Safety

1
  Approaches
Seven Steps of Safety (plant-wide) Step 7
Fully
implemented
Management initiated Self-initiated Step 6 safety
management

Step 5 Autonomous
safety standards
(*Overall
inspection of
safety levels
Step 4 Autonomous *Reevaluation if
inspection safety control)
(Predictive
General countermeasur
Step 3 inspection for es against
Analysis of safety safety Team initiated
accidents (Train and problems)
(Analysis of grow people
Setting in such a
causes) Step 2 tentative way that they
standards care for
for safety safety)
Countermeasure (Listing all
s and horizontal safety
Step 1 expansion problems)
(Countermeasur
es at the similar
areas)

Reactive Preventive Proactive

2
Seven Steps for Improvement
Step 1 :
Analysis of accidents followed by an analysis of the causes of accidents.
What are the sources and frequency of events? Get the facts !

Step 2 :
Identify what countermeasures can be introduced to remove the hazard and
to eradicate the source of the hazard. Deploy the countermeasures
horizontally. Bring the understanding of the risks to other parts of the
operation, where they can be used in similar areas.

Step 3 :
Set tentative standards for safety by listing all the safety problems. Prioritize
problems by severity and potential consequences.

3
Step 4 :
Make safety important to everyone. Introduce a general inspection for safety.
Remove the perception that safety is the Safety Officer’s job. Train people in
their understanding of what safety means and how they can affect their safety

Step 5 :
Autonomous safety inspection. Move to the point where everyone looks at his
or her own environment in a critical way looking for safety issues and
opportunities to improve them because those who can protect people from
accidents to happen are themselves. People should be actively looking for
ways to improve the safety of their working environment.

Step 6 :
Autonomous safety standards. Armed with an understanding of the theory
behind creating a safe working environment and the experience of carrying
out defined safety checks, the workforce can move by teamwork to defining
how it wants to set its own standards for a safe and secure working
environment.

4
Step 7 :
Fully implemented safety management system with the achievement of zero
safety incidents.

5
 Classification of areas

Reactive Preventive Proactive

AA Very high number of Very high Very high

accidents, medical potential risk*
treatments, first aids
A High High High risk
potential
B Medium Medium Medium risk
potential
C Low Low potential Low risk

* Risk (kinds of risk, its probability, its severity)

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 materials, chemical materials, thermal risk
6
(heat, fire, cold), gasses (vapors), radiation (non-ion, ion), asbestos, etc.
 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
incidents to alert people about safety,
Compliance with the safety legal regulations
Safety risk assessment*
SMAT, Safety audit
Self-initiated safety activities
Proactive 6 - 7 Team initiated safety activities
Root cause analysis of incidents with special
emphasis on a near misses and unsafe acts

7
STEP 1 –Model Areas Selection

ACCIDENTS
FI Index
(Accidents)

MODEL
AREA
SELECTION
8
 BEFORE WCM
Prevention service – Central Entity SAE
Prevention Service –
Central Entity SAE
WCM

Permanent Model Area

Work Team Work Team

Integration of WCM in the

other columns, with direct
participation in:
Transversal Vertical implementation of
-Early equipment
implementation of WCM-Safety
Security in all the Transversal implementation -Environment
Security level with an
plant
of Security in of
objective allzero
the accidents
plant - Professional
Maintenance
-Workplace organizatión
9
 11
AA
13 15
AA
1º MODEL
6 + A A
A AREA
B B B B
7 B
C C C C C
CC
C C C
C C C

Nº = Number of Accidents

Completed Area
modification in
November

10
 BEFORE WCM WITH WCM
ALL THE
PLANT
Detection Detection

“Root Cause
Analysis Analysis”
WCM

Countermeasures
Countermeasures

ALL THE Effectiveness Check

PLANT
MODEL
AREA
Horizontal Extension

11
 ALL THE PLANT

MODEL AREA
Detection - Detection form

Analysis - Report
Medications
form
Near Misses
- EWO
Unsafe Conditions
Countermeasures - Quick
Unsafe Acts
Kaizen
- Action Plan
Effectiveness Check - Safety Audit Unsafe Conditions
Charts
- Quick Audit
Check list operator

Horizontal Extension Safety Audit

- Safety Meetings
- Reports by Central 12
Board
The Iceberg Principle

Fatalities
Lost time
injuries
Minor injuries

Unsafe Acts and Conditions

13
The Safety Pyramid

1 Fatality

30 Lost time injuries

300 Minor injuries

30,000 Unsafe Acts &

Conditions

14
 Unsafe Acts and Conditions

Safety Unsafe
Conditions 23
Clearness
Cleaness
Maintenance Unsafe Acts
15
Visualization
1st Quarter ‘08

15
Step 1 : Safety matrix
 To start : data of accidents, medical treatments and first aids

16
Safety matrix
 Root causes of safety problems

Environment External factor

Equipment External factor

Object
Operation

Internal factor
Operator

Supervision External factor

External and Internal Factors of Human Errors

17
 Unsafe conditions
Root causes No. Contents
Supervision
01 Insufficient instructions
02 Poor signal and communication during operation
03 Insufficient preliminary meeting
04 Others
Safety Equipment/workshop
05 Safety devices (lock, etc.) were not installed
06 Did not utilize safety devices
07 Workshop too small; the floor surface and safety passage are not in good
condition
08 Others

18
Operational method / environment
09 Standards and rules such as standard operation procedures were
unsatisfactory
10 Operation was carried out in dangerous positions (which can be resolved by
reviewing the rules)
11 The problem can be resolved by the operator’s attention
12 The problem can be resolved by improving equipment
13 Poor 5S during operation
14 Poor operational environment (noise, lighting)
15 Others
Management and supervision
16 Introductory education and training and instructions for safety standards
and rules were not carried out sufficiently
17 Poor allotment of operators (number, qualification, etc.)
18 Poor management of equipment and tools
19 Others

19
 Pallet (4th level)

The object to be Reflecting mirror (big)

checked

Reflecting Check
mirror (small)

20
Relationship between near-miss experiences and unsafe conditions
0 2 4 6 8 10 12 14 16

Dangerous work position 15.5

Small workshop 14.9
Poor design structure 8.6
Poor floor surface 7
Poor operational environment 6.1

