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

Job Safety Consciousness

HSE-RM Solutions Risk Assessment & Consciousness Sessions (Trainings)

Consultancy Services Include:

•    Safety Risk Assessment

•    Facility Risk Assessment

•    Process Risk Assessment

•    Chemical Risk Assessment

•    Fire Risk Assessment

•    Electrical Risk Assessment

•    Perception Risk Assessment

Job Safety Consciousness

A customized Program on Job Safety Consciousness, tailored to suit industry specific demand. Consciousness sessions focused on worker level, supervisor level for leadership map and evaluation matrix. Job Safety Consciousness focusses on understanding safety, the perception of safety and evaluate the need for change in understanding safety perception. 

Each industry functions differently, each company has its own policies and plans. The workforce is always misguided on practices and often confuses with what to adapt. This blog share includes some elements focussing on Job Safety, Our awareness and evaluation base training with a practical interactive session can result in bringing out leaders in safety.  

What you need to know?

• Understand the importance of safety and safety awareness.
• Understand accident and causes of the accident.
• Understand various types of workplace hazards.
• Understand various control measures that can be used to minimize the risk.
• Understand how you can contribute to enhance your workplace safety.

Leadership Safety Values and Actions

Leaders demonstrate a commitment to safety in their decisions and behaviors

Problem Identification and Resolution

Issues potentially impacting safety are promptly identified, fully evaluated, and promptly addressed and corrected commensurate with their significance

Personal Accountability

All individuals take personal responsibility for safety

Work Processes

The process of planning and controlling work activities is implemented so that safety is maintained

Continuous Learning

Opportunities to learn about ways to ensure safety are sought out and implemented.

Environment for Raising Concerns

A safety conscious work environment is maintained where personnel feel free to raise safety concerns without fear of retaliation, intimidation, harassment or discrimination

Effective Safety Communications

Communications maintain a focus on safety

Respectful Work Environment

Trust and respect permeate the organization

Questioning Attitude

Individuals avoid complacency and continually challenge existing conditions and activities in order to identify discrepancies that might result in error or inappropriate action

How to assess the risks in your workplace

·         Identify the hazards

·         Decide who might be harmed and how

·         Evaluate the risks and decide on precautions

·         Record your significant findings

·         Review your assessment and update if necessary

HAZARD	WHO MIGHT BE HARMED?	IS THE RISK ADEQUATELY CONTROLLED?	WHAT FURTHER ACTION IS NECESSARY TO CONTROL THE RISK?
Look only for hazards which you could reasonably expect to result in significant harm under the conditions in your workplace.  Use the following as a guide: ·          Slipping/tripping ·          Electricity (wiring) ·          Fire (flammable materials) ·          Dust (from grinding) ·          Chemicals ·          Fume ·          Moving parts of machinery ·          Manual handling ·          Work at height ·          Noise ·          Vehicles ·          Poor lighting ·          Low temperature	There is no need to list individuals by name - just think about groups doing similar work or who may be affected. E.g: ·          Office staff ·          Operators ·          Maintenance personnel ·          Cleaners ·          Contractors ·          Members of public ·          People sharing your workplace Pay particular attention to: ·          Staff with disabilities ·          Inexper. Staff ·          Visitors ·          Lone workers	, Have you already taken precautions against the risks from the hazards you listed? For example, ·          have you provided adequate info/training or  systems/procedures? Do the precautions:- ·          Meet the standards set by a legal requirement? ·          Comply with a recognised industry standard? ·          Represent good practice? ·          Reduce risk as far as reasonably practicable? If so, then the risks are adequately controlled, but you need to indicate the precautions you have in place.	What more could you reasonably do for those risks which you found were not adequately controlled? You will need to give priority to those risks which affect large numbers of people and/or could result in serious harm. Apply these principles when taking further action, if possible in the following order: ·          Remove the risk completely ·          Try a less risky option ·          Prevent access to the hazard (guarding) ·          Organize work to reduce exposure to the hazard ·          Issue personal protective equipment ·          Provide welfare facilities
List hazards here:	List groups of people who are especially at risk from the significant hazards which you have identified:	List existing controls here or note where the information may be found:	List the risks which are not adequately controlled and the action you will take where it is reasonably practicable to do more.  You are entitled to take cost into account, unless the risk is high:

Myths of Understanding Risk

1.      “Risk” must have a single, well-defined meaning.

2.      The severity of risks should be judged according to probability-weighted averages of the severity of their outcomes.

3.      Decisions on risk should be made by weighing total risks against total benefits.

4.      Decisions on risk should be taken by experts rather than by operators/stake holders.

5.      Risk-reducing measures in all different sectors of society should be decided according to the same standards.

6.      Risk assessments should be based only on well-established scientific facts.

7.      If there is a serious risk, then scientists will find it if they look for it.

At each stage, our training program is designed to suit industry specific need. Practical learning method, Viz. Classroom session, Group discussion session & Practical Session for identification. To custom design your Job Safety Program Please feel free to communicate on support@hse-rm.com   

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.