安全意識(shí)培訓(xùn)(擠壓點(diǎn))

BehavioralStrategyonPinchPointsforBBSFacilitatorsandSteeringCommittees

October,2013

?TennecoAutomotiveOperatingCompanyInc.2013ConfidentialInformationBBS推動(dòng)者和指導(dǎo)委員會(huì)的擠壓點(diǎn)行為策略BehavioralSafetyStrategyonPinchPointsFirstweneedtoknowthatBehaviorisjustanobservableactTherearethreetypesofbehavior:easy,difficultandimpossible.Itreferstothelevelofcontrolthattheindividualhas…h(huán)oweasyitisforthemtodothatactionsafelyBBSobserversshouldbefocusedonallthetypesofbehaviors.Thefirsttaskofanobserveristoreinforcesafebehaviors,thenhe/sheshouldlookforpossibleat-riskbehaviorsAt-riskbehaviorsonpinchpointscanbechangedthroughactionplansinvolvingpeopleandactionsatalllevels,quickfixesorverbalfeedback.Observersandsteeringcommitteemembersareresponsibletocollectaccuratedataandprovidegoodverbalfeedbackiftheycangetenoughtimetocarryoutgoodqualityobservations.Actionplansandquickfixesareusuallyunderresponsibilityofmanagersandsupervisors.首先我們需要明確這是一個(gè)可以觀察到的行為；有三種類型的行為：簡(jiǎn)單、困難、不可能；這取決于個(gè)體的控制能力……行為安全對(duì)于他們而言的容易程度；BBS觀察員應(yīng)該注意所有類型的行為動(dòng)作；觀察員首要任務(wù)是鞏固安全動(dòng)作，然后他/她應(yīng)該尋找可能的危險(xiǎn)動(dòng)作；擠壓點(diǎn)危險(xiǎn)動(dòng)作可以通過(guò)行為動(dòng)作計(jì)劃包括人和所有級(jí)別的動(dòng)作、快速解決方法或口頭反饋來(lái)改變；觀察員和指導(dǎo)委員會(huì)成員負(fù)責(zé)收集準(zhǔn)確數(shù)據(jù)、提高良好的口頭反饋，如果他們能夠獲得足夠的時(shí)間來(lái)開(kāi)展高質(zhì)量的觀察行動(dòng)；行為動(dòng)作計(jì)劃和快速解決方法通常由經(jīng)理和主管負(fù)責(zé)。擠壓點(diǎn)行為安全策略Thebehaviorlookslikeeasytobecarriedoutsafe.ItcanbeinfluencedbyfeedbackduringtheBBSobservation.Safebehaviorshouldbereinforcedduringbypositivefeedback.這個(gè)動(dòng)作看起來(lái)很容易變得安全。這可以通過(guò)BBS觀察中的反饋被影響。安全動(dòng)作應(yīng)通過(guò)積極反饋來(lái)增強(qiáng)。擠壓點(diǎn)擠壓點(diǎn)手伸入擠壓點(diǎn)手離開(kāi)擠壓點(diǎn)危險(xiǎn)動(dòng)作安全動(dòng)作Impossibleat-riskbehavior:theteammemberhastounloadtherubberformthepressmachine.Heisputtinghishandinapinchpoint.Althoughthismachinehaslightcurtainswhichdetectthearmoftheoperator,itisanat-riskbehavioraswellastheteammemberisbehavingat-riskaccordingtoourdefinitionofpinchpoint.不可避免的危險(xiǎn)動(dòng)作：組員必須從沖壓機(jī)上取下橡膠模塊。他將他的手放在擠壓點(diǎn)中。