Lack of necessary safety equipment 5.2

Lack of safety guarding 5
Poor arrangement of safety passage 4.8
Poor service of safety inspection 4.7
Dangerous placement of items 4.1

Old facilities 3.9

Lack of 5S 3.3
Poor safety guarding 2.1
Wrong materials selection of equipment 1.7

Removed safety guards 0.6

2.7
No unsafe conditions
Others 9.8
21
 Relationship between near-miss experiences and management and
supervision 0 2 4 6 8 10 12 14 16

Overlooking of unsafe acts 14.5

Insufficient setuo, operational preparations 13.3
Poor equipment/devices, tools and instruments 12.9
Insufficient operational education and training 10.7
Insufficient education and training of safety standards and 10.7
rules
Insufficient or unclear safety standards/instructions 10
Insufficient maintenance of equipment, machines,
tools and instruments 6.1
Improper instructions, order and communications 5.3
Insufficient checking of PPE 2
Improper operational process 1.4

Improper allotment of personnel 1.2

Unproper and dangerous operationsl plan 1.1

Allotment of non-qualified and not appointed operators 0.1

No problem in terms of management and supervision 2.2

Others 8.5

22
 Issues of management supervision
No. Contents
01 Insufficient or unclear safety standards/instructions
02 Insufficient setup, operational preparations
03 Poor equipment / devices, tools and instruments
04 Insufficient checking of PPE
05 Improper instructions, order and communications
06 Overlooking of unsafe acts
07 Allotment of non-qualified and not appointed operators
08 Improper allotment of personnel
09 Insufficient operational education and training
10 Insufficient education and training of safety standards and rules
11 Improper and dangerous operational plan
12 Improper operational process
13 Insufficient maintenance of equipment, machines, tools and instruments
14 Others
15 No problem in terms of management and supervision

23
 Integrated
Recognition Operation
Thinking
1, 2, 3 10, 11, 12
4, 5, 6

Sentiment/
Emotion
7, 8, 9

Mental appeals
24
Classification of information processing errors in the
cerebrum
1) Errors of recognition / identification

Errors taking place up to the process of recognizing an object in the

sense center of the cerebrum

2) Errors of judgement / memorization

Errors taking place from the point of recognition via decision making of
adaptive action up to the process of ordering action from the motion center

3) Errors of operation

Errors taking place during the movement by mistake or scamping

in spite of the order of action from the motion center

25
 Near miss report
When Who
Where How
Outline
Environment
There are
There are There are There are
problems with
problems with problems with problems with
tools and
Equipment environment
equipment
procedures operators

1
Operation
Operation 2
3
4

Operator 5
6

7
8
9
Findings of the location of
problems in environment, 10
11
equipment, procedures and the
12
operator 26
Subjective mental appeals based on the functions of
mind and body
1) Recognize the (1) Could not see (hear)
situation
(2) Did not notice
(3) Did not remember

2) Integrate thinking (4) Did not know

(5) Did not pay attention
(6) Thought it would be OK
3) Functions of emotion (7) Was confused
and emotional deeds
(8) Was irritated
(9) Was tired
4) Function of taking (10) Unconsciously did
action
(11) Was not easy to do
(12) Lost body balance

27
 Unsafe acts
No. Contents
01 Could not see very well
02 Could not see at all
03 Could not hear very well
04 Did not notice
05 Overlooked
06 Could not recognize (misheard)
07 Forgot (could not remember)
08 Misremembered
09 Was aware, but forgot to do
10 Did not know
11 Did not understand
12 Was not aware of the important critical points
13 Was not careful enough
14 Took it easily
15 Did not grasp the problem (fact) properly
16 Anticipated wrongly
17 Thought it OK 28
No. Contents

18 Did not take it as dangerous

19 Felt it troublesome and so did it to get rid of it
20 Paid no attention due to another matter
21 Was absentminded due to another matter
22 Was in a hurry
23 Was tired
24 Was bored of repetitive work
25 Was irritated
26 Was upset
27 Was concerned with another matter
28 Did unconsciously
29 Was difficult to handle
30 Could not operate precisely
31 Could not catch up with the speed
32 Lost body balance
33 Was in an ergonomically difficult posture
34 Was not strong enough
29
 Classification of operation
No. Contents
01 Crane operation
02 Operation of transportation vehicles
03 Operation of general power-driven machines
04 Operation of furnace
05 Driving cars
06 Slinging work
07 Inputting and transportation of products/materials
08 Manipulation of tools
09 Gas welding/prearcing
10 Electrical welding/prearcing
11 Assembly/disassembly
12 Repair
13 Inspection/adjustment
14 Cleaning
15 Walking
99 Others
30
Classification of regular operations and irregular operations

No. Contents
01 Regular production operations
02 Regular inspection/repair
03 Restoration operations which do not take place ver often, can be predicted to some e
xtent and have already taken place in the past
04 Restoration operations which do not take place very often, cannot be predicted nor
have taken place in the past

31
 Classification of incidents
No. Classification Contents
01 Fall / sliding down An operator falls down from the scaffold or slides down the installment
02 Fall down An operator tumbles down by tripping or stumbling
03 Crash An operator crashes into hanging items or machines
04 Come flying / drop Items come flying over operators or drop down on operators

05 Being crashed A hanging item or a part of a driving machine crashes into an operator
06 Caught in / rolled Being caught in or rolled up into a machine, etc., an operator gets injured
up
07 Cut / rubbed out An operator gets cut or rubbed out by edged tools or the handling product
08 Contact with hot or Contact with hot or cold temperature by fire, arc, welding metal, hot water or
cold items steam, etc., hot or cold environment
09 Contact with Exposed to radiation, carbon monoxide poisoning, oxygen deficiency disease,
harmful items etc.
10 Electric shock
11 Explosion
99 Others

32
 Degree of risk

No. Contents
01 The risks which may have caused serious disasters or serious physical damages
02 The risks which may have caused a lost time accident excluding the ones under (01)
03 Minor accidents excluding (01) and (02)

33
 Rate
0 2 4 6 8 10 12 %

Thought it was OK 11.6

Did not notice 9.2

Overlooked 8.4

Could not see very well 7

Was not careful enough 5.5

Did not take it as dangerous 5.3

Was in a hurry 5.1

Lost body balance 5.1

34
 0.0
10.0
20.0
30.0
40.0
(%)

