (After)


Risk Assessment Result

Risk Eliminated




Before After

Tolerable 1&2 5 6.41% 37 48.05%

Moderate 3&4 54 69.23% 40 51.95%

Substantial 6,8&9 19 24.36% 0 0.00%

Intolerable 12&16 0 0.00% 0 0.00%

Table: The Summary of Risk Levels

Risk Assessment Results

COUNTERMEASURES

0

10

20

30

40

50

60

OPL SOP Training Training onthe job

(includingPreventional

Register)

VisualManagement

WorkplaceOrganization

Poka Yoke Procedures Kaizen PPE EEM NewProcesses





KNOWLEGE OF THE TOOL (LEARN and CREATE a DOCUMENT)


MODEL AREA COMPLETED Risk reduction: 24.36%

Step 3: Risk Assessment Result


1 PM pillar member

1 AM pillar member

1 line leader





Risk Analysis

Applicable to the




CONTROL

Ris

k A

ss

es

sm

en

t


LEGAL

COMPLIANCE NOK OK

LEGAL COMPLIANCE

EVALUATION

Applicable to the


ALL TASKS and

ACTIVITIES

FOCUS ON UNSAFE CONDITIONS ENGINEERING

CONTROL

To reduce the level of the Risk

Le

ga

l C

om

pli

an

ce


ENGINEERING CONTROL

PROCEDURES

TRAINING

VISUAL MANAGEMENT



HIGH LOW

EVALUATION

LEVEL OF RISK

-PHYSICAL FACTORS

- EQUIPMENT FACTORS

- EXPOSURES

DATA AGGIORNAMENTO DATA AGGIORNAMENTO 10/10/2014

WORKING STATION Mechanical Risks 2 3 4 5 MACHINE Mechanical Risks 7 8 TOOLS Mechanical risks 10 11 12 13 CHEMICAL SUBASTANCES and MATERIALS Risks 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

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ale

Line Events (Injury/ First

Aid) Recorded

Operation/

Activity

Task

numberTask Description P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R P G R

OP

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Countermeasure Description

UPS07 M1 1 Prelevare da contenitore 1 riflettore mtz 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 1 2 2 NA NA NA NA NA NA 1 2 2 1 1 1 1 1 1 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 55 600 647 X XQK prelievo componenti +QK fermo rulliere + QK corretta inclinazione rulliere per

ergonomia

M1 2 evacuare foglio pe 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA 1 1 1 1 2 2 1 1 1 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 55 -8% X X QK evacuatore pelure

M1 3 posizionare riflettore su posaggio avvitatura 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 1 2 2 NA NA NA NA NA NA 1 2 2 1 1 1 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 54 X

M1 4 Prelevare da contenitore 1 basetta led 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 1 2 2 NA NA NA NA NA NA 1 2 2 1 1 1 1 1 1 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 55 X XQK prelievo componenti +QK fermo rulliere + QK corretta inclinazione rulliere per

ergonomia

M1 5 orientare e posizionare 2 basette laterali 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA 1 2 2 1 1 1 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 52 X

M1 6 orientare e posizionare 4 basette centrali 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA 1 2 2 1 1 1 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 52 X

M1 7 sistemazione cavetti 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 51 X

Infortunio 04/2010 (UA) M1 8 avvitatura di n. 4 viti 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 NA NA NA NA NA NA 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 NA NA NA NA NA NA 1 1 1 1 2 2 NA NA NA NA NA NA 1 2 2 1 1 1 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 63 X X XQK caricatore avvitatore a bussola + QK deposito avvitatore + Controllo periodico

avvitatori + visite mediche periodiche + campionamenti vibrazioni periodici

M1 9 deporre su mensola 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 51 X

M1 10 Scaricare contenitore riflettore mtz 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 1 2 2 NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 56 X X QK Scarico automatico rulliere + Controllo integrità imballi/cassette

M1 11 Scaricare contenitore basette 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 1 2 2 NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 56 X X QK Scarico automatico rulliere + Controllo integrità imballi/cassette

M1ATTIVITA' EXTRA

CICLOPulizia Linea 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 51 X

M1ATTIVITA' EXTRA

CICLOLucidatura 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA 1 3 3 NA NA NA NA NA NA 1 1 1 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 56 X

M1ATTIVITA' EXTRA

CICLO1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 NA NA NA 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 51 X

M1ATTIVITA' NON

ROUTINARIESblocco cassetta rulliera 1 2 2 NA NA NA NA NA NA 1 2 2 NA NA NA 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 2 2 1 2 2 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA 1 1 1 NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 2 2 1 2 2 1 1 1 NA NA NA NA NA NA NA NA NA 1 3 3 NA NA NA NA NA NA 1 2 2 NA NA NA 1 2 2 1 2 2 NA NA NA 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 NA NA NA 1 2 2 NA NA NA 1 2 2 55 X

Overall total

level risk for

activity

Risk Assessment UPS 07 Before

Legal requirements

Overall total

level risk for

task (A)

Overall total

level risk for

activity

NOTE: Il rischio derivante da incendio ed altre emergenze è gestito mediante dispositivi, impianti e procedure previsti dal piano emergenza.

Il personale viene formato e periodicamente testato sulle procedure. L'accesso ai dispositivi di risposta in caso di emergenza è verificato

continuamente ed eventuali anomalie risolte immediatamente


P=1 1 2 3 4

P=2 2 4 6 8

P=3 3 6 9 12

P=4 4 8 12 16

Did you have

INJ or FA Caused

by UA? NO YES



For Model

Areas

Applicable to



WORKINGPLACE and


RISK LEVEL > 6 < 4

LEVEL OF RISK

- MECHANICAL RISKS

- HUMAN FACTORS

- ENVIRONMENTAL

FACTORS

EVALUATION

Ris

k P

red

icti

on


MOVEMENT

FOCUS ON UNSAFE ACT


new UAs found

Extension areas




Unsafe acts elimination

19

TYPES

OF

HAZARD

Estimated Risk level

PREDICTION

of what can happen

INVOLVEMENT:

Supervisor

Team Leader

Operators

THINK ABOUT:

• UNSAFE ACTS in the past.

• UNSAFE ACTS that may be risky

LEVEL OF

DETAIL:

Level of Task

RISK LEVEL:

Evaluation criteria

Coutermeasures

PRIORITY

(by level of

risk)

PROBABILITY

GRAVITY

x

COUNTERMEASURES

OPL

Training

Training on the job using specific

poster

Visual management

Workplace Organization

Poka Yoke

Procedures

Technical countermeasures

PPE

SOP

Video Training

Redefinition of engineering process

Work conditions improvement

(illumination, noise, ergonomics, …)

7 ENVIRONMENTAL

FACTORS

Step 3: Risk Prediction

METHOD







MODEL AREA SELECTED

Step 3: Working to Eliminate Unsafe acts -

TARGET


1 PM pillar member

1 AM pillar member

1 line leader





0

1

2

3

4

5

6

7

8

9

10

aa ab ac ad ae af ag ah ai aj ak al

am an ao ap aq ar as at au av aw ax ay az

aaa

aab

aac

aad

aae

aaf

aag

aah

aai

aaj

aak

aal

aam



Risk Prediction Pareto

48.1%

HIGH RISK

51.9%

LOW RISK

PRIORITY




Potential Risk /

Hazard:-

Technician did not

place the oil

container on the

secondary

containment

Risk of getting Slip

and Fall

Risk Prediction Process – Example 1


1°OPL Prepared to follow the procedure and

visualized the OPL on the machine, to remind the

technician to put the oil container on the secondary

containment platform

EXPANSION

Model Area

G=1 G=2 G=3 G=4

Risk Level

Slight:

potential

result first

aid

Medium:

potential

result

injury >1

day & <3

days

Serious:

potential

result injury

>3 days & <

30 days

Very

serious:

potential

result injury

>30 days

P=1

Very Low

Probability

to Occur1 2 3 4

P=2

Lower

Probability

to Occur2 4 6 8

P=3Probable to

Occur 3 6 9 12

P=4

Highly

Probably to

Occur4 8 12 16

Slip &

Fall

G=1 G=2 G=3 G=4

Risk Level

Slight:

potential

result first

aid

Medium:

potential

result

injury >1

day & <3

days

Serious:

potential

result injury

>3 days & <

30 days

Very

serious:

potential

result injury

>30 days

P=1

Very Low

Probability

to Occur1 2 3 4

P=2

Lower

Probability

to Occur2 4 6 8

P=3Probable to

Occur 3 6 9 12

P=4

Highly

Probably to

Occur4 8 12 16

Root Cause:

Technician Not Place

the oil container on

secondary

containment

Unsafe Act:

Lack of attention






EXPANSION

Model Area

G=1 G=2 G=3 G=4

Risk Level

Slight:

potential

result first

aid

Medium:

potential

result

injury >1

day & <3

days

Serious:

potential

result injury

>3 days & <

30 days

Very

serious:

potential

result injury

>30 days

P=1

Very Low

Probability

to Occur1 2 3 4

P=2

Lower

Probability

to Occur2 4 6 8

P=3Probable to

Occur 3 6 9 12

P=4

Highly

Probably to

Occur4 8 12 16

Potential Risk

/ Hazard:-

Unclosed

pump cover

Risk of

getting

electrocuted.

