How to Shape Smart Change “Shop Floor Management”

Consulting and Training By HSE RM Solutions.

Shop Floor Management is a tool to lead an organization to increase its profitability and gain access to the unlimited power of workforce in form of optimized production, quality, and target achievement.

Starting with basics

Material Handling:

1.     Inward of material

2.     Storage of Material

3.     Dispensing or Release for Production

4.     Movement of Material in changing form across process and production line.

5.     Final product or finish product handling and storage.

6.     Response to rejection, spill, damage, and reuse.

Process Handling

1.     Material quantification and checks.

2.     Controls and monitoring of process requirements.

3.     Response and human-machine interphase

4.     Line management

5.     Control over rejection and process optimization.

6.     Response to recycle, reuse and handling rejection.

Most managements focus on lean principles, behavior and rules rather than on describing management processes in more details. Due to the abstract nature of these rules, their interpretation and implementation still represent a major challenge for practitioners. The concept of shop floor management emerged from recognizing the need for efficient, onsite problem solving and therefore contributes to the highest in practice approach.

The present approach in practice is of problem-solving or performance tracking, such system or operational requirements are not supporting process to address the real needs of the production floor but, rather are for satisfying external requirements such as management reporting.

Thus, an objective of Shop Floor Management is to describe and close the gap between individual behavior and organizational guidelines principles and their application in a systematic, process-oriented industrial approach. The uniqueness of such a process is that is adaptive to any industry, applicable to any industry, and is unique for each installation.

System function is very simple

Shop Floor Management à

Established Systems	Development Systems
1.     Standards and abnormalities control (Standard work practices, process layer audit, cycle and checks of operations performed); 2.     Change Point Management (Process requirements, Data Reliability, and entry, system behavior) 3.     Efficiency improvement Management (Realistic Target Setting, Conditional change accounting, the holistic performance of man and machine monitoring)	4.     Visual management (hourly count, Card Systems, Metrics); 5.     Problem Solving (Standardized Methods, escalation in the process as required) 6.     Communication Management (Leadership, shift change over, purpose and need identification)

Contact HSE RM Solutions for more details : 

E: support@hse-rm.com 

What’s Up: +91-9824663306

Rigging Safety & Permit to Work Training Services by HSE-RM Solutions

Consciousness Session on Rigging Safety & Work Permit

HSE-RM Solutions [http://www.hse-rm.com/training-hse-consciousness/]

Changing conventional means of training to stakeholders Consciousness Session on Rigging Safety & Work Permit, Specially designed program to bring out, true meaning of learning. Focused on current practices, best practices and providing resourcing solution in safe handling procedures. 

Objective of Consciousness Session

·        To enhance awareness

·        In the proper selection, use, and maintenance of slings

·        In the recognition of hazards associated with rigging.

·        In adopting the safe rigging practices  

·        This training is designed to assist you in understanding and complying with OSHA's standards for sling use in General Industry, Maritime, and Construction.

·        To prevent any ACCIDENT related to RIGGING

Elements of Consciousness Session

ü  Safe Rigging Practices

ü  What standards apply?

ü  Factories Act Section 28 Hoist and lifts  and  Gujarat Factory Rules – 58 & 59

ü  FORM NO. 9 (Prescribed under Rule 58) Report of examination of hoists and lifts

ü  Factories Act Section 29 Lifting Machines, Chains, Ropes and Lifting Tackles and Gujarat Factory Rules – 60, & 60 A

ü  FORM NO. 10 (Prescribed under Rule 60) Prescribed for the report of Examination of the lifting machines, ropes, and lifting tackles.

ü  Rigging Hazards (Recognition, identification & Control) Basics; Rigging Safety - Signaling 

Å      Safe Rigging Practices

ü  Check the slings and ensure that the rigging angle is correct.

ü  Make sure the load is properly secured and inform the Crane Operator of the weight of the load.

ü  Make sure the lifting gears such as slings and shackles are well-maintained and in good working condition.

ü  Make sure the load is stable, secured and balanced before any lifting operation.

ü  Make sure any loose items are placed in a proper receptacle or container to prevent the load from falling during the lifting operation.

ü  Immediately report any defective or faulty lifting gear to the Lifting Supervisor.

ü  Place adequate paddings on the edges of the load to prevent the sling from damage.

Å      Good Practices

ü  Correct use of choker hitches

ü  Correct way to balance a shackle load

ü  Correct hook-up methods

ü  Correct rigging method

ü  Hook up unused slings

ü  Correct loading method

ü  Use paddings during lifting

ü  Correct methods of joining sling eyes.