Crane

Transportation
vehicles

Recognition
General power
driven machines

Furnace

Cars

Memory
Slinging work

Input and transport-ati

on of products

Manipulation of tools

Gas welding

Thinking
Electrical welding

Assembly

Repair
Value/emotion

Inspection

Cleaning

Walking

Others
35
Operation
 0.0
10.0
20.0
30.0
40.0
(%)

Fall/sliding down

Recognition
Fall down

Crash

Come flying/drop

Memory
Being crashed

Caught in/rolled up

Thinking
Cut/rubbed out

Contact with hot

or cold items

Contact with
harmful items
Value/emotion

Electric shock

Explosion

Others
36
Operation
 Causal analysis of subjective mental appeals from the viewpoint of man, operation and machine &
environment and items

Subjective mental Man Operation Machine, environment, items

appeals
(1) Could not see / • Eye : Eyesight weakened or • Bad operational position • Lack of visuality
hear well damaged, near sighted, far eg. Light coming from the • There is a problem in lighting an
sighted d illumination.
back
 Dark
 Big difference between dark
areas and light areas
(2) Did not notice • Lack in the knowledge of • It is difficult to notice where • Necessary working environment
the job there are many points to pay • Poor layout
• Lack in skills needed for the attention to. • The structure and functions of
job equipment are too complicated to
understand.
(3) Did not Cannot recall the critical • Where there are many • The mechanical structure of
remember points critical points, the operator equipment is too complicated to
Being over 50’s, memory is cannot recall one of them. remember.
getting poor • There are too many
instruction items.
• The operator forgot the
critical point due to an
irregular job which is not
often carried out.

37
Subjective mental Man
appeals
(4) Did not know • Don’t have the knowledge
of the job
• Don’t have enough skills of
the job
• Did not know the rules of
the job.
(5) Did not pay • Since it was a routine job,
attention did it without much thinking.
• Was tiresome to think.
• Did it instantly.
(6) Thought it would • Too confident of the job
be OK • Counted too much on my
past experience.
• Did not think it would be
dangerous to violate the rules.
Operation Machine, environment, items
• It is not easy to grasp the • Don’t know the structure of
procedures/critical points of equipment and its functional
the job. performance.
• Don’t know how to do
visual inspection.
• Don’t know how to cope
with troubles.
• It was the job which did not
require much thinking.
• Relaxed my attention
because it was a simple job.
• I have had no experience
of getting injured.
• Referred to the way of my
senior, it was dangerous.
• Kept on doing the job until
I got scolded.
38
Subjective mental Man
appeals
(7) Was confused • Have the habit of getting
confused.
• Got confused when the
superior rushes.
• Tend to forget critical points
in a tense situation.
(8) Was irritated • Was reluctant to do the job.
• Was not confident of the
job.
• Was not worth doing the
job.
• Had words with somebody.
• Had no mind to do.
(9) Was tired • Was not in a good physical
condition.
• Was not in a good mental
condition.
• Was tired physically.
Operation Machine, environment, items
• Get panicked when a
trouble takes place.
• No reflection of my opinion
to the job instructions.
• Cannot work in a friendly
atmosphere with other team
mates.
• Cannot get on well with • The working environment is not
other team mates. good. (high temperature, noise,
• Cannot continue to keep dust)
attention for a long time. • The job content is too much big
• Cannot engage in heavy for one operator.
manual labor work for a long
time.
39
Subjective mental Man Operation Machine, environment, items
appeals
(10) Unconscious • Did the job reflexively since • Repair was needed to be • Urgent repair was required.
deed it was a routine job. done in a hurry.
• Did the job because I was • The superior pushed me to
in a hurry. hurry up to do the job.
• Was in a habit of doing the
job without much thinking.
(11) Was not easy • Did not know how to do the • The work routine was not • Operationability of the equipme
to do job. standardized. nt was not designed in
• Lacked in practice. • Did the job in “my own • Standard operation procedures
• It was difficult to do the job. way”. are not very well established.
• Could not cooperate with
other team mates very well.
(12) Lost the • It was a very unnatural • Did not use a safety belt. • Poor foothold.
balance of the body posture. • Being in a hurry, forced to • The work space was too small.
• Being old, it was impossible do the job in a very difficult
to do the job. posture.
• There was a difficulty in
the operational method.

40
 Medical checkup, measurement of physical strength

Learning activity

Knowledge education Skill training

Operation
Recognition Integrated thinking
Behavior training

Practice
Emotion

Review of SOP

Make equipment free from injuries

Safe and pleasant environment

41
 STEP 2 - Countermeasures
GI Laterales
Causes
Events by Part of Body involved 5
in Injuries Nov 07 –Apr 08
4
1
10
3
2
Nº
6 2

se
ur
ed
1

oc

t
en
3

pr
on

m
in
ti

of

e
ce

n
au
1

dg
ai
0

en
ec
ec

tr

ju
lig
sp
pr

of

of
eg
re

ck
ck

r
ro
N
of

La
La

Er
ck
La
Actions

Exhaustiv Control Specific training to

OPL´s Correct use
e risk signs Visual all workers
of safety glasses
and compulsory use of management
protections

Screen for those who use prescript Increase Protection in

glasses robots

42
 Visual Management
MODEL AREA

43
 PPE

In front of each work place where it’s possible to use compressed air, a trust
warns the worker to dress protective glasses for accident prevention.
44
44
 PPE

List of all the prescripted PPE is hanged

in front of each work place.

100% of Plant
Workstations are
monitored
45
45
 Confined Spaces

ES
AC
S P
ED
FI N
ON
C

46
46
 Step 3 : Legal Compliance: risk evaluation
Risk Cecklist •mechanical
Matrix 13 Health Risk risks
Categories •electrical risks
Extend of losses •hazard materials
• …..