Electrocuted

G=1 G=2 G=3 G=4

Risk Level

Slight:

potential

result first

aid

Medium:

potential

result

injury >1

day & <3

days

Serious:

potential

result injury

>3 days & <

30 days

Very

serious:

potential

result injury

>30 days

P=1

Very Low

Probability

to Occur1 2 3 4

P=2

Lower

Probability

to Occur2 4 6 8

P=3Probable to

Occur 3 6 9 12

P=4

Highly

Probably to

Occur4 8 12 16

Root Cause:

Forget to close

pump cover

after

troubleshoot

Unsafe Act:

Lack of

attention

1°OPL Prepared to follow the procedure and visualized

the OPL on the machine, to remind the technician to

close the pump cover after troubleshoot

2° Update in the maintenance check list.

Maintenance

Checklist Updated






EXPANSION

Model Area

Trip Potential Risk /

Hazard:-

During the

process of

heating up mold,

hose not

arranged

properly which

can cause

tripping. Risk of

Trip and Fall.

G=1 G=2 G=3 G=4

Risk Level

Slight:

potential

result first

aid

Medium:

potential

result

injury >1

day & <3

days

Serious:

potential

result injury

>3 days & <

30 days

Very

serious:

potential

result injury

>30 days

P=1

Very Low

Probability

to Occur1 2 3 4

P=2

Lower

Probability

to Occur2 4 6 8

P=3Probable to

Occur 3 6 9 12

P=4

Highly

Probably to

Occur4 8 12 16

Root Cause:

Technician might

forget to upkeep

the hose

Unsafe Act:

Lack of attention

1°OPL Prepared to follow the procedure and visualized

the OPL on the machine, to remind the technician

arranged the hose and pipe properly.

2° Update in the maintenance check list.

Maintenance

Checklist Updated



© Copyright by Automotive Lighting 0

1

2

3

4

5

6

7

8

9

10

aa ab ac ad ae af ag ah ai aj ak al am an ao ap aq ar as at au av aw ax ay az aaa

aab

aac

aad

aae aaf

aag

aah aai

aaj

aak aal

aam


0

2

4

6

8

10

aa

ab

ac

Pareto of Risk Level (After)

Step 3: Risk Prediction Result

Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 0 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 0 Step 1

Risk Eliminated





Table: The Summary of Risk Levels

Risk Prediction Results TPM (Model Area)

Before After

Tolerable 1&2 38 48.1% 13 18.99%

Moderate 3&4 0 0% 64 81.01%

Substantial 6,8&9 41 51.9% 0 0%

Intolerable 12&16 0 0% 0 0%

COUNTERMEASURES

0102030405060







MODEL AREA COMPLETED Risk reduction:51.9 %

Step 3:Risk Prediction Results


1 PM pillar member

1 AM pillar member

1 line leader





In case of an injury or first aid we perform the analysis using the S-EWO and we update the RISK ANALYSIS

We improved our S-EWO format

Move the "X" on hit part of body

SELECT ROOT CAUSE CATEGORY

2 attitude behavior 3 management 6 tools equipments

a. negligence a. lack of training a. tool/equipment

insufficient

b. incorrect use of PPE

b. poor physical attitude known

b. lack of maintenance

c. other c. no regard of safety

rule

c. PPE not available c. design weakness

d. work cycles out of

sequence

d. inadeguate PPE d. unexpected running

of equiment/tool

e. lack of use of PPE e. physical attitude e. unscheduled cleaning

cycles

f. dubious event f. maintenance not performed f. climatic condition

g. other

g. cleaning cycle not performed

g. incorrect

install./fabbrication

h. no regard of procedures and

regulations

h. insufficient lighting

i. other i . Excessive noise

l. other

CLOSE DATE

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

A

C

T

F

O

R

I

N

J

/

F

A

DATE

Area

training/OPL maintenanceFI, kaizen, improvement

activities, ecc.

UNSAFE ACT

EXPANSION PLAN FOR SIMILAR AREAS

DATE

DUE DATE CLOSE DATE

VERIFICATION DONE BY

Unit

Employee Team Leader

Date

Signature

Safety Mgr

In the past three months, were

there events due to the same

root cause?

Do all required Unit Leaders (each shift or dept) understand

the root cause of the event and the corrective measure(s)

implemented? Is the S-EWO signed off?

C

H

E

C

K

ACHIEVED RESULTS

NOTES

Plant Mgr

In the past three months, were there events due to

the same root cause?

SIGNATURE NOTES

The expansion covered:

4 precaution attention

a. lack of attention

b. operations not

scheduled

c. misunderstanding

d. not correct use of PPE

f. unexpected illness

g. personal problems

h. other

training/OPL

1 competence/knowledge

b. little or not experience

in specific job

a. inadeguate training

counseling

ACTION PLAN - LONG TERM COUNTERMEASURES

FI, kaizen, improvement

activities, ecc.disciplinary action

FI, kaizen, improvement activities,

ecc.


activities, ecc.

counseling

RESPONSIBLE DUE DATE

disciplinary action


activities, ecc.

CATEGORIZE THE ROOT CAUSE

training/OPL

coach/return

POSSIBLE ROOT CAUSES

d. unclear procedures

e. undefined safety

practices and procedures

f. PPE inadeguate

ACTION

7 procedures systems

a. lack of standard

procedures

b. insufficient procedures

UNSAFE CONDITION

c. undefined roles

ANALYSIS OF ROOT CAUSE BY 5 WHYS ANSWER

Why

5

ROOT CAUSE:

SKETCHESSIGNATURE

WHAT (nature and body part)

4

5

3

VERIFICATION OF ROOT CAUSES OK NOK

1

N°

(was a Routine or Not Routine activity?)

HOW (how did the incident occur?)

Why

1

Why

2

Why

3

Why

4

SIGNATURE

If the answer is YES, please prepare a further action plan to take additional countermeasures

Female From other Dept

TemporaryPerm Agency

Job of the injured Analysis performed by

WHEN (when was it done? Start of shifts, end of shfit, ecc)

WHERE (is the job being done? e.g. workplace, machine, ecc)

WHO (who is doing the job?)

WHICH (which kind of operation is going on?)

2

ACHIEVED RESULTS

MaleBadge Nr

g. PPE unexpected

h. other

training/OPL

COUNTERMEASURES

5 personal condition

a. mental

deficiency/instability

b. physical

deficiency/instability

c. impaired state (due to

alcohol, drugs, Pr. Med)

d. family problems

e. health problems e. other

Name of injured Sequence number

Area/Machine/Operation/Station

5 W + 1 How Analysis (event description)

Depart. MgrSupervisor

Safety - Emergency Work Order

Safety - Emergency Work Order

SIGNATURE NOTESVERIFICATION DONE BY

SHIFT Date

Seniority of the role (internal) Hour

Does the job require a

specific training/permit? Seniority of the role (external)

Have the countermeasures been comunicated to all affected

employees and is S-EWO been signed off?

Have the countermeasures been implemented as

defined in the action plan?

Actions taken immediatilyBODY CHART SKETCH

RESPONSIBLE

Has the SOP or OPL been

updated to reflect the

implemented countermeasures?

Do all visual aid been posted and diffused?

U.T.E./Dept.

ADDITIONAL ACTION PLAN

Level of the Risk AFTERWas this Risk considered and evaluated in the Risk

Assessment (if UC)?

STANDARDIZE and ESTABLISH CONTROL

RISK ASSESSMENT & RISK PREDICTION STANDARD DOCUMENTS

F

O

R

I

N

J

/

F

A

PLA

N

D

O

In case of failure, justify:

DUE DATE CLOSE DATE

Can an Mpinfo be created for

this countermeasures? Can the

countermeasures been

proposed as a Best Practice?

Has a Ka izen been submitted to

FI / SA for this countermeasure?

Has the countermeasure been

added to the SAF audits

checking? (eg. SMAT, Operator

Check l i s t, o Check Lis t SAF)

If yes, was the countermeasure implemented not effective or

not sustained?

Was this Risk considered and evaluated in the Risk

Prediction (if UA)?

Has the Risk Assessment / Risk Prediction been updated with

the new countermeasure and level of the Risk?

Level of the Risk BEFORE

1 2 3 4 5 6

7 8 9 10 11 12

1 2° DN

< 1Week < 1 Month3 - 6 Months

> 6 Months

< 1Week < 1 Month3 - 6 Months

> 6 Months

NOT EFFECTIVE

NOT SUSTAINED

NA

NA

YES

NO

NA

YES

NO

NA

YES

NO

NA

YES

NO

NA

ROUTINE NON ROUTINE

Step 3:How to continuous improve




Risk Analysis Non Routine Activities


Performed infrequently and outside

of normal duties

Does not have a documented

procedure

Can be unscheduled and unplanned

A sequence of actions regularly

followed; a fixed program

Performed as part of a regular

procedure rather than for a

special reason

PLANT ACTIVITIES

SOP / SMP

NON-ROUTINE ACTIVITIES:

Non Routine

Risk Assessment

Routine

ROUTINE ACTIVITIES:

Analysed by

Risk

Assessment

Analysed by

Risk

Prediction

YES NO

Non-Routine

SOP /

SMP

participa

nts

ParticipaN .OP.

