Estrategia de Seguridad para la reduccin de

Accidentes

Approach
7 steps
Gestin Iniciada

Iniciativa

Equipo Iniciado

Propia
Paso 7
Paso 6
Paso 5
Paso 4
Anlisis de
Accidentes
(Analisis de
causas)
Paso 1

Reactivo

Paso 3
Paso 2
Contramedidas
y expansin
horizontal
(Extension en
areas similares)

Establecimient
o de
estandares de
Seguridad
(Listado de
todos los
problemas de
Seguridad)

Inspeccin
General de
seguridad
(Entrenar y
hacer crecer
a las
personas que
se preocupan
por la
seguridad)

Preventivo

Inspeccin
autnoma
(Contra
medidas
predictivas para
los problemas
de seguridad )

Gestion de
Seguridad
completamente
implementado

Estandares de
seguridad
autnomos
(*Inspeccion
general de los
nivels de
seguridad y
revaluacin)

Proactivo
2

Basic Data
Model Area Selection from S Matrix

Standards & Tools

Methodological standards
Analysis of
accidents
(Analysis of
causes)

STEP 1
Heinrich Pyramid
S- Matrix Area
Class.
Safety EWO
Near miss UA - UC
Injuries by body part
Injuries by kind
Risk Analysis
Risk maps
Lock off Lock out
Ergonomic risk map
Work instruction
Visual management
Safety audit
SMAT

Counterme
a-sures and
horizontal
expansion
(Extension
at the
similar
areas)

STEP 2

Standard introduced

Setting
tentative
standards
for safety
(Listing all
safety
problems)

STEP 3

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

Autonomou
s inspection
(Predictive
countermea
sures
against
safety
problems)

STEP 4

STEP 5

Standard in use and extended

Autonomou
s safety
standards
(*Overall
inspection
of safety
levels
*Reevaluati
on if safety
control)

STEP 6

Fully
implemente
d safety
managemen
t

STEP 7

Standard relevant use an

Ruta para llegar a la Excelencia en Seguridad

Tener una poltica de seguridad de Trabajo.

Tener integrada la seguridad en la organizacin.
Tener en toda la lnea de la organizacin su responsabilidad de seguridad.
Tener objetivos y metas de seguridad agresivos.
Tener altos estndares de desempeo
Contar con personal de seguridad suficiente
Debemos tener una planta y equipo Apropiado
Involucrar a los empleados
Crear motivacin Progresista
Tener una comunicacin efectiva de dos vas
Tener una formacin continua de la seguridad en todos los niveles
Necesitamos buenos Comportamientos de la gente (SBC, Comienzo Seguro)
Tener informes de lesiones e incidentes integrales y estandarizados
Tener Auditoras / observaciones
Tener implementado un Sistema de Gestin de Seguridad

Needs, vision, objectives, targets

Necesidades :

Alcanzar la seguridad de Clase Mundial, esto es fundamental del

desempeo de clase mundial.

Visin : Mejorar la cultura de seguridad para asegurar que ninguna

operacin presenta riesgo de Seguridad y Salud para ningn

empleado.

Objetivos : Para ser una planta de Cero Accidentes

Metas : 0 Timepo perdido
0 Tratamientos mdicos
0 Near Miss

KPIs

Seven Steps of Safety

Management initiated

Self-initiated

Team initiated

Step 7
Step 6
Step 5
Step 4
Analysis of
accidents
(Analysis of
causes)
Step 1

Reactive

Step 3
Step 2
Countermeasures and
horizontal
expansion
(Extension at
the similar
areas)

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)

Preventive

Autonomous
inspection
(Predictive
countermeas
ures against
safety
problems)

Fully
implemented
safety
management
Autonomous
safety
standards
(*Overall
inspection of
safety levels
*Reevaluation
if safety
control)

Proactive
8

Seven Steps of Safety

Step 1 :

Step 5 :

Analysis of accidents followed by an analysis

of the causes of accidents. What are the
sources and frequency of events? Get the
facts!