Probability

Risk Analysis
Assembly

German Legislation requests

a Risk Analysis of all
workplaces
and equipment
47
 Ergonomie Analysis

Rise and carrying

of loads Type of
Time
activity

Workplace

Load

Gender Calculation

Posture

Implementation Result
conditions
48
 Risk Analysis - Noise and Explosive Atmosphere
Noise
Explosive Atmosphere

Measurements and
Documentation TÜV – Report

Internal
Documentation
Noise Map

Improvement Plan

Result: No Events in the Past


49
 Risk Analysis -Electromagnetic Waves/Vibration
Electromagnetic Waves Vibration
Collection of
Own existing
Measurements measurements

Collection of Vibration Calculator

Producer Informations

Detail information
of Machines Risks

No infringement of the limits


50
 Dangerous Materials Management
Form for the Request of
a new Chemical
Definition of the
Protection Level

Proceed Instruction Inhales

Skin contact
Definition
of the Protection
Working Instruction
Level
51
 Dangerous Materials Management
New Safety Data Sheet ÜBERPRÜFUNG EINES NEUEN SICHERHEITSDATENBLATTES

Lfd. Nr.: 1416-1-2 Gefahrstoff: Teilenummer: 4180 8449

Verification
Hersteller/Lieferant Brenntag GmbH

Handelsname Citronensäure monohydrat E330

SDB vom 06.07.99 wurde überarbeitet 21.03.06

Alte Kennzeichnung Xi Neue Kennzeichnung Xi Änderung ja:

R-Sätze (alt) 36 R-Sätze (neu) 36 Änderung ja:

S-Sätze (alt) 24/25, 26 S-Sätze (neu) 24/25, 26 Änderung ja:

Inhaltsstoffe hinzu Änderung ja:

Inhaltsstoffe
Änderung ja:
entfallen
Wassergef.-Kl. (alt) 1 Wassergef.-Kl. (neu) 1 Änderung ja:

Ist ein Änderungsantrag zu stellen? ja nein

Anmerkung Handelsname hat sich geändert

NEW Request
PBA - Arbeitssicherheit Datum: 17.07.06 Bearbeitet von: Richter

Beantragung eines chemischen Stoffes zur Einführung im

Werk Donautal Werk Brandschutz

Gefahrstoff Lfd. Nr.: 1416-2 Teilenummer: 4180 8449

Freigabeverfahren: I Erstantrag:
Nicht vom Antragssteller auszufüllen

Neue Gefahrstoffe vermeiden und vorhandene minimieren

1. Antragssteller Ausgang Unterschrift
Name: Richter Abt.: PBA Tel.: 3212 17.07.06 Richter

Antrag für
noch nicht genehmigten Stoff - im Einsatz seit: Änderungsantrag für neues SDB
einen neuen chemischen Stoff
Versuchszwecke (einmalig)
einen bereits genehmigten Stoff für einen weiteren Arbeitsplatz Teilenummer :

Stoff ersetzt folgendes Produkt :

Teilenummer : Lfd. Nr.:
Bezeichnung :

Angaben zum Produkt :

Hersteller/Lieferant : Brenntag GmbH
Handelsname : Citronensäure monohydrat E330
Verkaufsbezeichnung :
Ansprechpartner :
Telefon :

Angaben zur Verwendung :

Arbeitsplatz / Halle : Abwasseraufbereitung
Kostenstelle : 9817
Tätigkeitsbeschreibung : Umfüllen in Behälter - ansetzen mit Wasser
Betroffene Mitarbeiter : 3 Anzahl

Bei der Tätigkeit verwendete Menge pro Mitarbeiter und Tag (Mengengruppe)
g – Bereich oder ml – Bereich niedrig
kg – Bereich oder l – Bereich mittel
t – Bereich oder m³ Bereich hoch
Dauer der Tätigkeit
Unterschreitet die tägliche Zeitdauer beim Umgang 15 Minuten? ja nein
Anwendungstemperatur

Updated Working Erfolgt die Anwendung bei Raumtemperatur?

Hautkontakt bei Tätigkeit möglich?
ja nein
Ja
Anwendungstemperatur: 60,00 °C
nein
Wirkmenge

Instruction kleinflächige Benetzung (Spritzer)

Großflächige Benetzung (Hände – Unterarme)
klein
groß
Wirkdauer des Hautkontakts
Unter 15 Minuten pro Tag kurz
Über 15 Minuten pro Tag lang

52
 External Company (“Contractors”)

Contractors Safety
Italian Law (Art. 7 D.Lgs. 626/94)

53
53
 Lock Out

The objective of a Lock Off-Out procedure is to ensure that no injury occurs through the energising or
movement of equipment or through contact with sources of energy. 100% of Termoli Plant Work
Station & Machines is under Lock-out procedure

Plan activity
plan activity

S.O.S.

J.E.S.
54
54
 Step 4 :Audit System

An integrated system of audit has been developed in TERMOLI Plant. The system
consists in personalized check list for each organizational level or role ( Plant Manager,
Area Manager, Supervisor, Team Speaker and Worker).
AP UR DO CI TE SDS I VP E RR OI F ICC EA TS I OS NO
F R EQ U EN ZA
V e rro n e P la n t - U n it à C a m b io ( A( uAt ou v tao luv t a zl ui o tna e z ei o/ on ve e Sr i fui c pa e Rr v. S i s. P o. Pr ). ) M E N S IL E

A R G O M E N TO : P R E V E N Z IO N E IN F O R T U N I E IG IE N E D E L L A V O R O

R IF E R . N O R M A T IV O : D . P . R . 5 4 7 / 5 5 , D . P . R . 3 0 3 / 5 6 , D . L g s . 2 7 7 / 9 1 , D . L g s . 6 2 6 / 9 4 e s u c c e s s iv e m o d ific h e e d in t e g r a z io n i.

U T E /A R E A 5 L A V O R A Z IO N E S U P E R F IN IT U R A P O S T -T .T . A L B E R I / C O R O N E / IN G R .C .T T O A U D IT N ° D A T A : 2 7 .0 4 .2 0 0 7

PLANT
to ta le v o c i v o c i n o n c o n fo r m i in d ic e d i c o n fo r m ità
c o n s id e r a te (T V ) n. p e s a te IC = 1 0 0 - (T P / T V x 1 0 0 )
g ra vit à 1 1 0
g ra vit à 2 0 0

MANAGER
21 9 5 ,2 4
g ra vit à 3 2 1

t o t a le p e s a t o (T P ) 1

C o n in d ic e d i g r a v it à ( I d G ) = 1 m o lt ip lic a r e x 1 , 5 ; c o n Id G = 2 m o lt ip lic a r e x 1 ; c o n Id G = 3 m o lt ip lic a r e x 0 , 5 .

