How do you overcome safety and risk management challenges in your sector?

Hazards are Risks are unavoidable and inherent in any manufacturing system. I recommend a proactive approach to Risk elimination or reduction. Every team member should be engaged in anticipating and preventing potential hazards rather than merely identifying and assessing existing risks, this approach encourages continuous vigilance and proactive measures.

Hazard identification and risk assessment should be conducted by a group of people - safety personnel who have knowledge on hazard identification and assessment tool - the worker who actually conduct the work - the supervisor/management who supervise or assign staff for the work (let them buy in) Methods on hazard identification should also include make reference to accident in similar trade and work operations

In manufacturing, manage risks with: 1. Hazard ID 2. Safety training 3. Strong safety culture 4. Equipment maintenance 5. Process safety (for hazardous materials) 6. PPE use 7. Continuous improvement 8. Audits and inspections 9. Emergency plans 10. Regulatory compliance 11. Employee involvement 12. Contractor safety 13. Data analysis 14. Communication. By addressing these areas, we can enhance safety in our manufacturing operations.

I would argue the order of this list is upside down. We make an assumption that WE can identify and assess hazards, implement and monitor controls, and develop training .... before we engage the key stakeholders. I believe our frontline employees know a lot more about the hazards and controls necessary and we should be engaging with them first to truly understand what drives the behaviors we see in the workplace - 'why do people do what they do?' The principle of H.O.P. are a great place to start.

-by simplifying safety processes -by minimising compliance burden -by integration of safe practices rather than adding them on top -by making safety related matter intuitive -maintaining a bottom up approach -dispensing with long, complicated procedure documentation - keeping everything simple, easily understandable and logical - no more than 4 mouse clicks to find the process, guide, instruction, document or procedure to be followed - prioritising practicalities over external compliance requirements - empowering workers to be responsible for their own safety - timely, consistent, detailed and personalised responses to reports of hazards and suggested OFIs -development of an ingrained safety culture -don't overthink it

From the perspective of a small business owner with experience in this in past roles in corporate America, I would say that you absolutely need buy in from those that will be executing the process. Prior Safety training before any work is paramount, so they can get a full understanding of risks they will face. I recommend OSHA 10. Integration of Safety into every facet of training would follow, so it continues to be of mind as they learn. You then need to ensure daily reminders of Safety by integrating it into their daily planning work process. The next part will be ensuring there is a way to record near misses, so that it can be learned from. Then a detailed review of any actual incidences so they can be prevented in future.

Some key performance indicators to be added in organisations AOP and KPI,s Zero tolerance policy Training No of incidents No of suggestion No of near misses captured Self audit score Layered audit score and CAPA Process review Bench marking and learning from others Reward and recognition

Safety must be acknowledged and practiced and the top priority by every level of leadership. If it’s not a safety culture will be elusive. If a leader walks by or allows unsafe practices or says they don’t need PPE to walk the shop it’s a sure sign that safety is talk the talk.

Having worked in the aerospace and nuclear industries, a strong safety culture is imperative to be successful. I have worked in companies where this was not understood, and those companies are no longer around.

With respect to controls, like many others most important factors are, do the controls are defined after having hands on prudent operational knowledge. do people competencies and skills are tested or verified Is there stringent protocols present to verify the working / effectiveness of controls in worst case scenarios to bring operations in fail safe modes, do maintenance management and operations managements systems are up to date and designed and people are trained to complement critical expectations

Hierarchy of controls is better presented as this: "eliminate", "transfer", "substitute", "isolate", "engineer", "administrate", "personally protect".

Ensure that proactive and reactive maintenance activities on manufacturing plant are controlled by LOTO (lock out, tag out) procedures and where necessary, PTW (permit to work).

Apart from this, behavioral reasons are there which can be tracked through a good culture of making safety contact with each other whenever we see any unsafe act by our colleagues at work. A culture of sharing such contacts during start of any meeting will make this an indispensable part of the work culture.

Define the system in detail and decompose your system into parts, diagrams, flows, operations, tasks, procedures, links, technology, interfaces and interactions; Bound and scope the analysis; Develop system abstractions…Figure out how to conduct inclusive system hazard, threat, vulnerability analysis and risk assessment; (many papers are accessible via LinkedIn); Perturb the system and identify hazards, threats, vulnerabilities, develop adverse sequences, (including actions, decisions, inactions); Define risk criteria and identify current risks given minimal controls...

Design controls to eliminate or control risks to acceptable levels (within adverse sequences (risks)); The output of analyses are both engineering and administrative controls: also proactive performance indicators; Monitor the system and continue to validate and verify all controls, update analyses and reports addressing system dynamics, changes, modifications, updates; Continually rank risks given risk criteria and allocate resources from high to lower risk...Hence a risk-based system.

