(the slides that accompany this presentation are available in PowerPoint Format)
A technique called "Safety Scanning" is directed towards that problem. It teaches people how to actually incorporate hazard recognition into their daily routines not just during that weekly or monthly safety tour they may participate in. It is much like the way new car drivers are taught. They learn how to scan the roadway and spot potential hazards while operating a car. This is practiced until it becomes a nearly subconscious activity. Similarly the goal of this technique is to have people continually scanning for safety while performing their jobs or even walking to and from their work stations. Most safety hazards are out in the open but are not really seen.
The training starts off with a discussion of the safety scanning technique which includes how to break an area down into small easily managed items to look at. Following the introduction to safety scanning three sets of slides are used in a very interactive session, it is NOT a slide show! The slides show a variety of potential and hazards. To make them more meaningful they are mostly from the same or a similar workplace. The first set of slides demonstrate how safety scanning is done. The next set of slides serve two functions, first to review what some of the more general hazards are, and second to lead the group through many examples to get them to start using the process. This helps develop a mental scanning habit and to train the eyes to continually scan the surroundings. The final set of slides are used for the group themselves to practice the process actively thinking about potential hazards and calling them out. If possible a brief field exercise is done where the group actually does a walk through of a small shop area. The group is then given an assignment sheet to help them work on this actively over the next few days until it becomes instinctive, much like scanning for road hazards while driving a car.
With the field portion the entire session lasts about 2 hours. In the short time for this class it is not possible to teach them about all hazards. The goal is to get them scanning for and recognizing the more common hazards. Additional sessions may be desired to train them further on specific safety rules and hazards.
The more successful OSHA inspectors have developed this ability of continually scanning for safety. How much better could our safety programs be if all our workers did the same !
To obtain further information about "Safety Scanning" contact Eugene Satrun, Mobil Joliet Refinery (815) 423-7739.
At first there may be reluctance to take shots of bad conditions, but if you consider that you are leveraging one persons experience and observations across the organization you can see that the positive benefits are great. Unless people learn from past mistakes of others they may repeat the mistake as part of their own learning process. As we share more information the mistakes made due lack of recognition will decrease.
To demonstrate the process I find it best to prepare a moderately complex series of slides to start with involving many potential hazards. About 15 slides work well for this first set. Show a large area such as a shop. Then use slides showing one section of the area such as a corner or a wall. Next focus in on specific items in that area and work your way around taking photos of each item. The slides do not all have to show bad conditions since the overall goal is to get people thinking. A slide of something that is correct will still get them thinking about the picture and all that could go wrong.
The second series of slides I use are organized by general types of hazards such as guarding, electrical, and PPE. I have about 8 categories that I used in my last presentation (listed under slide description section). One purpose of these slides are to review with the group what a hazard looks like to help them recognize it. Each category may have from 6-12 slides showing a variety of hazards in that category. It must be recognized that in the short amount of time for this class all hazards cannot be shown, so try to get shots of the more serious and more frequently seen ones. Again the objective is to get them to scan their area and to question the hazard potential of each item. Do not overload them with shots of all possible hazards.
The third series of slides are a mix of hazards or potential hazards for the group to actively scan. About 20-30 slides should be used for this. Some slides with less obvious hazards will provide more of a challenge for the group and stimulate more thinking. Most likely over a period of time by having a camera ready you will have shots of many hazards. If not, you could stage some shots but be careful not to create a real hazard.
Following the slide portion a hands on field exercise could be used. Choose an area such as a shop and make arrangements for the group to do a walk through. If there are many in the group they could break up into smaller groups and each group look at a different part of the area. About six in a group seems the right size. The exercise sheet in App. B can be filled out by each group to help them focus on each item and think about the potential hazards.
This is a highly energetic and interactive session, not a slide show. To succeed the participants all must be involved, the more energetic the better. The instructor needs to be very enthusiastic and well prepared, know the slides and material. The session starts off with the instructor doing a short lecture on what safety scanning is all about (overheads can be used) followed by a demonstration of the process with the first set of slides. With the second set of slides the participants are drawn into the process by starting to ask a few questions at first then as they get more familiar with the process ask even more. Remind them to break areas down into small single items. Ask them questions like what do you see, ask what are some potential hazards, what are you thinking about when you look at this, etc.