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

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.
Step 4 :
Make safety important to everyone.
Introduce a general inspection for safety.
Remove the perception that safety is the
Safety Managers job. Train people in their
understanding of what safety means and

Main Countermeasures per Phase

Step
Reactive

Countermeasures
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
10

Levels and Extension

11

Preliminary Activities

EX

E
L
P
M
A

Pillar Master Plan

12

Preliminary Activities
Safety Policy

13

Preliminary Activities
Periodical checks procedure

Employees periodical check

Process flow description

All the employees attend initial and

periodical checks in terms of ability to
perform their work according to the
following flow-chart

D Base

14

Preliminary Activities
Machines / Equipment Compliance with local directives
Relevant EU directives:
DPR 547/55 related to machines
and equipment installations before
1994

Compliance Statement

CE certification after 1994

15

Preliminary Activities
Management Meetings
Safety is daily reported at management and Unit level
DAILY MANAGEMENT MEETING:
Head Manager, 1st line Managers

DAILY PRODUCTION MEETING

(OPERATING UNIT LEVEL):
Unit Manager, Manufacturing
Engineering, Supervisor

16

Preliminary Activities
Heinrichs Pyramid

17

Preliminary Activities
Heinrichs Pyramid: detailed data
ASSEMBLY
SHOP

ETU 22

ETU 15

ETU 16

ETU 14
ETU 13
ETU 03

ETU 02

ETU 01

ETU 05

ETU 04
ETU 18

ETU 19

ETU
21
ETU 07

ETU 55

ETU 27

ETU
20

18

Preliminary Activities
Map of accidents

19

Preliminary Activities
Map of first aids

20

Selection of model areas

S Matrix (global overview)

21

SEVEN STEPS OF SAFETY

Step 7
Self-initiated

Management initiated

Step 6
Step 5
Step 4
Analysis of
accidents
(Analysis of
causes)

STEP 1

Reactive

Step 3
Step 2
Countermeasure
s and horizontal
expansion
(Countermeasur
es at the similar
areas)

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)

Preventive

Autonomous
inspection
(Predictive
countermeasur
es against
safety
problems)

Fully
implemented
safety
management

Autonomous
safety standards
(*Overall
inspection of
safety levels
*Reevaluation if
safety control)

Team initiated

Proactive
22

Step1 - Analysis of Accidents

Description of
accident /
incident (very
very clear)

Analisi causa
radice
Safety EWO
Tipologia del
causa
detagliato

Extension to
similar areas

Proper
Countermeasur
e and
standardization

Control of
Effectiveness of
countermeasur
e (No similar
accident)

23

Step2 - Countermeasures and horizontal

expansion
Model
Identify Areas
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.
Description of
accident /
incident (very
very clear)

Key Points:
Explain how you
are selecting
similar areas to
extend same
countermeausure
Control of
results for
enough time 3-6
months before

No similar
accident in
PLANT

Analisi causa
radice
Safety EWO
Tipologia del
causa
detagliato

Extension to
similar areas

Proper
Countermeasur
e and
standardization

Control of
Effectiveness of
countermeasur
e (No similar
accident)

24

Safety approach with WCM

ALL THE PLANT
MODEL AREA

Detection

Detection form

Analysis

Report form EWO

Medications

Countermeasures

Effectiveness Check

Horizontal Extension

Quick Kaizen
Action Plan

Safety Meetings
Reports by Central
Board

Near Misses
Unsafe Conditions
Unsafe Acts

Unsafe Conditions
Charts
Check list operator
Safety Audit

25

Classification of Safety Events

Accident Classification

Ops Classification

26

Classification of UA&UC
Unsafe Act and possible Root Causes

27

Step 1 Analysis of accidents Safety Emergency Work Order

Safety EWO

28

Safety Book Methods Standards

Safety EWO: Plan

29

Safety Book Methods Standards

Safety EWO: Do - Check

30

Safety Book Methods Standards

Safety EWO: Act

31

Step 1 Analysis of accidents

32

Step 1 Analysis of accidents

33

Step 1 Analysis of Near Misses

34

Step 1 Analysis of Near Misses

35

Step 1 Analysis of Near Misses

36

SEVEN STEPS OF SAFETY

Step 7
Management initiated

Self-initiated
Step 5
Step 4

Step 3
Analysis of
accidents
(Analysis of
causes)

Step 1

Reactive

STEP 2

Countermeasure
s and horizontal
expansion
(Countermeasur
es at the similar
areas)

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)

Preventive

Autonomous
inspection
(Predictive
countermeasur
es against
safety
problems)

Step 6

Fully
implemented
safety
management

Autonomous
safety standards
(*Overall
inspection of
safety levels
*Reevaluation if
safety control)

Team initiated

Proactive
37

Step2 - Countermeasures and horizontal

expansion
Model
Identify Areas
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.
Description of
accident /
incident (very
very clear)

Key Points:
Selection of
similar areas to
extend same
countermeausure
Control of
results for
enough time 3-6
months before
extension