ü  Use original screw pin

ü  Use tag line to control movement of the load

ü  Correct method of unloading

ü  Check hook for any defects and make sure it is in good working condition

ü  Check shackle for any defects and make sure it is in good working condition

ü  Check wire ropes for any defects and make sure they are in good working condition

ü  Understand and practice correct hand signals

Job Hazard Analysis

(Pre-Task Planning and Lifting Plans)

The Pre-Task Planning or Lifting Plan (Job Hazard Analysis) shall recognize all elements of foreseeable risk inherent in an operation and satisfactorily address them thus ensuring that safety is not compromised. This shall include the following, but is not limited to:

ü  Ground conditions and crane support

ü  Crane and rigging suitability.

ü  Structural capability of the load.

ü  Direction of an operation and control of the load.

ü  Discussion about load supports, support, and stability of cribbing, horizontal rotation requirements, where horizontal requirements are to take place (these should only take place at a minimally elevated position and any cribbing fully supported).

ü  Personnel not being subjected to location/working below a suspended load.

ü  Interface with other contractors.

ü  Access to/from lifting attachments.

ü  Interface with the Manufacturing personnel (where required).

ü  Safety procedures.

ü  Exclusion zone.; PPE

ü  Hazards of horizontal rotations if required.

Fire Risk Assessment

Qualitative Fire Risk Assessment & Impact Assessment

By HSE-RM Solutions (www.hse-rm.com)

Every organization has an existing fire risk assessment done at the time of project and fire safety plan, is this plan continuously updating, is it adequacy and efficiency checks done on regular basis, you need to redo the assessment to ensure your provisions are in line with the new legislation & continuously evolving process plant. In addition, every time your business changes in terms of premises, business activity or even staff, you should undertake a revision of the assessment.

Fire risk assessment requires you to examine both your premises and your work practices to assess the fire risk they pose, it is an opportunity to examine how your business could be improved as in important exercise of reducing or eliminating risk. Fire risk assessment and impact assessment gives insight, you may discover under used parts of your premises, or work practices that can be reviewed, not only to ensure the safety of your staff, but also potentially improve productivity too.

Fire Safety Requirements

The Fire Safety Standards requires you, the business manager, to provide and manage:

·         Means of Escape

·         Signs and Notices

·         Emergency Lighting

·         Fire Alarm

·         Fire Extinguishers

·         Fire Doors and Compartments

Fire Risk Assessment

A detailed fire risk assessment for both your premises and business practices is required to draw up fire safety policies and procedures best suited. It’s important to explore modern means of protection system in the industry making our processes, premise, operations, and work force safer. Is detection system adequate, does the detection system positioned correctly, some very basic system sometime give more proactive protection, each facility quantity and quantum of risk differ.

With correctly evaluated economical blend of technology and science, protection level can be achieved, response time evaluation, reach path, evacuation path, access path, exit path are some commonly miscalculated measures of a safety plan.

Regular update and perception analysis of collective data can enhance protection, response, institutional real time assessment, monitoring and adaptation is possible HSE-RM Solution & Associate partners have developed digital system of OSH Management to assist organization in achieving such goals.

Fire Training

As the responsible person, you are also required to implement and keep records of:

·         Fire Procedures, including evacuation

·         Staff Training

·         Fire Drills

Simplify Selection & Practical Guide

Guidelines for how many? A person should not have to:

·         Travel more than 25 metres to get to a fire extinguisher.

·         Reach out more than two doors to get to an extinguisher.

·         Reach to different floor level to find an extinguisher.

How many is not always easy to gauge but, as a general rule, you will need one water-based extinguisher such as water, water additive (the best option for most) or foam (3 litre or bigger) for every 2000 square foot or 200 square metres of floor space. This is per floor.

Once you have a water-based one, you are likely to have electrical risks such as computers, retail lighting, fridges, machinery, servers, electric forklifts, etc. This will need a CO2 extinguisher and it makes sense to have a pairing of CO2 and water-based for every fire point. The 2kg is by far the more popular but the 5kg CO2 size would be better for server rooms, machinery, industrial, etc.  It is best not to have too many different types on the same premises if possible as this adds to confusion in a panic.

With upgrading technology and resource availability may it be management or protection level integration, system implementation organization like yours can be supported on both the fronts by our customized, tailored, and unique project capabilities.