UNIT
L E G E N D A A T T R IB U Z IO N E G R A V IT A '
P r io r ita ' Q uando E ' d a rim u o v e re :
- P u o ' e s s e r e p r o b a b ile c a u s a d i e v e n t o in fo r t u n is t ic o . S U B IT O a d o t t a n d o le n e c e s s a r ie
- P u o ' e s s e re p ro b a b ile c a u s a d i p ro b le m i a m b ie n t a li e / o c a s i d i m a la t t ia m is u re t e c n ic o / o rg a n iz z a t ive / p ro c e d u ra li

MANAGERS
FIAT
1 Powertrain Technologies p r o fe s s io n a le . p r o v v is o r ie e / o d e fin it iv e .
PREVENZIONE INFORTUNI E IGIENE DEL LAVORO
- E ' g ia ' s t a t a c a u s a d i e v e n t o in fo r t u n is t ic o o e v e n t u a le in c id e n t e .
- E ' u n a t ra s g re s s io n e a d u n a n o rm a t iva d i le g g e c h e p u o ' c o m p o rt a re
g ro s s e re s p o n s a b ilit a ' d i t ip o p e n a le (p e n a d e t e n t iva o p e c u n ia ria ).
UTE 5 AREA SUPERFINITURA
- A t t ivit a ' g ia ' m e s s a in a t t o s o s t a n z ia lm e n t e m a d a c o m p le t a re . A B R E V E a d o t t a n d o le n e c e s s a rie Data 27/04/2007
- N o n p u o ' e s s e r e c a u s a d i e v e n t o in fo r t u n is t ic o . m is u re t e c n ic o / o rg a n iz z a t ive / p ro c e d u ra li
2 Verifica esecuzione
- E 'u n a t r a s dag r e sparte s i o n e del a d uTeam
n a n o rSpeaker
m a t i v a d i ldel
e g g controllo
e c h e n o n giornaliero
p u o ' c o m p o r previsto
ta re sulla singola
p r o v v Operazione;
i s o r i e e / o d e f i n verifica
it ive . dell'avanzamento delle azioni relative presenti
r e s p o n s a b i l i t a ' d i t i p o p e n a l e .
nell'Action Plan Quality + Verifica esecuzione da parte dei Team Members dei piani di Manutenzione Preventiva (Sicurezza, Qualità, Ambiente, Manutenzione)
- P re s e n z a d i m is u re a lt e rn a t ive p ro vvis o rie

SUPERVISORS
- D a m ig lio ra re / a g g io rn a re A p p e n a p o s s ib ile e / o c o n c o s t a n t e
3 OK
- C o n d iz io n i g ia ' s o d d is fa c e n t i m a d a m ig lio r a r e . NON OK m ig lio ra m e n t o .
Resp. Area

n0 Argomento Descrizione anomalia Gravità Azioni correttive attuate/previste

pr. 1 2 3 Respons./tempist.

TEAM SPEAKERS
1 Il Team Speaker X NON ESEGUITE SV
ha effettuato regolarmente le
attività di audit nelle aree di sua
competenza?
2 I Team Member/Team Speaker hannoX

WORKERS effettuato regolarmente le attività di

autoverifica del loro posto
di lavoro?

The Plant Manager, Unit Manager, Supervisors perform Safety audits independently,
following their audit planning. The upper level checks the respect of the safety rules of the
lower level, by filling the audit form, that is personalized according to the specific
responsabilities about safety of each level.
55
55
 SAFETY EVERYDAY

MODEL 03/05/2008
AREA UNIDAD OPERATIVA MONTAJE

Produción [vehículos] Averiás [sec] Absentismo [%]

P G B C TOT A P G B C A TOT P G B C A TOT
Turno C 17 30 30 30 32 -6 0 0 0 0 0 5,3 3,6 8,7 18,2
IN THE DAILY DIRECTION
Turno B
Turno A
35
34
209
89
88
MEETING:
89
90
90
89
73
65
0
1
1
2
1
0
0
1
0
0
1
7,1
1,6
9,4
15,2
10,5
17,2
8
7,6
6,1
6,3
9,8
TOTAL 86 207 209 209 170 -5 3 1 1 0 2,9 10,0 10,4 8,1 10,2

Head
Stock Manager,
Rod.
Banco
Rod.
Fren.
Sup.
1st
Revision
Inf.
line
Repar. Managers
Mecc.
Elect. Ripar.
Rev. Prueba
Estet. Agua
Carro. Chapa Pint. Delib.
Falta
Mater.
Defec.
Audit
Q
Total

Budget 10 2 2 2 2 6 2 2 2 4 16 4 4 4 4 4 12 82
GIRO 21 2 2 2 2 3 2 2 2 2 7 1 0 1 2 12 0 63
Δ 11 0 0 0 0 -3 0 0 0 -2 -9 -3 -4 -3 -2 8 -12 -19

VEHÍCULOS DESPUÉS DE RODAR VEHÍCULOS ANTES DE RODAR

IN THEhoras
DAILY PRODUCTION
vehíc. h. Total Motivo vehíc. horas h. Total Motivo

MEETING 2 AT2 OPERATING

PIERDE ACEITEUNIT:
2 2 4 MECANICO 19 0 PARA RODAR
1 1 2 2 PIERDE PARAFLU
0 1 2 2 MOTOR MAL
Meca 0 0
O.U. Responsible, O.U. 0
0
0
0
Technologist,
2 2
I.G. Responsibles
PLASTAL
0
4
0
0
2 0,5 1 COLAUDO 0
OTROS
8 1 8 OTROS 0
0 0

IN THE
Q
1
DAILY
2
MEETING WITH WORKERS
0
2
GOLPES PEQUEÑOS
21 4 4
ACCIDENTES/MEDICACIONES
Chapa
AT THE BOARD: 0
DAVID FERNANDEZ DE LA CALLE se corta con bastidor
0

I.G. Responsible, Workers, Technologist

Pintura 0
0
1 2 2 NAVEGADOR PLASTAL
1 2 2 FALTA PARAGOLPES COLOR VARIOS
Falta 0
Mater. 0
0
0
TOTAL 18 13,5 25