Result
should be : No
similar
accident in
PLANT

Analisi causa
radice
Safety EWO
Tipologia del
causa
detagliato

Extension to
similar areas

Proper
Countermeasur
e and
standardization

Control of
Effectiveness of
countermeasur
e (No similar
accident)

38

SEVEN STEPS OF SAFETY

Step 7
Management initiated

Self-initiated
Step 5
Step 4

STEP 3

Analysis of
accidents
(Analysis of
causes)

Step 1

Reactive

Step 2
Countermeasure
s and horizontal
expansion
(Countermeasur
es at the similar
areas)

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)

Preventive

Autonomous
inspection
(Predictive
countermeasur
es against
safety
problems)

Step 6

Fully
implemented
safety
management

Autonomous
safety standards
(*Overall
inspection of
safety levels
*Reevaluation if
safety control)

Team initiated

Proactive
39

STEP 3 VISUAL SAFETY MANAGEMENT IS STANDART

To Welcome You and escort all the way inside
DAILY
SAFETY
INFO

STAIR
SAFETY
GUIDES

RISK
INFO

PEDESTRIAN
LANE
GUIDES

SAFETY
MODEL AREA
SIGNS

40

STEP 3 VISUAL SAFETY MANAGEMENT IS STANDART:

To work with Safety in mind

41

STEP 3 PTI (Point Welder) WARNINGS

Fig. The range of height which can be easily watched

87
%

Obtaining rate

7%
Eye

Ear

3.5%
Nose

1.5
%
Skin

1%
Tongue

Fig. Obtaining rate of information by five senses

42

STEP 3 SAFETY CULTURE:

Risk Analysis Cycle Since 2002
RISK ANALYSIS
PROCESS CYCLE
DIRECTORS
MANAGERS

SAFETY
EXPERTS

Annual Risk Level

Assesment & Approval

Improvement Plan

(Annual Budget /Catchball)

OPERATORS

Basic Training

43

Risk Assessment

44

Risk Assessment Items

45

Risk Assessment Items

Risk Analysis: kind of risks

46

Risk Assessment Items

47

Safety standard Lock offout Procedure

48

Safety Book Methods Standards

DPI map per workstation
Step 3

THANKS
THANKS TO
TO RISKS
RISKS MAP
MAP WE
WE
IDENTIFIED
ALL
KIND
OF
INDIVIDUAL
IDENTIFIED ALL KIND OF INDIVIDUAL
PROTECTION
PROTECTION DEVICES
DEVICES(DPI)
(DPI)

49

Safety Book Methods Standards

Work Instruction

E
L
P
M
A
X
E

50

Safety Book Methods Standards

Work Instruction

51

STEP 3 VISUAL MANAGEMENT:

Safety Info Boards

ROOT CAUSE ANALYSIS

RISKS & PPES

AUTONOMOUS IMPROVEMENT ACTIVITIES

IMPROVEMENTS

MONTHLY DATA

DAILY DATA
52

Safety Book Methods Standards

Visual management

Andamento UTE

Andamento su turni

Record

53

Safety Book Methods Standards

Visual management: Green Cross

54

Safety Book Methods Standards

Visual management

55

Safety Book Methods Standards

Visual management: Lost time accident record

56

Safety Book Methods Standards

Visual management: Activity board
Utilizzo DPI

Utilizzo
DPI
Andamento
segnalazioni

segnalazioni

Croce verde

Ultimo infortunio

Anamento infortuni

SAFETY Team

Body chart

Piramide Heinrich

Croce
verde

Ultimo
infortunio

Andamento
infortuni
annuo

body chart

Piramide
Hainrich

Elenco
Miglioramenti
implementati

Mappatura
Area rischi

Risultati
Smat audit

Check-List
Step
di verifica

IF

OPL

Check list
Smat audit

Self audit

Action plan
formazione

SKETCH
miglioramenti

Proposte miglioramento

SMAT audit check

lis t

Modulo Segnalazioni
NM_AC

miglioramento
prima-dopo

Mapatura area
ris chi

IF infortuni

Verifiche di reparto
7 s teps

Aggiornamento infortuni

1.30 m da terra

57

Safety Book Methods Standards

58

Safety Book Methods Standards

Visual management

E
L
P
M
A
X
E
PPE
List of all the prescribed PPE is
hanging in front of each work place.

