审核标准.pptx

单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,2019/11/6,#,WORLD CLASS MANUFACTURING,PLANT AUDIT&EVALUATION GUIDE,1,Dr.Hajime Yamashina,Professor Emeritus,Kyoto University,Member of RSA,Member of Royal Swedish Academy of,Engineering Sciences,New Audit Guide,September,2009,2,The score is determined by this level as in,the case where customers see our quality.,Step,6,6,6,10 Technical,Pillars,Step 7,10 Managerial,issues,Final Target,Step,Step 4,4,4,Step 3,Step 2,Step,1,3,Step 5,Step 2,Countermeasures(Listing all,and horizontal,expansion,assessment,Step 6,1.Safety(plant-wide),Step 7,Fully,implemented,safety,management,Management initiated,Self-initiated,4,Analysis of,accidents,(Analysis of,causes),Step 1,Step 3,Setting,tentative,standards for,safety,safety,problems),(Countermeasures Risk,at the similar,areas),Step 4,General,inspection for,safety,(Train and,grow people,in such a,way that they,care for,safety),Step 5,Autonomous,inspection,(Predictive,countermeasur,es against,safety,problems),Reactive,Preventive,Proactive,Autonomous,safety standards,(*Overall,inspection of,safety levels,*Reevaluation if,safety control),Team initiated,Step,Countermeasures,Reactive,1,Accident analysis and countermeasures,Incident analysis and countermeasures,Preventive,2-5,Horizontal expansion of countermeasures,Visual demonstration(simulation,video,etc.)of,accidents to alert people about safety,Compliance with the safety legal regulations,Safety risk assessment*,Management SMAT,Safety audit,Root cause analysis of incidents with special,emphasis on near misses and unsafe acts,Self-initiated safety activities,Proactive,6-7,Team initiated safety activities,System to make people not able to make,mistakes,5,Safety(Reactive),1.5G,6,Heinrich pyramid,6.S-Matrix,7.Management,initiated safety,2.5W+1H,5Why,10.Emergency,plan,3.7 WCM tools,9.Basic safety,standards,4.Knowledge,8.Safety,Step 1,5.The principle of,Safety(Reactive),1.5G,2.5W+1H,5Why,3.7 WCM tools,4.Knowledge of all safety legal requirements and company standards and,compliance analysis,5.The principle of Heinrich pyramid,6.S matrix,7,7.Management initiated safety activities,8.Safety step 1:Accident analysis*,safety RCA of injury incidents and,their countermeasures,9.Basic safety standards for pedestrianization,control of vehicles,work at,height,machinery safety guarding,etc.,10.Emergency plan and facilities for accident,fire,explosion,etcMany,factors,Accident Structure,FR,1,Linear,2,3,Lot of,Accident analysis,Factors,Frequency,Rate,Evolution,Time,8,FR,Frequency,very frequent,Accident analysis,1,Permanent,2,Sporadic,or episodic,3,Exceptional,Activity,Problem,Anticipate,Detection,Specific,habitual,link,with job,Technical,failure,Easy,Connected,secondary,no inhabitual,Organisational,misfit between,activities,Difficult,Not connected,with job,Gap and drift,accumulation,Very difficult,Means of,detection,Check,inspection,Job Analysis,Worst case,Audits,Gap Detection,Time,9,Reactive,Preventive,Proactive,AA,Very high number of,accidents,medical,treatments,first aids,Very high,potential,Very high,risk*,A,High,High,potential,High risk,B,Medium,Medium,potential,Medium risk,C,Low,Low,potential,Low risk,Classification of areas,10,1.Safety,step 2,2.Safety standards,gap analysis,matrix,9.Effective,Safety(Preventive),10.Occupational,health checkup,3.Safety,Responsibility,5.Safety RCA,7.Safety,Step 4,6.Incident trend analysis,11,reporting,4.Safety,Step 3,8.Safety,Step 5,Safety(Preventive),1.Safety step 2:Safety standardization and horizontal expansion,2.Safety standards gap analysis,3.Safety responsibility matrix,safety communication system,green cross,4.Safety step 3:Visual safety standards,PPE,Risk assessment*,5.Safety RCA inclusive of near misses and unsafe acts+TWTTP and,suitable countermeasures,6.Incident trend analysis,12,7.Safety step 4:Periodic safety audits by senior management*,Manage-,ment SMAT,shift manager SMAT,8Safety step 5:Operator SMAT,9.Effective reporting of non-injuries incidents,10.Occupational health checkup and follow up,*Note:Fire risks,earthquakes,thunders,typhoons,hurricanes,mobile,equipment,safety guarding,first aid boxes,noise,irrespirable dust,harmful,dust,explosive atmosphere,mechanical risks(falling from a height,slipping,falling over,stabs,cuts,grazes,particles projections,blows,impacts,crushing,fall of manipulated objects),electrical risks,electromagnetic waves,vibration,ergonomics,illuminations,overloads,material handling,VOC,(volatile organic compounds),CO,O3,hazardous materialschemical,materials,thermal risk(heat,fire,cold),gasses(vapors),radiation(non-ion,ion),asbestos,etc.,13,*Audits and guidance by senior management have an important place in all,WCM activities,including safety.Regular audits keep people and,organizations on their toes and help raise technical standards.Prepare lists,of audit items that relate to safety,health,and pollution;clarify evaluation,standpoints and levels;and establish a system of(at least)every four,months on-site audits