Please feel free to communicate us for your further requirements at support@hse-rm.com; 

Fire Safety By HSE-RM Solution 

Heat Stress

Heat Stress

Safety Consulting By HSE-RM Solution (www.hse-rm.com)

Qualitative assessment of heat perception and impacts

Qualitative assessment of heat perception and impact by HSE-RM Solution advisors, a tailored program with practical solutions, analysed collective data given a unique insight, a 2-day onsite assessment, and 1-day practical implementation consciousness/training, could mould overall understanding of changed work environment and impacts.

Practical approach questionnaire

1.        General information (awareness on heat stress element understanding)

2.       Type of work (knowledge of work, activities & type)

3.        Workers’ exposure to heat (provision & safety plan review)

4.       Health impacts (impact assessment & record verification, with provisions)

5.       Productivity impacts (measure of work activities, productivity graph & personal involvement)

6.       Impacts of clothing (PPE matrix, use, selection)

7.       Process mechanisms (impact time, controls, and provisions assessment)

HSE-RM Solution advisors, walk-through qualitative assessment of heat perception & impact program is personally tailored. Safety perception of the different workplace to identify sampling locations for heat monitoring and to make observations about the workplace ventilation and existing cooling provisions. Qualitative data collected on different days when work is in progress.

Based on Indian condition and mercury rising to 35-40 and 40+ degree, international guidelines state, under the controlled cycle of operations, work limitation, corrective & preventive action to be imparted. All such words on practical implementation, however, these programs ignore the most appropriate methods for eliminating health and safety hazards. Safety is often the starting point for positive change initiatives within organizations. Planning and managing change is a strategic advantage if successfully executed. If not, however, a downward spiral of negative expectations can eventually paralyze any willingness to confront change. Therefore, in addition to being an important area for positive change, a safety initiative's success or failure may foreshadow the success or failure of future change efforts.

The practical solution to adaptive climate change:

Health and productivity impacts of occupational heat stress have significant consequences for the large workforce of India. Heat-rashes, dehydration, heat syncope and urinogenital symptoms are self-reported health issues. Assessed reasons for productivity losses were: extended work hours due to fatigue/exhaustion, sickness/hospitalization and wages lost. Reducing workplace heat stress will benefit industries and workers via improving worker health and productivity. Adaptation and mitigation measures to tackle heat stress are imperative to protect the present and future workforce as climate change progresses. During hotter and cooler seasons, wet bulb globe temperatures (WBGT) are used to quantify the risk of heat stress, according to international workplace guidelines. Questionnaires assessed workers’ perceived health and productivity impacts from heat stress.

Practical, adaptive solution is to revisit & reinforcing safety plan on a regular basis, especially when new risks are identified or working conditions change. These changes may include not only the introduction of new equipment or processes but also changes in the weather. Many businesses, warmer months mean a potential increase in heat-related workplace injuries or illnesses. In addition to the work whose positions are primarily outdoors, such as construction, project engineers, landscapers, it is important to remember that people who primarily work indoor service, repair shop workers, are also at risk when the mercury rises. Heat exposure — whether from the sun or from process machinery — can be a contributing factor to employee injuries or illnesses across a range of industries.

Even brief exposure to heat can cause a serious burn or sunstroke, but prolonged exposure to high temperatures makes it difficult for the human body to cool down, which can lead to dangerous and even life-threatening conditions. At the very least, high temperatures can cause potential hazards such as sweaty, slippery hands, fogged-up safety equipment and distractions due to physical discomfort.

Facts to be known don’t confuse

A fellow employee who is exposed to extreme temperatures can experience any of the following heat-related illnesses:

Heat cramps

Caused result from loss of a large amount of salt and water through exercise. Heat cramps are associated with cramping in the abdomen, arms, and calves. This can be caused by inadequate consumption of fluids or electrolytes. Heavy sweating, fatigue & thirst, are the mildest form of heat-related illness.  Prompt treatment, including consumption of electrolyte-containing beverages and moving to a cool area, can usually help keep heat cramps from progressing to heat exhaustion.

Practical steps:

·         Stop activity.

·         Rest in a cool environment.

·         Drink plenty of fluids. (prefer electrolyte mix rather than only water)

·         Perform gentle stretches to the affected muscle group.

·         Monitor the cramp. (record and report incident)

·         Do not return to the activity right after cramps go away.

·         Anticipate future reappearances.

Call your doctor if these conditions develop:

·         If you are unable to drink sufficient fluids because you have nausea or are vomiting, you may need rehydration with normal saline.

·         Heat cramps may accompany heat exhaustion.

·         If you have more severe symptoms of heat illness, including dizziness, fatigue, vomiting, headache, fast heartbeat, shortness of breath, or a high temperature, get immediate medical care.