When the third set of slides are started the objective is to have the participants take over the class calling out potential or observed hazards with the instructor just facilitating. The louder and more energetic they are the better. The time spent on each slide in this last segment is short, for most less than a half minute. The intent is to quickly scan, think about possible hazards that could exist with the item, see if they are in fact present, then move on to the next item. Even if there is no actual hazard present on a slide the potential hazards need to be called out as the thought process is what is important here. If they quickly do a mental review of the possible hazards each time they look at something, good or bad, when there is a problem they will be more likely to recognize it. Try to get everyone involved with calling out potential hazards, the more involved they get the more likely it is they will use the technique.
Appendix B gives some slide examples and has a brief summary of what possible hazards could exist or what actual hazards can be seen. A list of slides like this is not a script, only a memory jogger. Since the session is very interactive no two classes will be the same. There may more comments about some slides then others as the group may think of additional hazards not listed. Other slides may be substituted to fit each particular workplace.
This training session will not instantly transform anyone into an expert safety scanner. Rather it serves as introduction to the technique and will allows the opportunity to practice it. To really master the process continuing practice is needed. It is like learning how to drive a car. At first someone showed you and pointed out what to look out for and hopefully how to scan for roadway hazards. It took a lot of concentration at first, but with increased practice and experience it started becoming automatic. Likewise when you become an experienced safety scanner it will be difficult for you to walk past an electric cord, fire extinguisher, or ladder without taking a quick glance at them as you pass to see if you can spot anything. Instead of walking straight ahead with blinders on you will be continually looking around to really see what it is you are passing.
To start off, the technique of safety scanning will be explained and then demonstrated by using a series of slides. The photos used we shot at a variety of places, many on-site. Some show hazards others do not. Don't feel offended if you recognize any of the areas with hazards as yours. This is a learning experience to share past experiences with others to hopefully avoid repeating the same mistakes.
After showing the process a second set of slides will be used to start practicing the safety scanning process. Also at the same time they will serve as a review of some of the more common hazards. Everyone will be asked to participate by identifying potential hazards. The last set of slides are of a wide variety of hazards and will be gone through much quicker than the previous set. This is to practice the process at more of a real time speed such as if you were walking through an area.
When this is completed a brief safety walkthrough of the shop will be done to practice safety scanning. Finally you will be asked to take along a safety scanning worksheet to help practice the process on your own.
A. Training on safety rules and procedures is a good start. The more a person knows the more likely it is that unsafe conditions will not be created. Prevention is the best approach. Training should include also past organizational experience to help people understand not only what not to do but why.
B. Job experience is very helpful but getting that experience presents many risks. To learn usually the person has either had a near miss or has had or observed an accident. When that person leaves the next one starts learning all over again often making the exact same mistakes.
C. Familiarity with an operation is often helpful in that a person may know what hazards to look for. Sometimes these are not obvious or may only occur at certain times in the operation.
D. Lack of familiarity with an area may be helpful. When an unfamiliar person comes into an area they tend to ask a lot more questions and are not as likely to take conditions for granted. They also bring experience from their own area which may include better ways of doing things.
E. Use of the "Safety Scanning" survey technique is another way to recognize hazards. By training people to actively scan their work area and ask questions about what they see many hazards will be spotted. How many hazards do people walk past day after day without really seeing and recognizing the hazard.
All of these methods are helpful and no one method will work by itself. A good accident prevention program needs many legs like a stool to be solid.
A. Caught in hazards : example - ask if someone could be caught in:
A. Actively looking for potential hazards (SIPDE)
2. Identify potential hazards - While scanning identify each item that could present a potential hazard, a fire extinguisher, a ladder, etc. Likewise when driving a car you spot potential hazards, a car running in a driveway, a child playing with a ball, a dog, a car ahead ready to make a left turn, etc.
3. Predict what could happen, is there a hazard - Briefly review in your mind what could go wrong involving the item you identified, a fire extinguisher if needed may not work or not be accessible, the ladder may be broken or too short or not tied off. All these conditions if they existed would create a hazard. Do they present a hazard?