FamilyPRESENT

(YES/NO)TASK

IMMEDIATE

COUNTERMEASURE -

If necessary describeFamily PRESENT (YES/NO) TASK

IMMEDIATE COUNTERMEASURE -

If necessary describe

OT

HE

RS Collision Possibility of investment by forklift or other equipments in motion

OT

HE

RS

Fluid, dust,

substances

projection

Possibility of penetration of foreign bodies on the

operator during working activities

AR

EA

Occupied

working areaOccupied working station

Falling of

objects

When there is the possibility of falling from a height of

objects or particles and that hurt the worker

RoutesAlternative working passages and temporary interference with

other things or peopleCrushing

When there exists the possibility to crush a part of the

body of the operator

Transport

of material

Temporary

working area

Workstations / temporary platforms created as a cause of the

change in the nature of workCut - Nip

Possibility of nip - cut due to the presence of sharp

material or equipment

Whenever a forklift, a truck, interacts or can interfere with a

workerStrike

There is the possibility that the operator can crash into a

ledge (knees, hips and head)

Temporary and

mobile sites

Every time you have to perform a temporary work activities (eg.

Construction site)Trip

When there exists the possibility of tripping with parts

protruding from the pavement or with obstacles

EQ

UIP

ME

NT

S /

TO

OLS

ToolsEquipment or instrumentation that can generate an hand

crushingExplosion

When there is the possibility of contacting with explosive

objects

Machines

Automatic machinery present in the work station that could

generate a risk of crushing, entanglement ... by moving

mechanical parts

Electric devices

Arco Flash

When there is the possibility of direct contact with

electrical devices

Lifting

equipments

Manual tools Use of manual tools (hammers, knives, pliers, wrenches) BurnWhen there is a risk that the operator can burn (hot

lamps etc.)

Laser /

Optical Rad.

Whenever you need to use for an acivity a Laser Class II or higher

(for example portable scanner)Piercing

When there is a possibility of direct contact with sharp

objects causing lacerations

Chemicals Each time that a chemical is used in the workplace

Pressure

equipmentUse or maintenance of pressure equipments Fire

When an element used in the job starts to burn due to

another element

Radiations Any radioactive material or machines that generate radiation

DA

NG

ER

S R

ELA

TE

D T

O T

HE

WO

RK

ING

AC

TIV

ITY

Jobs from

a height

Working over 1.80 meters without protection falls systems

(railings, slings etc.)

MicroclimateExcessively high or low temperatures of the working place.

Frequent temperature changes

Conifined

spaces

Whenever the operator operates under conditions of

inadequate oxygenation with risk of suffocation

Risk represented by the presence of suspended loads

Slip / FallingPossibility of slipping on the floor dirty by oil, wet or

slippery

Explosive

atmosphere

Potential risks of explosion due to the presence of chemical

material (eg. Fuel vapors)Strike

Each time the operator strikes an element with a body

part

Electromagnetic

fields

Exposure to electromagnetic fields generated by electrical or

electronic equipment or industrial machine (welding machines,

mixers ...)

Ergonomy

by tool

Tools used that presents difficulty in grip and easy

handling

Surface

temperatureWorking surface's temperatures excessively hot or cold Strech

When the operator must stretch beyond its shoulders or

below the length of his arms

Air quality Fumes, or dust clouds released in the workplaceWork

posture

Whenever you need a work posture uncomfortable or

bent to perform a task

EN

VIR

ON

ME

NT

AL

Lighting Excessive or insufficient lighting conditions.

ER

GO

NO

MY

Manual

handlingWhen there is a risk in the manual handling of loads

INDIVIDUARE TUTTI I PERICOLI RELATIVI ALLE OPERAZIONI SOPRA ELENCATE

Noise Excessive or persistent noise level Repetitive movementsWhenever an operator performs a movement / task more

than once per cycle

VibrationsExposure to excessive or repetitive vibration (vibrations

transmitted by tools/vehicles, high vibration surface)strength

Whenever the operator must push or pull toward a

component by applying excessive force

HAZARD: RISK DESCRIPTION HAZARD: RISK DESCRIPTION

BRIEF DESCRIPTION OF THE ACTIVITY:

Activity :

Non-Routine RISK ASSESSMENTDate: Plant: Dept: Area: Line/Working station: Compiled by:

Maintenance Activities

Logistic Activities Other……... Dept Manager Unit Manager Safety Manager Safety ExpertMaintenance Manager

Maintenance Supervisor/ Expert

Other: (specify) ………...




NON ROUTINE ACTIVITIES

1. Identify all the tasks

2. What is the procedure? Does one exist? (the main points)

3. Perform Risk Assessment Review the Layout of people, posture, positions of hands and feet to determine hazards

4. Establish and implement countermeasures

5. Update or create the procedure

6. For those activities which are very critical and request special attention perform also Risk Prediction

7. Review your Risk analisys document

1

2

3

4

5

6

7

Logic for Non-Routine Activities Risk Analysis





participa

nts

ParticipaN .OP.

FamilyPRESENT

(YES/NO)TASK

IMMEDIATE

COUNTERMEASURE -

If necessary describeFamily PRESENT (YES/NO) TASK

IMMEDIATE COUNTERMEASURE -

If necessary describe

OT

HE

RS Collision Possibility of investment by forklift or other equipments in motion

OT

HE

RS

Fluid, dust,

substances

projection

Possibility of penetration of foreign bodies on the

operator during working activities

AR

EA

Occupied

working areaOccupied working station

Falling of

objects

When there is the possibility of falling from a height of

objects or particles and that hurt the worker

RoutesAlternative working passages and temporary interference with

other things or peopleCrushing

When there exists the possibility to crush a part of the

body of the operator

Transport

of material

Temporary

working area

Workstations / temporary platforms created as a cause of the

change in the nature of workCut - Nip

Possibility of nip - cut due to the presence of sharp

material or equipment

Whenever a forklift, a truck, interacts or can interfere with a

workerStrike

There is the possibility that the operator can crash into a

ledge (knees, hips and head)

Temporary and

mobile sites

Every time you have to perform a temporary work activities (eg.

Construction site)Trip

When there exists the possibility of tripping with parts

protruding from the pavement or with obstacles

EQ

UIP

ME

NT

S /

TO

OLS

ToolsEquipment or instrumentation that can generate an hand

crushingExplosion

When there is the possibility of contacting with explosive

objects

Machines

Automatic machinery present in the work station that could

generate a risk of crushing, entanglement ... by moving

mechanical parts

Electric devices

Arco Flash

When there is the possibility of direct contact with

electrical devices

Lifting

equipments

Manual tools Use of manual tools (hammers, knives, pliers, wrenches) BurnWhen there is a risk that the operator can burn (hot

lamps etc.)

Laser /

Optical Rad.

Whenever you need to use for an acivity a Laser Class II or higher

(for example portable scanner)Piercing

When there is a possibility of direct contact with sharp

objects causing lacerations

Chemicals Each time that a chemical is used in the workplace

Pressure

equipmentUse or maintenance of pressure equipments Fire

When an element used in the job starts to burn due to

another element

Radiations Any radioactive material or machines that generate radiation

DA

NG

ER

S R

ELA

TE

D T

O T

HE

WO

RK

ING

AC

TIV

ITY

Jobs from

a height

Working over 1.80 meters without protection falls systems

(railings, slings etc.)

MicroclimateExcessively high or low temperatures of the working place.

Frequent temperature changes

Conifined

spaces

Whenever the operator operates under conditions of

inadequate oxygenation with risk of suffocation

Risk represented by the presence of suspended loads

Slip / FallingPossibility of slipping on the floor dirty by oil, wet or

slippery

Explosive

atmosphere

Potential risks of explosion due to the presence of chemical

material (eg. Fuel vapors)Strike

Each time the operator strikes an element with a body

part

Electromagnetic

fields

Exposure to electromagnetic fields generated by electrical or

electronic equipment or industrial machine (welding machines,

mixers ...)