by senior managers.This is indispensable for,eliminating accidents.,Safety(Proactive),1.Safety,step 6,2.Safety RCA+10.Employee,satisfaction,3.System to,create motivation,9.Body age,4.Intrinsic safety,design for,equipment,5.Intrinsic safety,design for workshop,14,6.Safety step 7,8.Health advice,7.Health campaign,Safety(Proactive),1.Safety step 6:Team initiated safety activities,2.Safety RCA+TWTTP+human error identification at one of three phases,(perception,judgment and action)and its proper countermeasures,3.System to create motivation to record all kinds of near misses,unsafe condition and acts.,15,4.Intrinsic safety design for equipment and process,5.Intrinsic safety design for workshop and plant,6.Safety step 7:System to make people not able to make mistakes,7.Health campaign,8.Health advice to include well-being programs,9.Checking body age and actual age,10.Employee satisfaction with health and safety,Level 4,Level 5,6.Team initiated safety,*Proactive approach to,safety,7.Fully implemented,2,safety management,Level 6,3,4,5,The seven levels of safety,Level 7,16,Level 1,Level 2,Level 3,1.Setting safety organization,2.Model areas selection,*Safety matrix*Safety EWO to accidents,medications,5.Autonomous safety,4.Further detail root causes analysis,*Safety EWO to near misses,unsafe,conditions and acts,3.Step by step extension,*Model areas:Step 4 zero accidents,zero medications,1,Expansion and development,17,The seven levels of safety,1.Setting safety organization,*Appointed person for safety,*Reports of accidents,medications and countermeasures,*Safety pyramid,*Register and compliance analysis of national safety requirements,2.Model areas selection and creation of know-how to eliminate accidents and,medications,*Safety matrix,*Classification(AA,A,B,C),*Model areas selection,development of Safety step 1 3:zero accidents,*Safety EWO applied to accidents,medications,*Visible safety standards,*Risk assessment,3.Step by step extension,*Management SMAT,*Model area:Safety step 4,Zero accidents,Zero medications,18,*AA Safety step 1 3 :zero accidents,*Formal recorded risk assessments carried out,reviewed and updated,*100%adhered SMAT audit,*Contractor involved,*Occupational health program,4.Further detail root causes analysis,*Safety EWO applied up to near misses,unsafe conditions and unsafe acts,*Safety EWO+TWTTP,5.Autonomous safety,operator SMAT,*Dynamic risk assessments,*Model area :Safety step 5,*AA:Safety step 4,*A,:Safety step 1 3,6.Team initiated safety.Proactive approach to safety,*Further detailed root causes analysis(recognition judgment and action),*No lost time accidents for the last 3 years,*No unsafe conditions,*Health advice available for the last 3 years,*,*,*,*,Model area :Safety step 6,AA:Safety step 5,A :Safety step 4,B :Safety step 1 3,7.Fully implemented safety management,*No lost time accidents for the last 5 years,*Almost no medications,*Almost no unsafe acts,*Employee satisfaction with health and safety,*Model area :Safety step 7,*AA:Safety step 6,*A :Safety step 5,*B :Safety step4,*C :Safety step 1 3,19,Criteria to Evaluate Achievement Level Safety/Hygiene&Working Environment,(1)Safety Evaluation Levels,0.No action There are no activities to improve safety.,1.Reactive There are an appointed person responsible for safety and,an organization including finance.There are reports of accidents(fatal,severe,lost time),medical treatments and first aids with investigation,and countermeasures taken.Safety statistics (S-matrix)information,available.,Register and compliance analysis of legal safety requirements.Site,manager and team are aware of legal and company safety standards.,Plant and equipment visually appears to conform to all legal and,company safety standards.,Machinery safety guarding is visually,compliant with safety standards.,Site meets basic safety standards for pedestrianization,control of,vehicles,work at height,etc.,Emergency plan and facilities in place for accident,fire,explosion,etc.,No substantial reduction of accidents has been achieved yet.,20,Criteria to Evaluate Achievement Level Safety/Hygiene&Working Environment,21,2.Preventive,the model areas The principle of Heinrich pyramid,understood.Safety data collated and analyzed.All injury incidents are,reported,thoroughly investigated up to root causes(lack of knowledge,skills;unsafe tools,equipment;unsafe procedures,system;poor,attitude,behavior;lack of care,attention;personal conditions)and,countermeasures to avoid repeats for the similar injury in the similar,areas are implemented.Professional safety tools are in place and used,(Responsibility matrix,risk assessment,incident trend analysis,managerial SMATs,standards gap analysis),Safety improvement,action plan in place,displayed from the model areas.Housekeeping 5S,in model areas and a good standard elsewhere.Responsibility matrix,with named persons with H+S responsibilities.Management site safety,inspections scheduled and up to date.Risk assessment process in,place and job safety