Look at each item individually. The fire extinguisher has no pressure indicator but the seal is intact, there is a current inspection date on it, there are boxes in front of it. There appears to be a hazard with accessing the extinguisher, if the boxes are large it may not be reached or a person could sprain their back trying. Starting at the top of the ladder and looking down you observe the top is tied off and extends 3 feet past the landing, looking down the sides and rungs look good, the base has antislip feet and is on a firm level surface. It appears there is no hazard with the ladder (but what could go wrong with a person climbing it?)
Driving your car you predict that the running car in the drive may back up and hit you, the child playing with a ball could run into the street and be run over, likewise with the dog, the car ahead may turn left in front of you hitting you. You take a split second to quickly analyze each item. The car in the drive while running has no driver, as you got closer you note he the door is open and he is beside the car. The child and dog you see are inside a fenced in yard with a closed gate so this does not appear to present a current hazard. The left turning car is at the intersection with the wheels already turned, this is a hazard and you predict a possible collision.
4. Decide that if a hazard exists what action should be taken - The boxes in front of the extinguisher could be moved, or if unable to, another extinguisher could be temporarily placed in an accessible area nearby. The left turning car you realize you can deal with by honking the horn, slowing down, or getting over into the far lane.
5. Execute needed action - Unless you take the action all the previous activity did no good. You must be willing to act to prevent a possible accident. If unable to act yourself get someone else who can act to take corrective action. So move the boxes, slow and be ready to brake when you pass the intersection.
6. Additional Example:
2. Shop or unit - hundreds of potential hazards, still too big a bite
3. One wall or unit section - tens of potential hazards, better but still a lot
4. One piece of equipment - 0-10 hazards makes it easy to take in
A. Taking action for an identified hazard.
2. Refer to supervisor
3. Call Safety Dept.
4. Bring up in safety meeting
5. Bring up in EHS Committee
6. Call 5410 hotline
7. If the hazard cannot be immediately corrected take whatever action is possible to reduce the risk of an incident and injury.
B. Near miss - even if an accident was narrowly avoided and the obvious condition is now corrected it is important to look closely at all significant near misses.
2. It must be recognized as an opportunity to avoid a future accident to yourself or others
3. This is near the base of the accident pyramid, there may have been a hundred near misses, and opportunities to intervene, before an injury actually occurred.
4. Use the near miss hotline x7511 or (800) closecall
5. Need to conduct a near miss incident investigation and publicize the findings
Field practice assignment to work on over next month
- Increase area covered and practice time
- Goal is to make it almost automatic
- Review at next months EHS Committee premeeting
Refinery distant shot:
Instead of trying to look at a refinery as a whole to find possible hazards lets break it down into smaller bite sized pieces.
Shop walk through wide angle:
Lets look at a maintenance shop. Start with just one wall. You have a lot of potential hazards to look at all at once so break it down into manageable bit sized pieces.
Exit door, trash can, water cooler:
Taking a closer look there are still many items so scan each one and think briefly how could this present a hazard?
The exit door. What if I need to get out in an emergency? What if it is locked? What if it is blocked? What is on the other side?
The trash can. What if oily rags are in it? Could it present a fire hazard? Why is it full? Is it in the way?
The water cooler. Is it safe to have water here, any contaminants? Is the water clean? Could I come into contact with an electric hazard?
Electric to cooler:
Sometimes to answer a question just glance around, look at the electric cord to see.
Other side of door, general shop area:
Looking to the other side of the door we see many other potential hazards, again break them into bite size pieces, start at one side and scan across each item.
Fire extinguisher:
What if there is a fire? Can the extinguisher be readily seen? Will it work (charged, inspected, look in good condition)? Is it accessible? What kind is it?
The electric outlet below it. Trip hazard? Contact hazard (uncovered openings, exposed wires)?
Crane base and utilities:
Starting with the base of the jib crane, is there a falling hazard (securely mounted, inspection sticker up to date)
Electric outlet as before, hose line, Contact hazard (what is in it, is it hazardous, steam, high pressure, chemical, labeled)? Struck by hazard (could the hose pop off, is the hose in good condition)?