Ergonomy

by tool

Tools used that presents difficulty in grip and easy

handling

Surface

temperatureWorking surface's temperatures excessively hot or cold Strech

When the operator must stretch beyond its shoulders or

below the length of his arms

Air quality Fumes, or dust clouds released in the workplaceWork

posture

Whenever you need a work posture uncomfortable or

bent to perform a task

EN

VIR

ON

ME

NT

AL

Lighting Excessive or insufficient lighting conditions.E

RG

ON

OM

YManual

handlingWhen there is a risk in the manual handling of loads

INDIVIDUARE TUTTI I PERICOLI RELATIVI ALLE OPERAZIONI SOPRA ELENCATE

Noise Excessive or persistent noise level Repetitive movementsWhenever an operator performs a movement / task more

than once per cycle

VibrationsExposure to excessive or repetitive vibration (vibrations

transmitted by tools/vehicles, high vibration surface)strength

Whenever the operator must push or pull toward a

component by applying excessive force

HAZARD: RISK DESCRIPTION HAZARD: RISK DESCRIPTION

BRIEF DESCRIPTION OF THE ACTIVITY:

Activity :

Non-Routine RISK ASSESSMENTDate: Plant: Dept: Area: Line/Working station: Compiled by:

Maintenance Activities

Logistic Activities Other……... Dept Manager Unit Manager Safety Manager Safety ExpertMaintenance Manager

Maintenance Supervisor/ Expert

Other: (specify) ………...Team that perform the Evaluation

Non routinary activity TASK DESCRIPTION

RISKS IDENTIFICATION &

DEFINITION OF IMMEDIATE COUNTERMEASURES

Countermeasures definition

PPE

OPERATION RISK BEFORE RISK AFTER

NEEDED FOR OPERATION

Nr.

NEEDED FOR

OPERATION Nr.

NEEDED FOR

OPERATION Nr.

NEEDED FOR OPERATION

Nr.

NEEDED FOR

OPERATION Nr.

DATE

1. ALL THE PPEs MUST BE WORN FOR ALL THE ACTIVITIES AND DURING ALL THE WORKING TIME

2. IMMEDIATELY REPORT TO YOUR SUPERVISOR ANY UNSAFE CONDICTION OR ACT

3. MANTEIN SAFEYOUR WORKING AREA IN ORDER TO DON'T CREATE ANY RISK FOR YOURSELF OR YOUR COLLEAGUES

4. BE CONSCIUS OF THE RISKS RELATED TO YOUR ACTIVITES

5. ALWAYS USE THE PEDESTRIAN PASSAGES TO ACHIEVE YOUR WORKING AREA

6. RESPECT THE WORKING INSTRUCTION AND MAKE YOUR COLLEAGUES TO RESPECT THEM TOO

7. ALWAYS PAY ATTENTION TO FORK LIFT DRIVERS OR TO TRUCKS

8. DO NOT USE ANY TOOL / MACHINE / EQUIPMENT THAT HAS BEEN GIVEN TO YOU BY AN UNAUTHORIZED PERSON

9. IT'S FORBITTEN THE USAGE OF MOBILES DIRING THE WORKING TIME

10. PAY ATTENTION TO ALL THE SIGNALS, EMERGENCY LIGHTS AND EMERGENCY EXITS. PAY ATTENTION TO THE AREAS THAT HAVE BEEN CLOSED OF FORBITTEN TO THE ACCES OF UNAUTHORIZED PERSONS.

WORK SAFE IN EVERY TIME!

WORKER'S SIGNATURE

WITH THE SIGNATURE THE WORKER DECLARES THAT RECEIVED THE WORKING INSTRUCTION ABOUT RISKS RELATED TO THIS SPECIFIC WORKING ACTIVITY

LOCK OUT PROCEDURE

NAME AND SURNAME OF THE WORKER ROLE SIGNATURENAME AND SURNAME OF THE

SUPERVISORSIGNATURE

GENERAL INSTRUCTIONS AND RULES

SCREW DRIVER / MANUAL TOOL

MACHINES / TOOLS / PROCEDURE REQESTED TRAINING/ AUTHORIZATIONS / PERMITS NEEDED CHEMICAL SUBSTANCES TO BE USED

TYPE OF MACHINE/ TOOL TYPE OF PERMIT / AUTHORIZATION SUSTANCE NEEDED FOR OPERATION Nr.

LIFTING PLATFORMTRAINING / AUTHORIZATION FOR ELECTRICAL

WORKS

WELDERTRAINING / AUTHORIZATION FOR DRIVING

FORKLIFTS

SCAFFOLDING PERMIT FOR WELIDING / CUTTING

PPE TYPE TIPO DI D.P.I.: TIPO DI D.P.I.:

HEARING PROTECTION GLASSES SLEEVES

CUT RESISTANT GLOVES GLOVES FOR HEAT GLOVES FOR CHEMICAL SUBSTANCES

HIGH VISIBILITY VESTS FINGER PROTECTION SAFETY HEARNESS

NON CONDUCTIVE CLOTHES SAFETY CLOTHES SAFETY MASK

MECHANICAL PROTECTION GLOVES SAFETY SHOES RUBBER BOOTS

HELMET ANTIFOG GLASSES SAFETY VISOR

PPE REQUESTED

RISK= PROBABILITY*GRAVITY

ALL THE RISKS MUST BE MAGED BEFORE TO START THE ACTIVITY

HAZARD IDENTIFIED COUNTERMEASURE COUNTERMEASURE DESCRIPTIONRESP. OF CHECKING THE

EFFECTIVENESSSKTECHES

R G = 1 G = 2 G = 3 G = 4

P = 1 1 2 3 4

P = 2 2 4 6 8

P = 3 3 6 9 12

P=4 4 8 12 16

R G = 1 G = 2 G = 3 G = 4

P = 1 1 2 3 4

P = 2 2 4 6 8

P = 3 3 6 9 12

P=4 4 8 12 16

R G = 1 G = 2 G = 3 G = 4

P = 1 1 2 3 4

P = 2 2 4 6 8

P = 3 3 6 9 12

P=4 4 8 12 16

R G = 1 G = 2 G = 3 G = 4

P = 1 1 2 3 4

P = 2 2 4 6 8

P = 3 3 6 9 12

P=4 4 8 12 16

R G = 1 G = 2 G = 3 G = 4

P = 1 1 2 3 4

P = 2 2 4 6 8

P = 3 3 6 9 12

P=4 4 8 12 16

R G = 1 G = 2 G = 3 G = 4

P = 1 1 2 3 4

P = 2 2 4 6 8

P = 3 3 6 9 12

P=4 4 8 12 16

R G = 1 G = 2 G = 3 G = 4

P = 1 1 2 3 4

P = 2 2 4 6 8

P = 3 3 6 9 12

P=4 4 8 12 16

R G = 1 G = 2 G = 3 G = 4

P = 1 1 2 3 4

P = 2 2 4 6 8

P = 3 3 6 9 12

P=4 4 8 12 16

PROBABILITY DESCRIPTION GRAVITY DESCRIPTION

P = 1

Very Low Probability to

Occur: There are not

previous cases

S = 1 Slight: potential result first aid

P = 2

Lower Probability to Occur:

Exist in the past previous

cases very rare

S = 2Medium: potential result injury

>1 day & <3 days

P = 3Probable to Occur: Exist in

the past previous cases S = 3

Serious: potential result injury

>3 days & < 30 days

P = 4Highly Probably to Occur:

Previous cases are frequent S =4

Very serious: potential result

injury >30 days, or Fatal, or

Occupational illness

LEGENDA

Risk Level G=1 G=2 G=3 G=4

P=1 1 2 3 4

P=2 2 4 6 8

P=3 3 6 9 12

P=4 4 8 12 16

Countermeasures

Very high

risk

Not

acceptable

The risk is not acceptable and must strongly attached . Is

needed to implement immediate countermeasures in

order to reduce the level of the risk at least to a tolerable

level.

High risk Improvable

The risk is not acceptable and must be improvable. Is

needed to implement rapid countermeasures in order to

reduce the level of the risk at least to a tolerable level.

Medium risk Tolerable

The risk is tolerable. Is needed to evaluate possible

countermeasures in order to reduce the level of the risk

to an acceptable level. Continuous improvement

approach is required.

Low risk AcceptableThe risk is acceptable. Continuous monitoring about

safety conditions is required.