雖然這臺(tái)設(shè)備有光柵來(lái)檢測(cè)操作員的手臂，這還是一個(gè)危險(xiǎn)動(dòng)作，以及根據(jù)我們對(duì)擠壓點(diǎn)的定義，組員仍在進(jìn)行危險(xiǎn)動(dòng)作UsualdefinitionofpinchpointincludedonthelistofdefinitionsconcerningtheCBI?checklist(observationsheet)Doesthepersonkeepbodypartsfromareabetweenmovingorstationarypartsthatareclosing,ormayclosetogether?Thegeneraldefinitionappliesacrossawiderangeofsituations.Thisistheusualdefinitionofpinchpoint.Ifyoudidnotchangethedefinitionofpinchpointonyourlistofdefinitions,thebehaviordisplayedinthepreviousslideshouldbemarkedkikeat-riskevenifthemachinehaslightcurtain.Ifyoudisagree,pleasechangeyourlistofdefinitionsandinformfordiscussionTheCBI?checklististhestandardmeasurethattheBBSobserverswilluseinthefield,itshouldprovideaguideline.Ittellstheobserverswhattolookforandhelpthemtodecideifthebehaviourisbeingdonesafelyorat-risk.擠壓點(diǎn)的一般定義，包括關(guān)于ＣＢＩ?檢查表(觀察記錄表)的定義列表人員是否把身體部分放在會(huì)關(guān)閉的或可能一起關(guān)閉的移動(dòng)或靜止的部件之間；一般定義適用于很大范圍的情況；這是擠壓點(diǎn)的一般定義。如果你沒(méi)有改變?cè)谀愕亩x列表上的擠壓點(diǎn)的定義，前一張幻燈片上列舉的動(dòng)作應(yīng)該被標(biāo)明為危險(xiǎn)的，即使設(shè)備裝備有光柵；如果那你不同意，請(qǐng)改變你的定義列表并通知進(jìn)行討論；CBI?檢查表是標(biāo)準(zhǔn)衡量方法，BBS觀察員應(yīng)該在現(xiàn)場(chǎng)使用，這個(gè)列表應(yīng)該提供指導(dǎo)指南。這個(gè)列表高速觀察員尋找什么，并幫助他們確定行為動(dòng)作是安全的還是危險(xiǎn)的。Shouldweconsiderat-riskbehaviorwhensafeguardingsystemsarepresent?.......WhatcanourBBSsteeringcommitteesdowiththisinformation?

Someriskreductionmeasurescanactuallyincreaseproductivity;forexampletheuseoflightcurtainstoprotectaccesspointsofmachinescanalloweasieraccessforloadingandunloading;zoningofisolationdevicescanallowpartsofamachinetobeshutdownformaintenancewhileotherpartsremainproductive.Howeveramalfunctionofthesesystemscangenerateaserious(irreversibleaccident).Alsoconsiderthepossibilityofentanglement,crushing,cuttingfromtools,sharpedgesonthemachineoronthematerialbeingprocessed.Otherfactorssuchasthestabilityofthemachine,vibrationorgravityalsoneedtobeconsidered.ThesefactorshavecontributedtorecentaccidentsinTenneco.Pleaseconsiderthepossibilityofuseofamachinebyuntrainedpersons,andthirdpersonswhomightbepresentintheworkplace(aflagwithregardtotheyearsofserviceorexperiencebytheobserveecanbeincludedonyourobservationsheet)在有安全防護(hù)裝置存在時(shí)是否應(yīng)該考慮危險(xiǎn)動(dòng)作？BBS指導(dǎo)委員會(huì)應(yīng)該怎樣處理這個(gè)信息一些減小風(fēng)險(xiǎn)的措施的確能夠提高生產(chǎn)率；例如使用光柵保護(hù)設(shè)備進(jìn)入點(diǎn)可以允許更簡(jiǎn)單地裝/卸工件；分區(qū)隔離裝置可以允許設(shè)備的一部分關(guān)機(jī)維修，同時(shí)另一部分保持生產(chǎn)；但是這些系統(tǒng)的故障可能產(chǎn)生嚴(yán)重的(或不可逆的)事故；也要考慮纏繞、擠壓、工具和設(shè)備及材料的鋒利邊緣造成的割傷得到處理；其他原因，例如設(shè)備穩(wěn)定性，振動(dòng)、地球引力也要考慮。