Electric panel box, what if it needs to quickly turned off (accessible, labeled as to what it controls)? Contact hazard (exposed electric parts, opening in box, wires)?
Top of the jib crane:
Scan each part breaking the whole down into small parts:
Struck by hazard (is the hook hanging down in walkway, is control cord out of the way)? Falling hazard (is the hook in good condition, clasp good, sling looks good, chain in good condition, top motor secure)?
Air hose reel and tool:
Trip hazard (could the hose be tripped over, is it out of the way, not coiled up in walkway, tool out of the way)? Struck by (could the hose blow off or rupture, is it in good condition, connections secure)?
Impact tool, is it in good condition, socket retainer pin in place?
Broom and box, any trip hazard, are they out of the way, neatly stored?
Work table and degreaser:
Continuing to scan around the shop wall and walking ahead looking at each item
Pipe sticking out into walkway:
While scanning one item at a time, what is in front, could that pipe present a hazard? Struck by or fall hazard? Is it in a possible travel way, could someone not see it, is it secure on the table or could it roll off or cause something else to be knocked off the table? Can the hazard be corrected, can you do it, how to do it? Flag off area to keep people from using this as a walkway, move the pipe. Do it. SIPDE
Degreaser:
Contact hazard? What is the chemical, is it labeled, should there be gloves used when handling, face shied or goggles, are there vapors being emitted, should the lid be closed, What if there is a fire, will the safety fuse on the lid close work, can the lid close or is it obstructed, what is stored in it? Could I come into contact with electricity, is there a bulb in the socket or is it exposed, any exposed wires, cord in good condition?
The more questions asked the better, think of possible hazards then answer the questions, while you may not have time to check everything, still ask the questions and next time you may have the opportunity and the question will pop to mind.
Work table, trash can:
Is the can in the way, can the work table be safely reached or will someone stretch across the can to reach something perhaps hurting the back, are material on the table secure or could they fall. is the work at a safe height or will I have to stoop over it for long periods causing a backache?
Note: this entire process may take less than a minute as you walk by, obviously in that time though you will not be able to answer all the questions you have. If you pass the area several times there is more opportunity to scan and answer more questions. Perhaps next time you walk past you may take an extra 5 seconds to see if the fire extinguisher is charged, or if that air hose looks secure. If you are doing a safety and housekeeping audit you may spend 10 minutes taking a very close look at everything to answer all your questions. If it looks good today scan again tomorrow as conditions change, keep asking yourself questions. You may ask a thousand questions for every one hazard you find but it is that one hazard you find and correct that could save someone from injury.
Guards poster:
Lets go a little slower as we start to practice the safety scanning process. One major hazard potential is contact with moving equipment. We need to ask could I come into contact with it and if so what can be done to prevent or minimize the chance of it.
Coupling guard:
Is there a potential for contact? guard looks in good condition, it is secure, entire coupling is covered, no holes in screen.
Exposed fan blades:
Possible contact? Large openings in wire guard, hand could fit through easily, rotating fan blades could cause serious injury. Need to turn off and lock out power, if needed to stay in operation could block off access to keep people away, could put on smaller mesh guard, could remount on ceiling out of reach.
Horizontal band saw:
Is there a contact hazard? Blades are exposed so yes but to cut blades have to be exposed, is the entire exposed area need to cut or only a few inches? could the unused part of the blade be guarded to reduce the potential risk?
Is there a slip or trip hazard? Oil on the floor, are anti slip mats used, oil leaks fixed, cord across floor?
Is there an electrical contact hazard, cords in good shape
Vertical band saw:
Contact Hazard? Blade guarded as much as possible, dust contact minimized by exhaust ventilation (is it working?), slip hazard on floor? debris cleaned up, cords out of the way, plywood neatly stacked in designated areas.
Pedestal grinder:
Lets break this down into even smaller pieces. Start with the cord in back what do think of? neatly stored to prevent tripping, good condition so it doesn't rupture, ends securely pinned or connected, reel turns easily to avoid strain.