Risk level

Risk Level

R=P x SRange

RR= 1 - 2

R R= 3 - 4

R R= 6 - 9

R R= 12 - 16

RISK LEVEL

RISK ASSESSMENT CRITERIA

Risks ASSESSMENT (R=PxG)

COUTERMEASURES DEFINITION

SUPERVISORs / PERSONS IN CHARGE TO ENSURE THE APPLICATION OF THE COUNTERMEASURES

PPE REQUESTED PER TASK

EQUIPMENTS/ PROCEDURES REQUESTED PER TASK

TRAINING/ AUTHORIZATIONS / PERMITS PER TASK

CHEMICALS REQUESTED PER TASK

SAFETY RULES

AND

SIGNATURES

TOOL

Non Routine Activities





Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X



INSTALLATION


1

Machine component

IMPACT / PILLAR


Project Information



2


CHECK FUNCTIONAL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)

Suzuki YV7 HL


MFE/Zamzam



Plant Unit Pillar

SAF

EEM

Lock out station SOP

EXPANSION

Model Area

We trained our workers how to use the

lock out and tag out. We created the

LOTO Board

Non Routine Work – LOTO Procedure




Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X



INSTALLATION


1

Machine component

IMPACT / PILLAR


Project Information



2


CHECK FUNCTIONAL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)

Suzuki YV7 HL


MFE/Zamzam



Plant Unit Pillar

SAF

EEM

G=1 G=2 G=3 G=4

Risk Level

Slight:

potential

result first

aid

Medium:

potential

result

injury >1

day & <3

days

Serious:

potential

result injury

>3 days & <

30 days

Very

serious:

potential

result injury

>30 days

P=1

Very Low

Probability

to Occur1 2 3 4

P=2

Lower

Probability

to Occur2 4 6 8

P=3Probable to

Occur 3 6 9 12

P=4

Highly

Probably to

Occur4 8 12 16

G=1 G=2 G=3 G=4

Risk Level

Slight:

potential

result first

aid

Medium:

potential

result

injury >1

day & <3

days

Serious:

potential

result injury

>3 days & <

30 days

Very

serious:

potential

result injury

>30 days

P=1

Very Low

Probability

to Occur1 2 3 4

P=2

Lower

Probability

to Occur2 4 6 8

P=3Probable to

Occur 3 6 9 12

P=4

Highly

Probably to

Occur4 8 12 16

RISK ASSESSMENT: NUMERICAL EVALUATION


EXPANSION

Maintenance


Risk Analysis Maintenance

(Non-Routine)

9

Set up life line for person who work on the Hoist Crossbeam

3

When Maintenance Person walk on the Hoist crossbeam, there was not Life line for them to attach safety belt.




Routine Procedure Non - Routine

Procedure


Safety Standards Documents

TPM (Model Area)





Non Routine Activities: Plant Results

LIST OF NON ROUTINE

ACTIVITIES (PM +AM+SAF) 268 SMP

11 SAF

Procedures

1. Working at height 2. Handling Chemical 3. Welding Work External 4. Pressure vessel 5. Crane Handling 6. Electrical Appliance 7. Traffic Control 8. Fire Fighting Equipment 9.Personal Protect Equipment 10.Safety Devices 11.Chemical Labelling

268 STANDARDIZED ACTIVITIES

11 Non-routine work Procedures

SAF

PM

AM




Contractors Management

Contract

Safety Procedures

Safety Meeting

Legal Requirements

Risk Analysis

Training

Audit / Inspection

Activities follow up

Monthly follow up meeting

Safety Information

Process review

Contractors Management






EHS Contractor

Compliance Form

Type of hazard

PPE requirement

Job safety analysis

in sequence

Environmental

aspect

Contractor Job

Safety

Analysis

Training course outline:

1. Legal requirement on

EHS

2. ALMA EHS requirement

3. Communication process

4. Emergency contact

5. Risk assessment on site

Pre-assessment Site Assessment

Zero

Accidents

Risk Analysis Process for

Contractors

SAF

ENV

Construction map at Security

Room



© Copyright by Automotive Lighting UA & UC Condition Root Causes Countermeasures


Audit Frequency/Number of UA & UC

Step 4

Contractors Audit

*Data updated to March 2016 All

findings

Closed




Visual Safety Standards Examples


Employee

Safety

Machinery

Safety

Fire

Protection

System

Employee

Communication

Center

FIRE PANNEL

FIRE HOSE

PPE CHECKS

SAFETY TRAINING ROOM

PPE SIGNAGE & DETAILS

WALK WAYS

WALK WAYS

MACHINE SAFETY

EVACUATION PLANS SAFETY

MIRRORS

MACHINE FENCING

SAFETY

BLIND SPOT




Visual Safety Standards Examples


Employee

Safety

Fire

Protection

System

Employee

Communication Center

SAFETY FENCING

SAFETY POSTER

SAFETY BOARD

EMERGENCY POINT

SAFETY SHOE

SAFETY VEST

SAFETY HELMET

FIRE EXTINGUISHER

ERT EQUIPMENT

PPE FOR CRANE OPERATOR

DOJO ROOM




Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X



Plant Unit Pillar MFE/Zamzam


Suzuki YV7 HL

12B AllHousing Assy , Headlamp Assy.&

Function TestingHeadlamp Assy.

MACHINE


STATUS

PLANNING


MANTENANCE (P.M)

After - Easy excess o trouble shoot problem.

CHECK FUNCTIONAL





2

1

Machine component

IMPACT / PILLAR


Project Information Status update

REVIEW RESP. OBJECT

INSTALLATION


HOUSING ASSY. STATION GLUING STATION

GLUING STATION


Safety MP info Model Area (TPM)

Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X



INSTALLATION


1

Machine component

IMPACT / PILLAR


Project Information



2


CHECK FUNCTIONAL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)

Suzuki YV7 HL


MFE/Zamzam



Plant Unit Pillar

Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X



INSTALLATION


1

Machine component

IMPACT / PILLAR


Project Information



2

After - Avoid danger to operator

CHECK FUNCTIONAL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)

Suzuki YV7 HL

12B All

Housing Assy. Headlamp Assy.

G;luing & Lens Pressing, Light

Test & Leak Test

Headlamp Assy.

MFE/Zamzam



Plant Unit Pillar

Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X





Suzuki YV7 HL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)


CHECK FUNCTIONAL





2

1

Machine component

IMPACT / PILLAR



REVIEW RESP. OBJECT

INSTALLATION



GLUING STATION

Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X



INSTALLATION


1

Machine component

IMPACT / PILLAR


Project Information



2


CHECK FUNCTIONAL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)

Suzuki YV7 HL


MFE/Zamzam



Plant Unit Pillar

Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X



INSTALLATION


1

Machine component

IMPACT / PILLAR


Project Information



2


CHECK FUNCTIONAL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)

Suzuki YV7 HL


MFE/Zamzam



Plant Unit Pillar

Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X



INSTALLATION


1

Machine component

IMPACT / PILLAR


Project Information



2


CHECK FUNCTIONAL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)

Suzuki YV7 HL

12B All



Test & Leak Test

Headlamp Assy.

MFE/Zamzam



Plant Unit Pillar

Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X





Suzuki YV7 HL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)


CHECK FUNCTIONAL





2

1

Machine component

IMPACT / PILLAR



REVIEW RESP. OBJECT

INSTALLATION



GLUING STATION

Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X



INSTALLATION


1

Machine component

IMPACT / PILLAR


Project Information



2


CHECK FUNCTIONAL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)

Suzuki YV7 HL


MFE/Zamzam



Plant Unit Pillar

Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X



INSTALLATION


1

Machine component

IMPACT / PILLAR


Project Information



2


CHECK FUNCTIONAL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)

Suzuki YV7 HL


MFE/Zamzam



Plant Unit Pillar

Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X



INSTALLATION


1

Machine component

IMPACT / PILLAR


Project Information



2


CHECK FUNCTIONAL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)

Suzuki YV7 HL

12B All



Test & Leak Test

Headlamp Assy.

MFE/Zamzam



Plant Unit Pillar

Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X





Suzuki YV7 HL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)


CHECK FUNCTIONAL





2

1

Machine component

IMPACT / PILLAR



REVIEW RESP. OBJECT

INSTALLATION



GLUING STATION

Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X



INSTALLATION


1

Machine component

IMPACT / PILLAR


Project Information



2


CHECK FUNCTIONAL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)

Suzuki YV7 HL


MFE/Zamzam



Plant Unit Pillar

Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X



INSTALLATION


1

Machine component

IMPACT / PILLAR


Project Information



2


CHECK FUNCTIONAL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)

Suzuki YV7 HL


MFE/Zamzam



Plant Unit Pillar

14 SAFETY MP INFO ALREADY CREATED

SAF

EEM




POKA-YOKE SAFETY

The mistake-proofing philosophy recognizes that people sometimes

forget and make errors. The approach uses common-sense ideas and

methods in both process and product to eliminate human and mechanical

errors.

• Great efforts have been made in applying these concepts

to Safety and accident prevention.

Curtain Sensor

Two hand Start Push Button Two hand Start Push Button


23 POKA-

YOKE

SAF

EEM





BEST PRACTICES




Lock-out & Tag-out Work Flow


Maintenance people check the energy points according to machine lock-out sop

Take lock and tag go to machine

Implement lock-out and tag-out

Start the maintenance

Remove the lock and tag from the machine .