這些因素已經(jīng)導(dǎo)致天納克最近這些事故的發(fā)生；請(qǐng)考慮由未經(jīng)培訓(xùn)的人員使用設(shè)備的可能性，并且第三方人員可能出現(xiàn)在車間(被觀察人員的入職年數(shù)或經(jīng)驗(yàn)的標(biāo)志可以包括在觀察表中)Howcanwetakebenefitofthebehaviorsrecordedinobservations?PositivefeedbackshouldreinforcethesafebehaviorandmaketheobserveeawareofthehazardAt-riskfeedbackshouldbehelpfultofindpossiblesolutionsoralternativestotheat-riskbehavior.Easyanddifficultbehaviorscanbechangedtosafethroughaccuratefeedback.TheBBSsteeringcommitteetogethertheEHSteamshouldgeneratealistofat-riskbehaviors(easy,difficultorimpossible)andthentolookforalternativeorsolutionstotheat-riskbehavior.Ifafterhavingreviewedthesafetysystemsavailable,theat-riskbehaviorwasacceptedortolerated,theBBSobserversshouldbeclearlyinformedandinstructedtoleavetheinitialat-riskbehaviorwithregardtopinchpointinblankorsafe.Thestrategyshouldbedecidedbythedifferentlocalteams.Itisexpectedtocreatealistofplaces,machinesorsituationswhereat-riskbehaviorswereobservedusingtheinformationrecordedinobservations.Aperiodicalinspectionofthispointsisexpectedtobeconductedandregistered.Thefrequencyoftheinspection(daily,monthly,…atthebeginningoftheshift)andresponsibleshouldbetypicallydecidedbythesafetyresponsibletogethertheBBSSC.如何使用觀察中記錄的行為動(dòng)作？正面的反饋應(yīng)該加強(qiáng)安全行為動(dòng)作并且使被觀察者意識(shí)到危險(xiǎn)。危險(xiǎn)反饋應(yīng)該來(lái)幫助找出危險(xiǎn)行為動(dòng)作的可能的解決方法或選擇方法。BBS指導(dǎo)委員會(huì)同EHS團(tuán)隊(duì)一起做出危險(xiǎn)動(dòng)作列表(簡(jiǎn)單、困難、不可能)并且尋找危險(xiǎn)動(dòng)作的選擇方法或解決方法。如果在檢查安全系統(tǒng)是可用之后，危險(xiǎn)動(dòng)作被接收或容忍，BBS觀察員應(yīng)該被明確告知并使關(guān)于擠壓點(diǎn)原來(lái)的危險(xiǎn)動(dòng)作保持空白或改為安全。該策略應(yīng)該由各自當(dāng)?shù)氐膱F(tuán)隊(duì)決定。期望使用觀察中記錄的信息創(chuàng)建觀察到危險(xiǎn)行為動(dòng)作的地點(diǎn)、設(shè)備、情況的列表期望對(duì)這些點(diǎn)進(jìn)行周期性地檢查和登記。檢查頻率(每天、每月……每班次開(kāi)始前)和負(fù)責(zé)人應(yīng)該由安全負(fù)責(zé)人會(huì)同BBS指導(dǎo)委員會(huì)共同決定。Howcanwetakebenefitofthebehaviorsrecordedinobservations?Historicalaccident/incidentratescanbeusefulindicators,butcannotgiveareliableindicationofaccidentratesthatcanbeexpected.Canthetaskthatresultsintheriskbeeliminated?Eliminationcansometimesbeachievedbyautomationofsometaskssuchasmachineloadingortheuseofatool.Ingeneral,ifariskcanbereducedthenitshouldbereduced.Butsomerisksmightnotbepossibletoeliminatewithoutagrosslydisproportionatecost.Usuallyasafebehaviorcouldavoidanaccidentorreducetheseverityoftheaccident.However,behaviorcannotbethemostappropriatesolution.ArobustBBSprocessshouldtakeintoaccountallkindofsolutions(behavioralorconditional)fora′-riskbehaviorsrecordedinobservations.