100% of Plant
Workstations are
monitored
59

59

SEVEN STEPS OF SAFETY

Step 7
Management initiated

Self-initiated
Step 6

Fully
implemented
safety
management

Step 5
STEP 4

Step 3
Analysis of
accidents
(Analysis of
causes)

Step 1

Reactive

Step 2
Countermeasure
s and horizontal
expansion
(Countermeasur
es at the similar
areas)

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)

Preventive

Autonomous
inspection
(Predictive
countermeasur
es against
safety
problems)

Autonomous
safety standards
(*Overall
inspection of
safety levels
*Reevaluation if
safety control)

Team initiated

Proactive
60

STEP 4 SAFETY INSPECTION SYSTEM:

Safety Audits For Safe Man and Machine
WHO

CEO &
Steering Team

CEO

WHAT

WHEN

HOW

OTHER PEOPLE INVOLVED

Period:
6 Months

SMAT

All Necessary

Monthly

SMAT

All Necessary

Monthly

RCA
SMAT

All Necessary

Clean and tidy

Weekly

Check of unsafe acts

and conditions
Questions to workers

Plant manager
Industrial
Group Director
&
Manager

Check of unsafe acts

and conditions

Questions to workers

Manager

Safety
Team

Machines and tools

Safety
Team

Workplaces
Chemical agents
Emergency plan

BPU &
Maintenance
Leader
Team Expert

Check of utilization of PPE

BPU&
Main-tenance
Leader

Check machine safety guards

Lean Team
Leader

Lean Team Leader, Safety Specialist

Lean Team Leader,Safety Specialist

Weekly

Safety Diary

Lean Team Leader

Safety Specialist
Maintenance Employee

Check Workpiece storage

Collection and analysis of safety suggestion

Lean Team Leader

Worker

SMAT

Weekly

Check of utilization of PPE

Daily

Personal Risk
Declaration

SMAT
RCA

Check of metarial storage

Lean Team Leader

Lean Team Leader, Safety Specialist

Maintance, Office

Operator

Operator

Autonomous Inspection

Daily

T Card
P.R.D.

Safety Specialist, Lean Team Leader

61

Safety Book Methods Standards

Audit System
Issues

PLANT
MANAGER
MANAGEMENT

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) Ergonomic

SPECIALISTS
MIDDLE MANAGEMENT
TEAM LEADERS
WORKERS

Unsafe
Condition
Unsafe
Act

11) Transport
12) Noise in working environment
13) Machinery and electric devices
14) Safety warnings
15) Safety document
16) Medical exams

All work area (ETU)

Leader or Supervisor
audits the entire work
area (ETU), through this
form.

62

Safety Book Methods Standards

Audit System

PLANT
MANAGER
MANAGEMENT
SPECIALISTS
MIDDLE MANAGEMENT
TEAM LEADERS
WORKERS

Issues
1)

Safety Devices

2)

Electrical equipment integrity

3)

Prevention Protective Equipments

4)

Routes

5)

Tiding and Cleaning

6)

Evacuation and emergency plan

Unsafe
Condition

Each Team Leader daily

audits the entire work
area (ETU), through this
form.

63

Safety Book Methods Standards

Audit System

PLANT
MANAGER
MANAGEMENT
SPECIALISTS
MIDDLE MANAGEMENT
TEAM LEADERS
WORKERS

Issues
1)

Safety Devices

2)

Equipment integrity

3)

Prevention Protective equipments

4)

Routes

5)

Tiding and Cleaning

6)

Evacuation and emergency plan

Unsafe
Condition

Each worker daily audits

his on workplace before
starting working,
through this form.
64

Safety Book Methods Standards

Audit System

OK / KO

Before starting
PPEs state

Order and cleanliness

Safety devices working

Testing other possible unsafe

conditions
Unsafe
Condition

65

Safety Book Methods Standards

Audit System

PLANT
MANAGER
MANAGEMENT
SPECIALISTS
MIDDLE MANAGEMENT
TEAM LEADERS
WORKERS

The Lift Truck Driver Audit is performed every

day at the beginning of each shift.