Breakdown

Operator deliver order to

maintenance

Preventive Maintenance

Lock out station &Tag Maintenance Lock out SOP




KAI Formula Reporting

Frequency

Implemented standard N° of OPL Monthly

Implemented standard N° of SOP Monthly

KAI

Step 3 – TPM (Model Area)


0

20

40

60

80

100

120

140

160

180

200

2008 2009 2010 2011 2012 2013 2014 2015 Mar-160

2

4

6

8

10

12

14

16

2008 2009 2010 2011 2012 2013 2014 2015 Mar-16

OPL Cumulative SOP Cumulative




TPM (Model Area)

Heinrich’s Pyramid

Fatality

LTI > 30 days

LTI < 30 days

First Aids

Near Misses

Unsafe Conditions

Unsafe Acts

2008 2009

0 0

0 0

3 0

3 0

4 9

9 78

18 56

Step 0 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 0 Step 1 Step 2 Step 3 Step 4 Step 6




Expansion Area


Fatality

LTI > 30 days

LTI < 30 days

First Aids

Near Misses

Unsafe Conditions

Unsafe Acts

2009 2010

0 0

0 0

0 0

1 0

1 1

6 26

58 150


BMC




Expansion Area


Fatality

LTI > 30 days

LTI < 30 days

First Aids

Near Misses

Unsafe Conditions

Unsafe Acts

2010 2011 2012

0 0 0

0 0 0

0 0 0

2 3 0

3 4 4

5 4 0

96 243 365


AO




Plant Wide



2011 2012 2013 2014 2015

0 0 0 0 0

0 0 0 1 0

0 0 0 0 0

5 3 0 1 0

9 13 8 3 3

58 45 168 295 208

1362 1410 132 342 346

Transferring


Feb ’16

Mar ‘16

0 0 0

0 0 0

0

0

0

0 0 0

0 0 0

26 16 25

47 24 44

Fatality

LTI > 30 days

LTI < 30 days

First Aids

Near Misses

Unsafe Conditions

Unsafe Acts




Expansion Area


Fatality

LTI > 30 days

LTI < 30 days

First Aids

Near Misses

Unsafe Conditions

Unsafe Acts

2013 Jan ‘14

0 0

0 1

0 0

0 0

3 0

23 11

31 5


WAREHOUSE




While

transferring PES

unit into bins the

operator have

pain at back


Effectiveness Check Horizontal Expansion

Step 3

We have no similar accidents

INJURY

EXPANSION

Analysis of Incident

Countermeasures Train all the operator to inform his

history of medical problem (related to

work) to their superior or to nurse at

sick bay. And retrain the method of

lifting of heavy bins. Problem

Fatality

LTI > 30 days

LTI < 30 days

First Aids

Back pain

Phenomena

Root Cause: Never tell his history of medical problem (related to work) to the superior. Unsafe Act: Physical deficiency / instability




81 TOTAL

Rating

B M A B (low) M (medium) A (high)

3.01Safety-critical aspects are discussed periodically by the

production committee8 3 5 8 Sometimes Often Always

3.02An action plan exists and responsibilities and dates of

completion of the activities have been assigned5 3 5 5 Sometimes Often Always

3.03 This plan is shared with the resources involved 5 1 3 5 Sometimes Often Always

3.04 Safety tags are used 5 1 3 5Have been formalized but not

deployed

Have been formalized and

deployed

Are used regularly in the pilot

area

3.05 A safety tags management plan has been drafted 5 1 3 5Have been formalized but not

deployed


deployed


area

3.06 5S activities have been mainteined 5 1 3 5 No Partially Yes

3.07Kaizen, OPL, SOP have been implemented to improve

safety in workplace5 1 3 5 Sometimes Often Always

3.08 A workplace risk assessment exists. 8 3 5 8 In some workstation In many workstation In all workstation

3.09

Documentation for risk assessment are updated

periodically after modifications to work cycles,

replacement of chemical products, equipment,

5 3 5 8 Sometimes Often Always

3.10Supervisors know the assessment of risks regarding

their area of responsibility.5 3 5 8 Some Many All

3.11 People heve been trained about area risks 3 1 3 8 Some Many All

3.12 One point lessons on safety exist 3 1 3 5Have been formalized but not

deployed


deployed


area

3.13 SOP for safety critical operations have been created 3 1 3 5 Yes some examples Yes, many examples Everywhere

3.14 Visual control of safety-critical aspects in the area exists 1 1 3 5 Yes some examples Yes, many examples Everywhere

3.15Machine and process specific Lock-out/ tag-out sheets

exist.5 1 3 5

Have been formalized but not

deployed


deployed


area

3.16PPE Visual Management are displayed at workstation

level.5 1 3 5 Sometimes Often Always

3.17 Pedestrian Walkways have been clearly idenfied. 5 1 3 5 No Partially Yes

Rating criteria

WCMSAFETY

PILLAR AUDIT CHECK-LIST STEP 3

CHECKS

PLANT

DATE 09-Mar-15

List of all the

problems

Standard Visual

Management

Risks

Assessment

REMARKSSCORE

Restore basic

condition

TOPIC No.

AREA TPM & BMC

INTERNAL AUDITORS GUNA, ZAMANI & TAN

AUDIT CHECK-LIST RATING STANDARDS

85 TOTAL

Rating








deployed


deployed


area


deployed


deployed


area





3.09









deployed


deployed


area




exist.5 1 3 5


deployed


deployed


area




Rating criteria

WCMSAFETY


CHECKS

PLANT

DATE 09-Mar-15

List of all the

problems

Standard Visual

Management

Risks

Assessment

REMARKSSCORE

Restore basic

condition

TOPIC No.

AREA TPM & BMC



93 TOTAL

Rating








deployed


deployed


area


deployed


deployed


area





3.09









deployed


deployed


area




exist.5 1 3 5


deployed


deployed


area




Rating criteria

WCMSAFETY


CHECKS

PLANT

DATE 09-Mar-15

List of all the

problems

Standard Visual

Management

Risks

Assessment

REMARKSSCORE

Restore basic

condition

TOPIC No.

AREA TPM & BMC




Target

Steps Audit Results

Achieved 93% proceed to

Step 4




EHS Training

Analysis of NM, UA & UC(S-EWO + S-TWTTP)

General inspection for safety

KPI step 1-4

Step 4





Analysis of Near Miss, UC & UA

Unsafe Condition

Near miss

First Aid

LTI >30 days

LTI ≤ 30 days

Unsafe Acts

Line walk by snapshot, audit or incident

reported

Investigation using S-EWO + S-TWTTP (UA)

Implement countermeasures

Report to EHS database action plan

Effectiveness check

Horizontal expansion

Standardization

P

D

D

C

A

A

EHS Database

Fatality

P

Countermeasures

Effectiveness check for

non recurrence Horizontal Expansion

Detection

“0” event

OK




Audit System


Daily Employee

Checklist

Daily Team

Leader Checklist

*Plant Manager

*Departmental Manager

*Safety & Health Committee

*Supervisor

*Plant Manager,


* Supervisor

Weekly SMAT

audit

Monthly EHS audit

SMAT Operator

Daily 6’S

SMAT

SCHEDULE

*Team Leader

*Operator

*Safety Captain

Daily Safety

Observation




Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X



INSTALLATION


1

Machine component

IMPACT / PILLAR


Project Information



2


CHECK FUNCTIONAL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)

Suzuki YV7 HL


MFE/Zamzam



Plant Unit Pillar

SAF

EEM

Update the risk assessment

EXPANSION

NEAR MISSES


Countermeasures


SMAT Near Misses Detection & Countermeasures

Technician

almost fall due

to imbalance

step.

Effectiveness Check for non recurrence

KAIZEN Near Misses

Unsafe Conditions

Unsafe Acts

Weld Back & Change the new stand for safe

Problem

Almost fall from

platform

Phenomena Hazard:

Fall on

Root Cause: No Support stand on the platform

Unsafe Condition:

Weakness Design




Num rev

Resp.

DATA

Product

BUSINESS LINE

X

X



INSTALLATION


1

Machine component

IMPACT / PILLAR


Project Information



2


CHECK FUNCTIONAL



MACHINE


STATUS

PLANNING


MANTENANCE (P.M)

Suzuki YV7 HL


MFE/Zamzam



Plant Unit Pillar

SAF

EEM

Update the risk assessment

Aug 10 Sep 10 Oct 10 Nov 10


Countermeasures

Horizontal Expansion Effectiveness Check for non recurrence

Grinding safety glass

already broke due to

lose holder

EXPANSION UC

Near Misses

Unsafe Conditions

Unsafe Acts

SMAT UC Detection & Countermeasures

KAIZEN To fabricate special holder with permanent rivet to hold the cover Detection: Unsafe

Condition

Hazard:

Fluid, dust,

substances

projection Root Cause:

Lose glass holder Unsafe

Condition: Tools

Equipment -Weakness

design




Update the risk prediction


Countermeasures



SMAT UA Detection & Countermeasures

Operator left

the pallet jack

at the walkway

EXPANSION

UA

Near Misses Unsafe Conditions

Unsafe Acts

Detection : Unsafe

Act

Disciplinary action

Root Cause: Operator not

following safety rules Unsafe Act: Attitude/ Behaviour

- Negligence




EHS Audit


Chemical Safety

Machinery

Electrical Safety

Fire Safety

6’

FINDING

S-EWO

ROOT CAUSE ANALISYS Unsafe

Act Unsafe

Condition

No repetitive events reported

S-EWO&S-TWTTP

IMPLEMENT COUNTERMEASURE

EXPANSION

PLANT WIDE

Model Area




EHS Training Process


Training effectiveness evaluation

People development plan by Departmental Head & HR

EHS established TNA

• Risk Prediction Assessment Advanced

• Hazard Communication

• Workplace Inspection

• Hazard Identification, Risk Assessment & Control

Intermediate

• Understanding S-EWO

• Accident Prevention

• Emergency Preparedness

• Machinery Safety

Preliminary

White

Collar

Blue

Collar

SAF

PD

EHS TRAINING RECORD / DATA

2015 JAN – MAR 2016

Cat. #

Courses # Part.