如何使用觀察中記錄的行為動(dòng)作？歷史事故/事件率可以作為有用的指示，但是不能給出一個(gè)可靠的期望的事故率指示。導(dǎo)致危險(xiǎn)的操作任務(wù)能否被取消？這一點(diǎn)有時(shí)可以實(shí)現(xiàn)，通過(guò)將一些操作過(guò)程自動(dòng)化，如機(jī)器裝載工件或使用工具。通常，如果風(fēng)險(xiǎn)可以被降低，那么它就應(yīng)該被降低。但是一些風(fēng)險(xiǎn)不付出不成比例的成本就不可能消除。通常安全動(dòng)作可以避免事故或降低事故的嚴(yán)重程度。但是行為動(dòng)作不會(huì)是最合適的解決方法。強(qiáng)有力的BBS流程應(yīng)該對(duì)所有的用于在觀察中記錄的危險(xiǎn)行為動(dòng)作的解決方法(行為動(dòng)作的或環(huán)境的)進(jìn)行考慮。Riskassessmentsvs.observationsApartofexpectedsmoothrunningofaBBSprocess,inorderforamachine(orotherequipment)tobemadesafe,itisnecessarytoassesstherisksthatcanresultfromitsuse.Afterriskshavebeenreducedasfaraspossiblebydesign,andthenbysafeguarding,ariskassessmentprocessshouldberepeatedtocheckthatnonewriskshavebeenintroduced(e.g.poweredguardscanintroducetrappinghazards)SomecomponentproductshavecertificationtoaspecificPL(PerformanceLevel).Theyarenotaguaranteethatacompletedsystem,equipmentormachinewillmeetanyspecificPL.BBSObserversshouldnotcheckconditions,rulesorconductariskassessment.Observersshouldlookforbehaviors.Usually,firsttheobservershouldlookforahazardonpinchpointsandthentorecordiftheobserveeresponseissafeorat-risk.風(fēng)險(xiǎn)評(píng)估vs.觀察除了期望的BBS流程的平穩(wěn)運(yùn)行，為了使機(jī)器(或其他設(shè)備)變得安全，有必要對(duì)設(shè)備使用中產(chǎn)生的風(fēng)險(xiǎn)進(jìn)行評(píng)估。在根據(jù)設(shè)計(jì)、通過(guò)安全防護(hù)盡可能降低風(fēng)險(xiǎn)后，風(fēng)險(xiǎn)評(píng)估應(yīng)該重復(fù)進(jìn)行確保沒(méi)有新的風(fēng)險(xiǎn)產(chǎn)生(例如有動(dòng)力的防護(hù)裝置可能產(chǎn)生人被夾住的風(fēng)險(xiǎn))。一些零部件產(chǎn)品有具體的PL(性能等級(jí))認(rèn)證。這不是完整系統(tǒng)、設(shè)備或機(jī)器滿足具體PL的保證。BBS觀察員應(yīng)該檢查環(huán)境、規(guī)則，或進(jìn)行風(fēng)險(xiǎn)評(píng)估。觀察員應(yīng)該尋找行為動(dòng)作。通常，首先觀察員應(yīng)該尋找擠壓點(diǎn)的風(fēng)險(xiǎn)，然后記錄被觀察者反應(yīng)是安全的，還是危險(xiǎn)的。AccidenthappenedonAugust26,2013whentheteammemberwasplacingaproductionsub-assemblyparttoverifythattoolinginthepresswastheproper事故發(fā)生于2013年8月23日，當(dāng)時(shí)組員通過(guò)放置產(chǎn)品裝夾部件來(lái)確認(rèn)工裝在沖壓過(guò)程中保持正確位置。IE的食指在產(chǎn)品裝夾部分和上模部分之間被擠壓模擬IE如何安放部件模具帶有兩根導(dǎo)向桿。