Heat exhaustion

With prolonged heat exposure, due to a loss of fluids and salts, heavy sweating and a rapid pulse is observed, this is a result of your body overheating. The body is unable to properly cool itself, and reduced blood flow to the brain may cause headaches and dizziness. People with high blood pressure are especially at risk.

Keep an eye on fellow workers for:

·         Faintness or dizziness.

·         Nausea or vomiting.

·         Heavy sweating often accompanied by cold, clammy skin.

·         Weak, rapid pulse.

·         Pale or flushed face.

·         Muscle cramps.

·         Headache.

·         Weakness or fatigue

Practical steps:

·         Drink water every 15 minutes, even if you are not thirsty.

·         Rest in the shade to cool down.

·         Wear a hat and light-colored clothing.

·         Learn the signs of heat illness and what to do in an emergency.

o    Remove any tight or unnecessary clothing.

o    Take a cool shower, bath, or sponge bath.

o    Apply other cooling measures such as fans or ice towels.

Heat stroke

Heat stroke shocks the body’s cooling system and causes it to shut down. The most common type of heatstroke is sunstroke, which is caused by the sun shining directly on the head and neck for prolonged periods of time. Heat stroke is the most serious disorder associated with heat stress. It occurs when the body's temperature regulation fails and body temperature rises to critical levels. It is a medical emergency that can lead to death. In severe cases, a person’s body temperature can spike to 40^o c or more in as little as 10 minutes, which can lead to organ failure. If heatstroke isn’t treated immediately, it can be fatal.

Normal human body temperature, also known as normothermia or euthermia, is the typical temperature range found in humans. The normal human body temperature range is typically stated as 36.5–37.5 °c  (97.7–99.5 °f)

Simplified heat stress index

Category	Apparent	Signe & symptom developed
Caution	26-32oc (80-90of)	Fatigue possible with prolonged exposure and physical activity
Extreme caution	32.5-40.5oc (90-105of)	Sunstroke, heat cramps, or heat exhaustion possible with prolonged exposure and physical activity.
Danger	40.5-54.0oc (105-130of)	Sunstroke, heat cramps, or heat exhaustion likely. Heatstroke possible with prolonged exposure and physical activity
Extreme danger	54.5oc (> 130of +)	Heatstroke or sunstroke imminent

               

Workable workload based on international standards

Work -rest regimen	Light	Moderate	Heavy
Continuous work	30 oc / 86of	26.5 oc / 80of	25 oc / 77of
75% work 25% rest, each hour	30.5 oc / 87 of	27.7 oc / 82 of	25.5 oc / 78
50% work 50% rest, each hour	31.6 oc / 89 of	29.4 oc / 85 of	27.7 oc / 82 of
25% work 75% rest, each hour	32.2 oc / 90 of	31.1 oc / 88 of	30 oc / 86 of

These threshold values are based on assumption that nearly all acclimatized, fully clothed workers with adequate water and salt intake should be able to function effectively under the given conditions without exceeding deep body temperature or core temperature of 38 ^Oc (100.4 ^Of). They are also based on assumption that the wet bulb globe temperature index (WBGT) of the resting place is the same or very close to that of the workplace. Where the WBGT of the work area is different from that of the rest area, a time-weighted average should be used.

Light	Sitting at ease, writing/typing, sorting light materials, inspecting crops, driving mobile equipment on paved roads.
Moderate	Using a hand rigger, off-road operation of mobile equipment, periodic handling of moderately heavy materials, digging, picking loads, spraying, container spraying on level ground, pushing or pulling light-weight carts or wheelbarrows, washing vehicles, walking 2-4 km/ph.
Heavy	Transferring heavy materials, shoveling, digging hard soil, hand mowing, loading sacks, stacking heavy loads, planting seedlings, hand-sawing wood, pushing or pulling loaded handcarts or wheelbarrows, moving irrigation pipe, laying cinder blocks, knapsack spraying on rough ground or an incline, walking 5 km/ph.
Very heavy	Heavy digging, ax work, climbing stairs, ramps, or ladders, lifting more that 15 kgs at 10 lifts per minute, walking faster that 5 km/ph, jogging, running

 

Certain medical conditions may be a factor in causing heat illness or may intensify by heat:

a)       Skin disorders may limit sweating (ex: dermatitis, when intensified by heat/moisture).

b)      Heart and lung diseases may limit the ability to cope with heat and may intensify by it.

c)       Diabetes, poorly controlled, may contribute to dehydration and may intensify by excessive heat.

d)      Diarrhea may contribute to dehydration.

e)       Obesity requires increased energy to move around and the extra insulation reduces heat loss – both contribute to the body's overall heat gain.