Total

Hours

#

Courses

#

Part.

Total

Hours

Adv. 6 22 148 1 1 40

Inter. 9 312 928 2 42 42

Prelim. 11 332 822.5 2 39 54

Total 26 666 1898.5 5 82 136




EHS SPECIFIC TRAINING

Training for Specific Tasks

FIRE FIGHTING &

FIRST AID TRAINING

EMERGENCY RESPONSE

TEAM MEMBERS


SAF

PD




Safety Poster Competition


1st Place

2nd Place

3rd Place




Month Subject

Jan Safety Leadership

Feb Stress Management

Mar Fire Safety

Apr Food Safety

May Road Safety

Jun Electrical Safety

Jul Obesity

Aug Hearing Conservation

Sep Healthy Diet Healthy Living

Oct Accident Prevention

Nov Workplace Safety – PPE

Dec 5S

#/Month Training Hours/ Month

EHS Theme

54 1.2


EHS Training Process

SAF

PD




05

1015202530354045505560

Jan

13

Fe

b 1

3

Ma

r 1

3

Ap

r 13

Ma

y 1

3

Ju

n 13

Ju

ly

13

Au

g 1

3

Se

pt

13

Oc

t

13

No

v 13

Dec

13

Jan

14

Fe

b 1

4

Ma

r 1

4

Ap

r 14

Ma

y 1

4

Ju

n 1

4

Ju

ly

14

Au

g 1

4

Se

pt

14

Oc

t

14

No

v 14

Dec

14

Jan

15

Fe

b-1

5

Ma

r '1

5

Ap

r '1

5

Ma

y '1

5

Ju

n '1

5

Ju

l '1

5

Au

g '1

5

Se

p '1

5

Oc

t '1

5

No

v '1

5

Dec

'1

5

Jan

'1

6

Fe

b'1

6

Ma

r '1

6

Smart Audit Result

UC UA SAFE ACT SMAT


Frequency

SMAT AUDIT N° of Smat Audit Weekly

UC N° of UC Monthly

UA N° of UA Monthly

Audit Results TPM (Model Area)


UA:↓85%

Safe Act:↑85 %




TPM (Model Area) Heinrich’s Pyramid

Fatality

LTI > 30 days

LTI < 30 days

First Aids

Near Misses

Unsafe Conditions

Unsafe Acts

20

08

20

09

20

10

20

11

20

12

20

13

20

14

20

15

Jan

‘16

Feb

‘16

Mar ‘16

0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0

3 0 0 0 0 0 0 0 0 0 0

3 0 0 0 0 0 0 0 0 0 0

4 9 3 1 3 2 0 0 0 0 0

9 78 33 51 45 38 13 9 0 0 0

18 56 260 182 209 65 37 24 0 0 0





20

09

20

10

20

11

20

12

20

13

20

14

20

15

Jan

’16

Feb

‘16

Mar ‘16

0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0

1 0 2 3 0 0 0 0 0 0

1 1 1 2 0 0 0 0 0 0

6 26 2 0 23 34 35 0 0 0

58 150 231 132 45 45 46 3 2 0

BMC

Fatality

LTI > 30 days

LTI < 30 days

First Aids

Near Misses

Unsafe Conditions

Unsafe Acts


Expansion Area Heinrich’s Pyramid




AO

Fatality

LTI > 30 days

LTI < 30 days

First Aids

Near Misses

Unsafe Conditions

Unsafe Acts

20

10

20

11

20

12

20

13

20

14

20

15

Jan

‘16

Feb

‘16

Mar ‘16

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

2 3 0 0 1 0 0 0 0

3 4 4 2 0 0 0 0 0

5 4 0 58 12 31 1 2 1

96 243 365 24 22 53 9 4 3








2011 2012 2013 2014 2015

0 0 0 0 0

0 0 0 1 0

0 0 0 0 0

5 3 0 1 0

9 13 8 3 3

58 45 168 295 208

1362 1410 132 342 346

Transferring


Feb ’16

Mar ‘16

0 0 0

0 0 0

0

0

0

0 0 0

0 0 0

26 16 25

47 24 44

Fatality

LTI > 30 days

LTI < 30 days

First Aids

Near Misses

Unsafe Conditions

Unsafe Acts




We consider our Step 4 consolidated

because:

1. The Plan of SMAT Activities is respected 100%

2. Appropriate countermeasures are correctly expanded after being verified

3. The number of Unsafe Acts has decreased significantly

and the number of SAFE Acts has increased

4. People react in a positive way to SMAT interviews

5. When people feel that safety culture has been rooted in their work area





70 TOTAL

Rating


4.01A Safety Audit System has been defined (people

involved, frequancy, tool…)5 1 3 5 Drafted Defined

Defined, shared, managed

and updated

4.02 An audit schedule has been developped. 5 1 3 5 Drafted DefinedDefined, shared, managed

and updated

4.04 Specialists perform audit (checklist). 8 3 5 8 No Sometimes As scheduled

4.05 Supervisors perform audit (checklist). 5 3 5 8 No Sometimes As scheduled

4.06The critical issues identified have been analyzed and the

solutions planned have been inserted in the action plan.8 3 5 8 No Sometimes Yes

4.07The critical issues identified have been reported in

Heinrich Pyramid.5 1 3 5 No Sometimes Yes

4.08 For corrective measures, a follow up system exsist 8 3 5 8 Drafted DefinedDefined, shared, managed

and updated

4.09The corrective measures adopted in the area are

extended to areas with the same type of risk.5 1 3 5 Drafted Defined


and updated

4.10Awareness campaigns have been launched to resolve

the critical aspects highlighted in the action plan.3 3 5 8 Defined and shared Drafted shared and deployed

Defined, shared, issued and

learning has been checked

4.11 Specific training paths have been initiated for managers. 3 3 5 8 Defined and shared Drafted shared and deployedDefined, shared, issued and


4.12Specific training paths have been initiated for

supervisors.5 3 5 8 Defined and shared Drafted shared and deployed



4.13Specific training paths have been initiated for team

leader/operators.5 3 5 8 Defined and shared Drafted shared and deployed



Activity Board 4.14

The improvements generated by corrective actions

(number of accidents, near misses, etc.) are monitored

periodically in the Activity board.

5 3 5 8 Drafted Present Present and updated

Safety

Meeting4.15

Safety meeting are regularly done involving all the

workers5 3 5 8 No Sometimes Yes

TOPIC

WCMSAFETY

PILLARAUDIT CHECK-LIST STEP 4

PLANT

AREA

GUNA, ZAMANI & TAN

DATE 09-Mar-15

SCORE

TPM & BMC

INTERNAL AUDITORS

REMARKS

General

Inspection

Personnel

training

RATING STANDARDS

Rating criteriaNo. CHECKS

AUDIT CHECK-LIST

83 TOTAL

Rating





and updated


and updated








and updated




and updated















Activity Board 4.14





Safety

Meeting4.15



TOPIC

WCMSAFETY


PLANT

AREA

GUNA, ZAMANI & TAN

DATE 09-Mar-15

SCORE

TPM & BMC

INTERNAL AUDITORS

REMARKS

General

Inspection

Personnel

training

RATING STANDARDS


AUDIT CHECK-LIST

95 TOTAL

Rating





and updated


and updated








and updated




and updated















Activity Board 4.14





Safety

Meeting4.15



TOPIC

WCMSAFETY


PLANT

AREA

GUNA, ZAMANI & TAN

DATE 09-Mar-15

SCORE

TPM & BMC

INTERNAL AUDITORS

REMARKS

General

Inspection

Personnel

training

RATING STANDARDS


AUDIT CHECK-LIST

Target


Steps Audit Results

Achieved 95% proceed to

Step 5




Autonomous inspection for safety

Safety Observation Card

Step 5




Audit System

Daily Operator

Checklist

Daily Team

Leader Checklist

*Plant Manager


*Safety & Health Committee

*Supervisor

*Plant Manager,


* Supervisor

Weekly SMAT

audit

Monthly EHS audit

SMAT Operator

Daily 6’S

SMAT

SCHEDULE

*Team Leader

*Operator

*Safety Captain


Daily Safety

Observation




SMAT by Operator



FINDING


Act

S-EWO&S-TWTTP

Unsafe Condition

S-EWO

Tools and equipments

Personal Protective Equipment

Fire Safety

6’

Electrical Safety


EXPANSION

Model Area




Performed

before starting

work

PPE’s state

Order and

cleanliness

Safety devices

working

Testing other

possible unsafe

conditions

CHECK

Performed

before starting

work

Verify Operator

checklist

complete

Safety devices

working

Check for any

deficiencies

CHECK

Report

Deficiencies

Fix

Deficiencies

Daily Checklist




Daily Operator Checklist


Machinery


Fire Safety

6’

Electrical Safety IMPLEMENT COUNTERMEASURE

FINDING

ROOT CAUSE ANALISYS

Unsafe Condition S-EWO


EXPANSION

Model Area




Daily Team Leader Checklist


Machinery


Fire Safety

6’

Electrical Safety

FINDING

S-EWO


Act Unsafe

Condition


S-EWO&S-TWTTP


EXPANSION

Model Area




0.0%

10.0%

20.0%

30.0%

40.0%

50.0%

Coaching Visual Aid Training/OPL Kaizen/ImprovementActivities

Countermeasure against UA


Audit Results TPM (Model Area)

0.0%

10.0%

20.0%

30.0%

40.0%

50.0%

Instruction Maintenance Kaizen/ImprovementActivities

Countermeasures against UC




Autonomous Safety – Safety Captain

Safety Captain Training

A captain trains workers UC / UA

SMAT with other operator

Main Aim of

SAFETY CAPTAIN:

To be an example and

support for the spread of

safety culture among

workers.