Unsafe
Condition
66

66

Safety Book Methods Standards

Audit System

67

Safety Book Methods Standards

Audit System

PLANT
MANAGER
MANAGEMENT
SPECIALISTS
MIDDLE MANAGEMENT
TEAM LEADERS
WORKERS

Unsafe
Act

Unsafe
Condition
68

SEVEN STEPS OF SAFETY

Step 7
Management initiated

Self-initiated
STEP 5

Step 4
Step 3
Analysis of
accidents
(Analysis of
causes)

Step 1

Reactive

Step 2
Countermeasure
s and horizontal
expansion
(Countermeasur
es at the similar
areas)

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)

Preventive

Autonomous
inspection
(Predictive
countermeasur
es against
safety
problems)

Step 6

Fully
implemented
safety
management

Autonomous
safety standards
(*Overall
inspection of
safety levels
*Reevaluation if
safety control)

Team initiated

Proactive
69

Safety Book Methods Standards

Safety Captain Program

OBJECTIVE
Seek effective and autonomous participation of
employees in accident prevention, preparing,
motivating, integrating and involving all the
team.
WHO IS THE SAFETY CAPTAIN?
Operator of Industrial Process who works as a
multiplying agent, encouraging good safety
practices and promoting accident prevention.
WORKING TOOL

ON
I
CT
E
SP
N
I

RD
A
C

Captain Card proposals for improvement.

70

Safety Book Methods Standards

Safety Captain Program

71

Worker Check List

Audit System

72

An example of workers Audit

73

Worker SMAT example on model area

74

Worker SMAT example on model area

75

STEP 5 AUTONOMOUS SAFETY OF MACHINERY:

T-Card for Work machines

ILY
A
D

NO

S
YES TION
ES
U
Q

76

STEP 5 AUTONOMOUS SAFETY OF MACHINERY:

T-Card for Workshops

BODYSHOP
Application for Welding Guns,
Fixtures & Other Equipment

ASSEMBLY SHOP
Two way communication for safety

77

SEVEN STEPS OF SAFETY

Step 7
Self-initiated

Management initiated

Step 5
Step 4
Analysis of
accidents
(Analysis of
causes)

Step 1

Reactive

Step 3
Step 2
Countermeasure
s and horizontal
expansion
(Countermeasur
es at the similar
areas)

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)

Preventive

Autonomous
inspection
(Predictive
countermeasur
es against
safety
problems)

STEP 6

Fully
implemented
safety
management

Autonomous
safety standards
(*Overall
inspection of
safety levels
*Reevaluation if
safety control)

Team initiated

Proactive
78
78

Autonomous Safety Definition

AS is the combined effort of employees within their teams to contribute to

the continuous improvement of safety in the workplace taking into account
their individual and collective capabilities.
Key Elements of AS
Employees show pride in their workplace
Employees willing to acquire and pass on knowledge and skills for
continuous improvement
Employees communicate effectively on safety
Employees are self directed and dont Walk By
Employees know their competence limits and seek advice when required
79

AS The benefits

Closes the loop on Safety-Management

Provides a mechanism for all personnel to contribute towards
achieving safety targets and gives them individual responsibility
Helps people identify when they are more at risk
Results in a safer working environment
Opens communication channels
Improves team-working

80

Autonomous Safety Standard Example

81

Autonomous Safety Standard Example

82

Autonomous Safety Standard Example

83

STEP 6 SAFETY IMPROVEMENT OPLs

One Point Lessons 2008
Blue Collar
(Operators)
98%

White Collar
(Leaders)
%2

84

STEP 6 IMPROVEMENT TOOLS

Before/After Kaizens 2008
Blue Collar
(Operators)
98%

White Collar
(Leaders)
%2

85

STEP 6 IMPROVEMENT TOOLS:

Opl, Before/After, Standard Kaizens

86

FEB

MAR

APR

MAY

JUN

JULY

AUG

SEP

OCT

NOV

DEC

JAN

FEB

STEP 6 B.P.U. 115/PRESS P.U.

FATAL

>30 DAYS

LTA

MTC

NEAR
MISS

UNSAFE
CONDITIONS

UNSAFE
ACTS

87

SEVEN STEPS OF SAFETY

STEP 7

Self-initiated

Management initiated

Step 4
Step 3
Analysis of
accidents
(Analysis of
causes)

Step 1

Reactive

Step 2
Countermeasure
s and horizontal
expansion
(Countermeasur
es at the similar
areas)

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)

Preventive

Step 6

Fully
implemented
safety
Autonomous
Step 5 safety standardsmanagement
(*Overall
inspection of
Autonomous safety levels
inspection *Reevaluation if
(Predictive safety control)
countermeasur
es against
Team initiated
safety
problems)

Proactive
88

STEP 7 MODEL AREA SAFETY DATA 5+20

89

STEP 7 ZERO ACCIDENT B.P.U.s

SUSP.
SHOP

PRESS
SHOP

BODY
SHOP

PAINT
SHOP

ASSEM.
SHOP

90