information available.Management SMAT,schedule displayed and up to date.Site safety steering group,established and functional.Evidence is displayed about the safety,communication system within the plant.Register of safety warning,receipt and local action plan.Basic occupational health system in,place(eye sight and hearing regular checks,etc.).,Criteria to Evaluate Achievement Level Safety/Hygiene&Working Environment,22,3.Preventive,all the major areas Safety data from fatal,severe,lost,time,medical treatments,fist aids,near misses and unsafe acts fully,analyzed up to root causes.Safety pyramid of incidents is displayed,regularly updated.Countermeasures prioritized with fully developed,action plan.There are visible safety standards(pillar and workshop,boards active,PPE requirements,etc.)established by safety risk,assessment and preventive counter-measures against accidents in the,past.Effective H+S management system in place.Up to date safety,information boards including green cross,but they are not strictly,followed by all employees.Written local standards and procedures with,full of sketches are available and communicated.Evidence of regular,compliance checks with national safety legislation plus action plan.,Formal recorded risk assessments carried out,reviewed and updated.,Regular access to and assistance of a competent EHS manager.,Regular meetings of health&safety steering group chaired by the plant,manager which sets objectives,assesses progress and identifies,resource requirements.Effective reporting of non-injury incidents data.,Visible SMAT audit schedule displayed and 100%adhered to by the,management.,Criteria to Evaluate Achievement Level Safety/Hygiene&Working EnvironmentManager uses SMAT as reinforcing tool:Root causes of unsafe,behaviors determined by using TWTTP with corrective actions,Evidence of contractor involvement in safety programme,Occupational health programme to include:,Active programme to reduce noise exposure where significant.,Health assessment and job risk assessment for all employees,Evaluation of total site risk level,23,4.Proactive,the model areas Employee participation in all areas is,evidenced by use of check lists,identification and control of hazards,employees involved in SMAT type observations.Autonomous safety,model areas fully active and successful.People are responsible for,their own safety,and take countermeasures autonomously against,safety problems.All near misses and unsafe acts are reported,thoroughly investigated up to root causes and countermeasures are,implemented.Root cause analysis is made up to at what stage,(recognition,judgment and act)unsafe act takes place.,24,Criteria to Evaluate Achievement Level Safety/Hygiene&Working Environment,Shape of safety pyramid is positive.The observation of the the near misses,unsafe conditions and acts are decreasing steadily after the increase of the,number of observations and taking proper countermeasures against them.,Demonstrable involvement of employees at all levels in safety system,development.Assessment of safety leadership by use of employee attitude,questionnaires determine appropriate action plan.Employees in all areas,demonstrate their participation in the safety management programme:,-Shift,daily,weekly safety inspections and check sheets.,-Regular use of dynamic risk assessments.,-Identification of a significant number of unsafe conditions and acts.,-Involvement in the risk assessment process.,-Ownership and contribution to safe working procedures.Employee participation in incident investigations.,-Employee writing of SOPs,Autonomous safety model in place with significant involvement and risk reduction.,-Eliminating or reducing risks where possible,-Workplace and work practice improvements in safety,-Evidence of contribution and involvement of team members,Safety pillar board and workshop boards are maintained to a high standard.,The site has good levels of housekeeping(5S)in all areas.,Criteria to Evaluate Achievement Level Safety/Hygiene&Working Environment,5.Proactive,all the major areas Proactive approach to safety.No Lost Time,Accidents for the last three years.Health advice to include well-being programme,(diet,weight,smoking and stress issues).Fully implemented Safety Management,System.OHSAS 18001 achieved.Safety leadership at all levels is visible and,appreciated by the employees.Employee questionnaires demonstrate continuous,improvement and high levels of employee satisfaction with health and safety.,Autonomous safety is a way of life in the plant.Employees take leadership in,some elements of the safety programme:,25,-Use SMAT skills to change behaviors in the workplace,-Coach and train other employees,-Review SOPs+risk assessments,-Analyze near miss incidents and unsafe acts,All employees are fully informed about relevant health and safety issues.,Demonstrated evidence of continuous risk elimination/reduction.,Contractors and suppliers actively involved in safety improvement programme.,Step 6,2.Cost Deploym