Safety Observation Board

Safety Captain Duty

Safety Observation Card

Training of Operators by the

safety captain




SAF Captain -Example

RISK : Unsafe Act


EXPANSION

PLANT WIDE

Model Area


COUNTERMEASURE APPLICATION



Immediate Briefing and training given by

Safety Captain to operators on using

PPE

Operator not using PPE

(mask, goggles & earplug)

when doing blowing activity

Root Cause: Not follow safety

procedure Unsafe Act:

Attention/negligence





Frequency

Safety Observation N° of Safety Observation Monthly

UC N° of UC Monthly

UA N° of UA Monthly

Safe Act N° of Safe Act Monthly


Safety Observation TPM (Model Area)




20

08

20

09

20

10

20

11

20

12

20

13

20

14

20

15

Jan

‘16

Feb

‘16

Mar ‘16

0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0

3 0 0 0 0 0 0 0 0 0 0

3 0 0 0 0 0 0 0 0 0 0

4 9 3 1 3 2 0 0 0 0 0

9 78 33 51 45 38 13 9 0 0 0

18 56 260 182 209 65 37 24 0 0 0

TPM (Model Area) Heinrich’s Pyramid

Fatality

LTI > 30 days

LTI < 30 days

First Aids

Near Misses

Unsafe Conditions

Unsafe Acts

Step 7 Step 6 Step 5 Step 4 Step 3 Step 2 Step 1 Step 0 Step 5




20

09

20

10

20

11

20

12

20

13

20

14

20

15

Jan

’16

Feb

‘16

Mar ‘16

0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0

1 0 2 3 0 0 0 0 0 0

1 1 1 2 0 0 0 0 0 0

6 26 2 0 23 34 35 0 0 0

58 150 231 132 45 45 46 3 2 0

BMC

Fatality

LTI > 30 days

LTI < 30 days

First Aids

Near Misses

Unsafe Conditions

Unsafe Acts








2011 2012 2013 2014 2015

0 0 0 0 0

0 0 0 1 0

0 0 0 0 0

5 3 0 1 0

9 13 8 3 3

58 45 168 295 208

1362 1410 132 342 346

Transferring


Feb ’16

Mar ‘16

0 0 0

0 0 0

0

0

0

0 0 0

0 0 0

26 16 25

47 24 44

Fatality

LTI > 30 days

LTI < 30 days

First Aids

Near Misses

Unsafe Conditions

Unsafe Acts




Steps Audit Results

80 TOTAL

Rating


4.01Training on SMAT audit has been performed to people

involved5 1 3 5 Defined and shared Drafted shared and deployed



4.02 Plant manager perform SMAT audit. 8 3 5 8 No Sometimes As scheduled

4.03 Manager perform SMAT audit 8 3 5 8 No Sometimes As scheduled

4.04 Team leader perform audit (checklist) 5 3 5 8 No Sometimes As scheduled

4.05 Workers perform audit (checklist) 5 3 5 8 No Sometimes As scheduled






and updated




and updated

4.10 Workers are involved in Safety Suggestion system 5 3 5 8 No Sometimes Yes

4.11 Workers partecipate to Quick Kaizen or Standard Kaizen 5 3 5 8 No Sometimes Yes

4.12 Workers update activity board 5 3 5 8 No Sometimes Yes

4.13Workers give evidence of Unsafe Condition using safety

tags5 3 5 8 No Sometimes Yes

Activity Board 4.14





PLANT

AREA TPM & BMC


09-Mar-15

WCMSAFETY


DATE

No.

Autonomous

Inspection

Workers

involvment

RATING STANDARDS

Rating criteria

AUDIT CHECK-LIST

CHECKS REMARKSSCORETOPIC

88 TOTAL

Rating















and updated




and updated






Activity Board 4.14





PLANT

AREA TPM & BMC


09-Mar-15

WCMSAFETY


DATE

No.

Autonomous

Inspection

Workers

involvment

RATING STANDARDS

Rating criteria

AUDIT CHECK-LIST


97 TOTAL

Rating















and updated




and updated






Activity Board 4.14





PLANT

AREA TPM & BMC


09-Mar-15

WCMSAFETY


DATE

No.

Autonomous

Inspection

Workers

involvment

RATING STANDARDS

Rating criteria

AUDIT CHECK-LIST


Target


Achieved

97%




Agenda

I. Introduction


– Pillar Team


– KPI/KAI

– Route Map


– 7 Steps Status


– Step 1

– Step 2

– Step 3

– Step 4

– Step 5


IV. Plant Results

– KPI Plant

– SWOT Analysis





Health Initiatives– Flow chart

Management

Consider all the hazards/job activities

(e.g.. Ergonomic, noise, chemicals…）

Annual check-up.Let people know

about their physical condition

EHS Dept. HR Dept.

Occupational health Medical checkup

Health Initiatives

Management





Occupational Health Program

Medical

Surveillance report

Audiometric Test

report

Tested

Chemical Risk Assessment 147

Eye Test 500

Audiometric Test 248

Medical Surveillance 69

Chemical Risk

Assessment report

Eye Test

100 %

Compliance




Occupational Health Program





Health Initiative

Health prevention– SPORT

Futsal





Agenda

I. Introduction


– Pillar Team


– KPI/KAI

– Route Map


– 7 Steps Status


– Step 1

– Step 2

– Step 3

– Step 4

– Step 5


IV. Plant Results

– KPI Plant

– SWOT Analysis




0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2008 2009 2010 2011 2012 2013 2014 2015 2016YTD

MACYears

First Aid Frequency Index

00.10.20.30.40.5

2008 2009 2010 2011 2012 2013 2014 2015 2016YTD

MACYears

Frequency Index0.45

KPI Plant

Start 05/2008

0

0.02

0.04

0.06

0.08

0.1

2008 2009 2010 2011 2012 2013 2014 2015 2016YTDMAC

Years

Gravity IndexStart05/2008

0.06

0.09

0.04

0 0.06 0

0.48

1.67

0.45

0.97

0.59

0

MAR

MAR MAR

Start 05/2008

0

0 0




0

2

4

6

8

10

12

14

2015 Internal Benchmarking

Worst Best

No

of

Accid

en

t

Plant




0

1

2

3

4

5

6

7

2015 External Benchmarking

Worst Best

No

of

Accid

en

t

Plant




THIS PLANT HAS WORKED

806 DAYS

WITHOUT AN ACCIDENT

LAST ACCIDENT: 28-01-2014

Conclusion

MODEL AREA WITHOUT AN

ACCIDENT 2520 DAYS




Projects Training & Benchmark Needs

Implementation of 3D module at safety dojo room

Next 2 Years

67

2017 2018 2015

11°Audit

59 3

71

2016

3

3

2014

2

3

50 56

SAF future plan




Benchmarking plant which safety pillar score 4.

Benchmarking plant which has implement step 7.

Benchmarking and training for risk analysis movement level.

Projects Training & Benchmark Needs Next 2 Years

67

2017 2018 2015

11°Audit

59 3

71

2016

3

3

2014

2

3

50 56

SAF future plan



© Copyright by Automotive Lighting WEAKNESSES STRENGTHS

OPPORTUNITIES THREATS

Top Management(MD) total involvement and

contribution in improving safety

management system.

Managers genuine intention in enhancing

and improve the safety management system.

Safety culture; high involvement and

expansion of team leaders and operators

S-MAT and E-MAT applications

OHSAS certificated more than 7 years

•Collaboration with WCM central

•Involvement of all workers towards

improving safety standards.

•Continuous improvement of working

conditions

•Know-how improvement on safety matters

•Local Authority Audit (DOSH) for safety

improvement

Some contractors are not at the

required level.

New legislation changes.

• SWOT

11th_WCM_ Safety Presentation 2016 updated 070416

Documents

Transcript of 11th_WCM_ Safety Presentation 2016 updated 070416