56
 Plant Smat Audit System

EVERY FOUR MONTHS AUDIT PER EACH

ETU BY SAFETY SPECIALISTS

MONTHLY AUDIT IN THE PLANT BY AREA

MANAGERS

WEEKLY CHECK-LIST BY ETU LEADERS

DAILY CHECK-LIST BY TEAM LEADERS

DAILY CHECK-LIST BY ALL WORKERS

ON THEIR OWN WORKPLACE

57
 Prevention Audit
Responsib Activity Frequenc Tools People
le y involved
RGI Order and Clean Every two Audit form Team expert
Preventive verification weeks Operators
Service
RGI – SAFETY TEAM Unsafe conditions Every two Audit form Team expert
monitoring weeks Operators
Unsafe Acts Every two Audit form Team expert
monitoring weeks Operators
Action Plan Every two Action Plan RUO, Mto,
Monitoring weeks Meeting safety TGI, TUO
PLAN DE ACCIÓN DE SEGURIDAD G.I.LATERALES Nº Acciones 114

(1)
Nº Origen Zona Problema Acciones Responsable Prioridad (2) Entrada Prevista Estado (3)

22 AB P.35/37 SUELO CON BACHES, RIESGO DE CAIDA TAPAR BACHES I.FERNÁNDEZ 2 4-10-07 8-10-07 COMPLETADA
PELIGRO DE TROPIEZOS Y MOLESTIAS
G.I.LATERALE
27 AB EN EL TRABAJO CON LOS BIPOLARES Y CORRECTO ACOPLAMIENTO DE LAS MISMAS MANTENIMIENTO 3 25-10-07 CONTINUO COMPLETADA
S CABLES DE CORRIENTE
RIESGO DE PROYECCIONES EN ISLAS POSICIONAR PLASTICOS EN LAS ZONAS DONDE SE CUELAN LAS
30 AB P.25 Y 31 ROBOTIZADAS PROYECCIONES
R.G.I. 3 26-10-07 18-1-08 COMPLETADA
G.I.LATERALE TROPIEZO CON BISAGRAS EXISTENTES ELIMINAR LAS BISAGRAS O PONER PROTECCION PARA QUE NO
31 AB I.FERNÁNDEZ 3 24-10-07 26-1-08 COMPLETADA
S AL NIVEL DEL SUELO EXISTA PELIGRO DE TROPIEZOS
PELIGRO DE RESBALAR EN ZONA DE
32 AB P.25 Y 31 ENTRADA A POR LOS LATERALES
PINTAR LA ZONA CON PINTURA ANTIDESLIZANTE I.FERNÁNDEZ 3 25-10-07 21-12-07 COMPLETADA

G.I.LATERALE PELIGRO DE CAERSE LA PINZA POR INSTALACIÓN DE CADENAS DE ACERO DE SEGURIDAD PARA
36 AB MANTENIMIENTO 3 26-10-07 30-11-07 COMPLETADA
S ROMPERSE EL ENGANCHE DEL BIPOLAR EVITAR ESE PELIGRO

PELIGRO DEGOLPE CON LOS CARROS DE

40 AB VANOS VANOS
PONER PROTECCIONES EN LAS ESQUINAS R.G.I. 3 26-10-07 7-11-07 COMPLETADA
G.I.LATERALE REVISIÓN DE TODOS LOS MOSQUETONES Y COLOCACIÓN DE
46 AB PUNTATRIZ SE CAE AL SUELO G.SERENA 1 24-1-08 23-1-08 COMPLETADA
S DOBLE CABLE DE SEGURIDAD EN PUNTATRICES
MANGUERAS DE MAQUINAS DE
SOMBREROS DX SOBRESALEN AL
48 AB P.35 PASILLO EN LA PARTE SUPERIOR Y LAS MODIFICAR DICHAS MANGUERAS O POSICIONAR VALLAS I.FERNANDEZ 2 25-3-08 16-4-08
CARRETILLAS PASAN CON
CONTENEDORES ENGANCHANDOLAS
P.34 MANGUERAS DE MAQUINAS DE
SOMBREROS SX SOBRESALEN AL
49 AB PASILLO EN LA PARTE SUPERIOR Y LAS MODIFICAR DICHAS MANGUERAS O POSICIONAR VALLAS I.FERNANDEZ 2 12-3-08 16-4-08
CARRETILLAS PASAN CON
CONTENEDORES ENGANCHANDOLAS
P.35 LA GARRA MANUAL DEL UTIL OP.20 CAMBIAR EL DISEÑO DE LA MANETA PARA QUE QUEDE JUNTO AL
FURGON EN LA PARTE INFERIOR ESTA UTIL CUANDO ESTÉ ABIERTO
50 AB PELIGROSA Y PROVOCA GOLPES EN LAS I.FERNANDEZ 3 28-2-08 16-4-08
PIERNAS
P.33 LA GARRA MANUAL DEL UTIL OP.20 CAMBIAR EL DISEÑO DE LA MANETA PARA QUE QUEDE JUNTO AL
FURGON EN LA PARTE INFERIOR ESTA UTIL CUANDO ESTÉ ABIERTO
51 AB PELIGROSA Y PROVOCA GOLPES EN LAS I.FERNANDEZ 3 28-2-08 16-4-08
PIERNAS
VANOS ALGUNOS CARROS CARECEN DE SOLDAR LA PLETINA
PROTECCION DE LA RUEDA DELANTERA,
55 AB POSIBILITANDO QUE EL ULTIMO VANO I.FERNANDEZ 3 13-3-08 30-4-08
GOLPEE LA RUEDA Y SE PUEDA CAER
HACIA DELANTE

MOSQUETÓN DESGASTADO SE SUELTA COLOCAR DOS CABLES DE ACERO PARA EVITAR LA CAIDA DE LAS
71 AB P.24
DE LA PUNTATRIZ MAQUINAS, Y REVISION DE TODA LA UNIDAD OPERATIVA
G.SERENA 1 24-1-08 27-1-08 COMPLETADA