上板重300磅CorrectiveActions改進(jìn)措施頂板和底板改造前改造后工裝定位工裝定位2013.9.12狀態(tài)工裝定位被重新設(shè)計(jì)以取消使用頂板，在模型中除了工裝定位要求使用一塊板，這對(duì)于檢查沖壓能力，使得板和工裝定位適合裝載率，是有必要的。Exampleofdifficultat-riskbehavioronaspinningmachine:theteammemberisputtinghishandsinapinchpoint.Adifferentbehavior(toplacehishandsinthemiddleofthepartandtoavoidpinchpointswouldbepossiblebutdifficultduetotheprobableforcedpostureofforearmsandwrists).旋壓機(jī)上的危險(xiǎn)動(dòng)作的實(shí)例：組員將他的手放在擠壓點(diǎn)上。一個(gè)不同的動(dòng)作(將他的手放在部件之間，這使得避開(kāi)擠壓點(diǎn)成為可能但是很困難，因?yàn)榍氨酆褪滞罂赡芴幱趶?qiáng)迫位置)Lightcurtainsaretypicallyusedinmaterialhandling,packaging,conveyor,warehousingandotherapplications.Theyaredesignedfortheprotectionofpersonsoperatingorworkinginthevicinityofmachinery,bythestoppingofdangerousmovementofpartsassoonasoneofthelightbeamsisbroken.Theymakeitpossibletoprotectpersonnelwhilstallowingfreeaccesstomachines.Theabsenceofadoororguardreducesthetimetakenrequiredforloading,inspectionoradjustmentoperationsaswellasmakingaccesseasier.Unexpectedmodificationsormalfunctioncangenerateaseriousaccident.光柵典型地用于材料處理、包裝、輸送帶、倉(cāng)儲(chǔ)和其他應(yīng)用。它們?cè)O(shè)計(jì)用于保護(hù)操作人員或在設(shè)備旁邊工作的人，一旦有光束中斷立即停止部件的危險(xiǎn)的移動(dòng)。它們使得保護(hù)人員同時(shí)允許自由出入設(shè)備成為可能。取消門或者防護(hù)裝置可以減少工件裝載、檢查、調(diào)整操作的時(shí)間，同時(shí)進(jìn)入設(shè)備變得更簡(jiǎn)單。意外的修改或不起作用可能造成嚴(yán)重的事故Eliminationofriskscansometimesbeachievedbyautomationofsometaskssuchasmachineloading.Onthepicturebelow,theteammembercantakethemuffleronbothsideswithouttoplacehishandsinpinchpoints.通過(guò)使一些過(guò)程自動(dòng)化，如設(shè)備裝載工件，有時(shí)可以實(shí)現(xiàn)消除風(fēng)險(xiǎn)。如下圖所示，組員可以將消聲器放在兩側(cè)托架，而不必將他的手放在擠壓點(diǎn)上。Typicalprotectivedevicesusedaspartofsafeguardingsystemsinclude:LightcurtainsInterlockswitchestodetectthepositionofmovableguardsforcontrolinterlocking,usuallytopermittaskssuchasloading/unloading,cleaning,setting,adjustmentetc;Twohandcontrolstations,etc.Iftheteammemberisnotdetectedbythelightcurtainatanymoment,thebehaviorshouldbemarkedat-risk用作安全防護(hù)系統(tǒng)部件的典型保護(hù)設(shè)備：光柵互鎖開(kāi)關(guān)，用于檢測(cè)可動(dòng)防護(hù)部件位置來(lái)進(jìn)行互鎖控制，通常用于裝/卸工件、清潔、設(shè)置、調(diào)整任務(wù)等雙手控制工作站等Iftheteammemberisnotdetectedbythelightcurtainatanymoment,thebehaviorshouldbemarkedat-risk如果組員沒(méi)有被光柵實(shí)時(shí)偵測(cè)到，則該動(dòng)作應(yīng)該是危險(xiǎn)動(dòng)作Avoidanceofsharpedges,cornersandprotrusionscanhelptoa