What do you think of with the grinder? Electric cord in good condition, trip hazard from cord, exposed light sockets in top viewing guard? What if the wheel broke? Top tongue guard adjusted(1/4 inch maximum gap to contain debris if wheel breaks), work rest close to wheel to prevent jamming item in between and shattering wheel? Is the wheel in good shape, any deep grooves, was the wheel ring tested when last replaced, could you come into contact with the rotating spindle, is the side guard in place? Is there a falling hazard, is the grinder securely mounted? Is the proper protective equipment used when it is used, eye and face protection hearing protection, sign posted?
As each slide is flashed up quickly scan and call out what possible hazards. After each slide some hazards are listed, see if more can be found. Most slides should no more than 30 seconds. Get everyone involved in calling out possible hazards. Not all slides show actual hazards, think. Let the group take over just facilitate. The notes here are just to point out some problems and help come up with possibilities for potential problems. Mention only if they do not.
Horizontal band saw:
exposed blade, possible electric defects, plugged in yet tagged out of service
Overhead heater on floor:
exposed blades, open electric box, cord is a tripping hazard
Hose across floor:
unused hose is a tripping hazard, wet floor could be a slip hazard
Lift truck:
in good condition, brakes, horn, seat belt, steering, is the daily inspection log up to date, operator trained, operated in a safe manner, aisle clear, trucks secure at loading dock before driving inside, overhead hazards possible, top screen if needed
Food with insecticide:
food stored with an insecticide
Turn around dump chute:
tripping hazards, falling debris from chute, poor housekeeping
Sulfur pit reline:
fall hazard at pit edge no barricade, hoses may be trip hazards need to string as neatly as possible, is there adequate safe access down into pit, are pipes going in locked out from process, any air contaminants
Welder inside vessel doing stainless trays:
possible fume hazard, ventilation?, flash burn potential for others,
Lockout tags with locks:
all power sources denergized, everyone has lock on box,
Scanned Area Shop West Wall - Example
Identify Potential Hazard
(What Are You Looking At)
Predict Possible Incidents
(What Could Go Wrong)
Decide If Hazard Exists
(Why Or Why Not)
Execute Corrective Action
(What Was Done To Correct)
electric cord
- could cause tripping
- could cause shock
- could start fire
- run along center of walkway
- current inspection tag, visual check OK
- overloaded cord for length & amperage used
- reroute along side
- replaced with heavier gauge and / or shorter length
fire extinguisher
- could malfunction
- may not be able to reach
- seal intact, indicator good, current inspection OK
- mounted properly, no obstruction OK
- no action needed
bench grinder
- wheel may shatter
- could be get elec shock
- grinder could fall
- fingers could contact wheel
- wheel ring tested, proper blotter and bolt tension, proper adjustments of tongue guard (_") & work rest adjusted (_"), wheel dressed, not side loading OK
- cord good, switch good, broken light bulb
- bolted down, all nuts tight OK
- side spindle guard in place, proper hand placement and tool use OK
- unplug and replace light bulb
Mobil Business Resources Corp. `97
Scanned Area
Identify Potential Hazard
(What Are You Looking At)
Predict Possible Incidents
(What Could Go Wrong)
Decide If Hazard Exists
(Why or Why Not)
Execute Corrective Action
(What Was Done To Correct)
Note: Break Area Down Into Small Sections To Scan. Ask What If questions? Major incident categories- struck by, fall from, exposed to, caught in or by.
Mobil Business Resources Corp. `97
Overview Of The Program
Program Preparation
Tips On Presentation Of The Class
Conducting The Class
Introduction
How To Recognize Hazards
What Is A Hazard
How To Scan For Safety
Practice Scanning For Safety
What To Do When Hazards Are Identified
Field Practice
Assignment For Continued Practice
Review
Abbreviated list of slides in handouts. Actual program with all slides listed may follow an outline similar to below.
Overview Slides
Review Of Hazards Slides (About 100 Slides)
Guarding
Electrical
Ladders, Platforms
Housekeeping
Slings, Lifting Equipment
Emergency Equipment
Personal Protective Equipment
Hazard Communication, Flammable Liquids, Compressed Gases
Ergonomics, Tools
Practice Slides (About 40 Slides)