PROYECCIONES QUE SALEN DE LA ZONA

DEL ROBOT POR LAS UNIONES TIENEN FORRAR HUECOS PARA EVITAR PROYECCIONES FUERA DE LA R.GARCIA/I.FERNAN
80 AB P.25
PELIGRO DE DAR A LOS OPERARIOS Y ISLA DEZ
2 11-1-08 11-3-08 COMPLETADA
GENTE DE PASO
PROYECCIONES QUE SALEN DE LA ZONA
DEL ROBOT POR LAS UNIONES TIENEN FORRAR HUECOS PARA EVITAR PROYECCIONES FUERA DE LA R.GARCIA/I.FERNAN
81 AB P.31
PELIGRO DE DAR A LOS OPERARIOS Y ISLA DEZ
2 11-1-08 11-3-08 COMPLETADA
GENTE DE PASO
PROYECCIONES QUE SALEN DE LA ZONA
DEL ROBOT POR LAS UNIONES TIENEN FORRAR HUECOS PARA EVITAR PROYECCIONES FUERA DE LA R.GARCIA/I.FERNAN
82 AB P.34A
PELIGRO DE DAR A LOS OPERARIOS Y ISLA DEZ
2 11-1-08 11-3-08 COMPLETADA
GENTE DE PASO
MAQUINA SUELTA EXCESIVAS CHISPAS,
107 AB P.27 CON RIESGO DE QUEMADURAS PARA EL PROTECCION PROVISIONAL Y REGULACION DE PARAMETROS R.GARCIA DE BLAS 3 8-4-08 15-4-08
OPERARIO

58
 Specialists Audit
The safety members audit
each ETU every four AUDIT DI PROCESSO
FIAT GROUP Automobiles S.p.A.
Manufacturing Cassino Plant
( Autovalutazione e/o verifica R.S.P.P. )

months, through this form. ARGOMENTO: PREVENZIONE INFORTUNI E IGIENE DEL LAVORO

RIFER. NORMATIVO: D.P.R. 547/55, D.P.R. 303/56, D. Lgs. 277/91, D. Lgs.626/94 e successive modifiche ed integrazioni.

Issues UNITÁ / UTE MONTAGGIO 1 ARCELLA Luigi AUDIT N° 2 DATA : 23-10-2007

totale voci voci non conformi indice di conformità

considerate (TV) n. pesate IC = 100 - (TP / TV x 100)
0

1) Risks evaluation of workplaces

gravità 1 0
gravità 2 2 2
74 92.57
gravità 3 7 3.5

totale pesato (TP) 5.5

2) Inquiries about accidents Con indice di gravità (IdG) = 1 moltiplicare x 1,5; con IdG = 2 moltiplicare x 1; con IdG = 3 moltiplicare x 0,5.

LEGENDA ATTRIBUZIONE GRAVITA'

Priorita' Quando E' da rimuovere:
- Puo' essere probabile causa di evento infortunistico. SUBITO adottando le necessarie

3) Substances and chemical compositions 1

- Puo' essere probabile causa di problemi ambientali e/o casi di malattia
professionale.
- E' gia' stata causa di evento infortunistico o eventuale incidente.
misure tecnico/organizzative/procedurali
provvisorie e/o definitive.

- E' una trasgressione ad una normativa di legge che puo' comportare

grosse responsabilita' di tipo penale (pena detentiva o pecuniaria).

4) Ergonomy
- Attivita' gia' messa in atto sostanzialmente ma da completare. A BREVE adottando le necessarie
- Non puo' essere causa di evento infortunistico. misure tecnico/organizzative/procedurali
2 - E'una trasgressione ad una normativa di legge che non puo' comportare provvisorie e/o definitive.
responsabilita' di tipo penale.
- Presenza di misure alternative provvisorie
- Da migliorare/aggiornare Appena possibile e/o con costante

5) Prevention Diary 3 - Condizioni gia' soddisfacenti ma da migliorare. miglioramento.

6) Safety Devices

7) Transport

8) Noise in working environment

9) Machinery and electric devices

10) Safety warnings

11) Personal Protective Equipment

12) Safety document

13) Evacuation and emergency plan

14) Routes

15) Medical exams

16) Tiding and Cleaning

59
 ETU leader Audit

Each ETU Leader weekly Issues

audits the entire ETU,
through this form. 1) Team leader audit check

2) Safety Devices

3) Routes

4) Tiding and Cleaning

5) Evacuation and emergency plan

6) Prevention Protective Equipments

7) Prevention Diary

8) Risks evaluation of workplaces

9) Substances and chemical compositions

10) Ergonomy

11) Transport

12) Noise in working environment

13) Machinery and electric devices

14) Safety warnings

15) Safety document

16) Medical exams

60
All workers Audit

Each worker daily audits his

on workplace before starting
working, through this form.

Issues

1) Safety Devices

2) Equipment integrity

3) Prevention Protective equipments

4) Routes

5) Tiding and Cleaning

6) Evacuation and emergency plan

61
 Team Member & Lift Truck Driver

The Team Member & the Lift Truck Driver

Audit is performed every day at the
beginning of each shift (for 3/5 minutes).

62
62
 Evolution of the Safety Actions in Model Areas
29
AI
Preventive Actions Reactive Actions

70

60
Nº Actions

50

40

30

20

10

8
00
0
7

08

,2
00

20

ch
.2

n.

ar
ov

Ja

M
N

STEP 1 STEP 2 STEP 3 STEP 4

63
 Step 5 – Autonomous inspection Self Control Checklists
Daily safety check at the
AS workplace TAKING CARE OF THEIR OWN SAFETY
ARE
L EVERY SHIFT THE OPERATOR CONTROLS HIS
O DE
M OWN WORKPLACE

OK / KO
Before starting

PPE’s state

Order and cleanliness

Safety devices working

Testing other possible unsafe

conditions
Unsafe
Condition

64
 Step 5 – Autonomous inspection
Unsafe Conditions Charts
MODEL AREAS
Easy tool for every worker

Unsafe
Condition
Nº unsafe conditions
Worker’s name charts
and workplace

115
Help to identify and classify unsafe
conditions

Unsafe condition description

Solution suggestion

65
 Step 5 – Autonomous inspection
Example Unsafe Conditions Charts
MODEL AREA

Unsafe Sharp Elements

Condition

Pieces stuck out the carts

To add a protective structure

66
 Safety Improvement - EMPLOYEES SUGGESTIONS

“Blowing Box”

AFTER

BEFORE
Noise Reduction

Spraying Reduction

Reduction of the danger of

ejection chips
67
67
 Safety KPI - HEINRICH PYRAMID

UNSAFE ACT & Implementation in Open issue

CONDITION UTE Safety discussed in the
NEAR MISSES data-base daily meeting

DATA
N.RO NC/NM DESCRIZIONE UTE SEGNALAZIONE Sol. TEMPORANEA Sol. DEFINITIVA

op55 interbloc c hi non funzionantiop 130

101 15/01/2008 ripristino interbloc c hi
interbloc c hi non funzionanti

• Segnalazioni Near Misses

001 NC
i passaggi pedonali sono ostruiti da
101 25/01/2008 sgombrare pedane

ACTION
002 NC pedane

• Audit (gravità 2-3) 003 NC

Le sc ale risultano essere sporc he 101 25/01/2008 pulire le sc ale

RIPRISTINO SICUREZZA

PLAN
RIPARI OP 55 NON OK 101 12/02/2008

• Certificazione Posto lavoro

004 NC RIPARI

Pavimenti sc ivolosi a c ausa dello

101 25/02/2008 pulizia pavimento
005 NC sversamento di refrigerante

• Richiami diario prevenzionale

RIPRISTINO SICUREZZA
OP55 RIPARI NON FUNZIONANTI 101 12/03/2008
006 NC RIPARI

Sostituzione dei
alc uni armadi hanno le porte aperte 101 25/03/2008 c hiudere le porte
007 NC dispositivi di protezione

• Segnalazioni sindacali 008 NC

Presenza di materiale di deposito sui
passaggi pedonali
101 09/04/2008
c reare area per deposito
Far togliere le pedane dai passaggi
materiale semilavorati

op 100 sc ale sporc he 101 09/04/2008 pulire sc ale

009 NC

ripari op 120 non fissati perfettamente 102 28/01/2008 Rec intare l'area c on del nastro
Ripristinare i ripari
010 NC
op.60 pavimentazione sc ivolosa dovuta intensific ato c ic lo pulizia

Check
102 19/02/2008
allo sversamento di lubrorefrigerante pavimentazio
011 NC
apporre delle saldature
c operture c anale refrigerante deformati 102 29/02/2008 per garantire c he non si
012 NC sollevino c on il passaggio

013 NC
OP. 60 ECCESSIVA NEBULIZZAZIONE OLIO
DA
102 07/03/2008
INTENSIFICAT E PULIZIE
APERTO CANTIERE
Activity Progress

NOT
Solved
Solved

68
68
 LWDC ETU – n° YEARS without Accidents

“ETU ZERO LWDC”




1
2 Y
 3 E
 Y
4 Y E A
5 Y E A R
Y E A S
R
E A R S
A R S 80%
R S
S 76%
72%
We have a ETU with
44%

1.500.000 hours of work, 24%

without LWDC
69
69
 External Benchmark

Benchmarking ….
Indice LWDC (12 mesi rolling) = n°eventi x 100.000
Ore lavorate
0,50

0,42
0,40 0,36
ENGINE PLANT
0,31
0,30
0,28
LWDC

0,20
0,20 0,17 0,16

0,10
0,00

0,00

70
70
LWDC – n° YEARS without Accidents

“ETU ZERO LWDC”

The whole
Engine 16V
e s
l v s &
4 years
e
Va a lv
1 6 V2 milions
8
hours of work
without
LWDC 71
71
PILLAR Activities

• The actions to improve our level

1 – Benchmarking - Indicators

35

30

25
Taux de fréquence

20

15

10

0
lt é n a lt E S y s it C s s e x) le x ia A n E di ia n di ta lé l in
rau ant com afr a col nau s S com SA ine erie fed SN zbu trie o up au vil vau r ec PS g e M Au r ec ag e Au yo per sou ma
lle s le s a e e r o
lé n ch tt S N lie u s r d e l le ci u a
w T M u w o
t im Ve de
te e la té oc R n g e té ody Pé ba p p SO He ind T G bor Be PE Fa ks Fa lks u r
hâ d ce c A c m T u N s I A ( E N ol
v o Q SA Co
C ité a n m F r I
li eo a n er iu F K H iro
n F A NP C V
DM
P F
re l to r F
r
v al Fr Th in SA en TC G C M C P ED
a au um ss U t - N
M
ti ute Al Th
y H
ai
n S
e
n a a n S
c
ag h Al 1
M
Organisations

72
PILLAR Activities

• The actions to improve our level

1 – Benchmarking - Indicators

1
0,9
0,8
0,7
Taux de Gravité

0,6
0,5
0,4
0,3
0,2
0,1
0

Organisations

73
PILLAR Activities

• The actions to improve our level Assis au fond de la chaise, les mains posés à l’intérieur des cuisses.

2 – Health campaign
We have realized specific training
about healthy ways of working

Example of advices given to our

people. Exercises to avoid pains in Monter les épaules le Rapprocher les omoplates vers
plus haut possible, en l’arrière en inspirant, puis
neck, back and shoulders inspirant et en expirant écarter les omoplates en
relâcher d’un seul enroulant les épaules vers
l’avant en expirant.
coup .
 Se mettre à 4 pattes et la  Faire glisser les
tête en avant, bras vers l’avant,
 Se recroqueviller sur soi Se redresser
même (assis sur les talons) doucement sur les
Doigts Tirer vers le Redresser la en touchant le sol avec le
Terminer talons en inspirant.
croisés et bas les tête front.
les mains coudes, doucement, en l’exercice en
derrières doucement partant du bas tirant les 
le cou, (sans douleur) du cou (ne pas bras vers le 
en soufflant, mettre la tête haut avec la
en arrière), tête droite.
 74
Training on personal health

Health of our employees is very important not only at work but also at home

Wrong food nutrition Information

campaign (in progress)

Smoking risk information campaign

(in progress)

75
PILLAR Activities

• The actions to improve our level

3 – Health campaign

Diet, smoke, hygiene, other… Blood

campaign
Tobacco Influenza

Alcool

76
TARGETS AND ACTIONS

NEXT TARGET:

• COMPLETE IMPLEMENTATION OF WCM SAFETY TOOLS DEPLOYMENT

• CONSOLIDATIONS OF PLANT SAFETY CULTURE THROUGH PROACTIVE
APPROACH AT ALL LEVELS
• IMPLEMENT TRAINING SAFETY PROGRAMS FOR ALL EMPLOYEES REGARDING
“HOME SAFETY”
• OHSAS 18001 CERTIFICATION

TARGET: ZERO ACCIDENTS

77
77