Implementar e monitorar controles e uns dos fatores em processo continuo com alguma engrenagem como hierarquia de controles, priorizando a eliminação do perigo sempre que possível. Substituição, controles de engenharia, medidas administrativas e Equipamentos de Proteção Individual (EPI) devem ser considerados nessa ordem. também temos que fazer avaliações regulares de risco para identificar mudanças nas operações com isso promover uma cultura de segurança na organização, incentivando a responsabilidade individual e coletiva em relação à segurança no trabalho.

One crucial aspect I've discovered is the necessity of integrating redundant systems. Instead of solely depending on a couple of safety devices, establish a comprehensive network of detection, prevention, and emergency stopping/shut-off devices. Ensuring personnel safety goes beyond mere continuous improvement; it demands an initial focus on implementing the most robust safety system right from the start.

Top management's commitment to developing and implementing an effective health and safety management system is essential for promoting a positive safety culture. This commitment helps in managing safety challenges and risks, ultimately reducing workplace injuries and accidents, and achieving the goals of health, safety, and fire safety policies.

Engage the workforce in participating in training. Allow them to tell stories about how they successfully dealt with upset conditions. Also allow them to discuss situations that did not resolve well. It will enhance your training events.

Subcontractors using client's facilities should also be considered for competency requirements, and alignment of internal and external workforce co-working in the same environment must have no gaps.

Continuous Training in different modes of training to the level of staff and ground level staff to enhance the safety knowledge to certain limit of extent. Plan a training calendar followed by different modules with refresher training and feedback and analysis methods

Ao investir no treinamento e na educação dos trabalhadores, as organizações podem fortalecer a cultura de segurança, reduzir riscos e promover um ambiente de trabalho mais seguro e saudável.

Training and educating workers is essential for effective safety and risk management. We offer comprehensive training programs on hazard recognition, safe work practices, and emergency response. Regular refresher courses and hands-on drills keep employees updated with the latest safety protocols. By fostering a culture of continuous learning and awareness, we empower workers to actively maintain a safe workplace. This commitment to education helps prevent accidents and ensures everyone can handle potential risks effectively.

Besides, reinforce supervision by the team leader or other’s management team to monitor staff work practices as to ensure they follow and do what they are learned and comply with the safety procedures.

Training and safe work practices to workmen on the field is very important at frequent intervals. It would definitely help to overcome.

Management leadership should demonstrate commitment with actions like engaging workforce on safety programs / trainings, having safety minute at start of any meeting etc...

Treinamentos com boa qualidade, com muito embasamento Tecnico, fazendo todos entenderem que ser seguro é um valor em nossas vidas. Evitar situações de riscos é principalmente cravar a marca registrada da segurança é a melhor forma de desenvolver qualquer trabalho com qualidade.

They own the Safety Program. Remember that. You can't be everywhere all the time. Exercise Servant Lradership and be inclusive. Encourage and support employee involvment

Engaging and communicating with stakeholders is the linchpin of effective safety and risk management. It's not just about compliance; it's about building a culture of shared responsibility and continuous improvement.

Keep it simple, visual and "at the place" to drive ownership and accountability. Promote targeted, on the spot reporting through hazard / near miss stations and report cards and ensure all hazards / near misses are displayed at the place and discussed at daily stand up meetings. Agree an action, owner and end date (max 30 days dependent on work required) and use plan, do, check, act to track progress, only closing out when confident a fully robust process is in place. As follow up action, use layered process audits to ensure embedded. Share your stories and successes with your team.

Recognize the workers on a very frequent basis in all different aspects. Reward the workers which were recognized in town hall meetings Organize the monthly town halls and extracurricular activities to make them more concentrate on their works

Training and educating workers is essential for effective safety management. We provide comprehensive training on hazard recognition, safe work practices, and emergency response. Regular refresher courses and hands-on drills ensure employees stay updated on safety protocols. By fostering a culture of continuous learning and awareness, we empower workers to actively maintain a safe workplace. This dedication to education helps prevent accidents and ensures everyone can effectively handle potential risks.

The Hierarchy of Hazard Control is a systematic way to make things safer by reducing exposure to dangers step by step. Imagine it as a ladder with six rungs. First, you try to eliminate the hazard entirely, like filling a dangerous hole in a playground. If that's not possible, you replace or change it, such as using a safer stove with cool handles. If neither is an option, isolate the hazard with barriers, like fencing off a construction site. For situations where people must be near the hazard, use protective measures, like wearing earmuffs in a noisy factory. Educate people on safe practices (training) and have emergency plans in place (emergency response), like wearing a helmet while biking for added protection.

Ao integrar essas práticas na cultura organizacional, a aprendizagem contínua e a melhoria constante tornam-se parte intrínseca da abordagem da empresa em relação à segurança e ao gerenciamento de riscos. Isso não apenas protege os trabalhadores, mas também contribui para a eficiência operacional e a reputação da organização.

Technologies are advancing rapidly and new skills are emerging every day. In this dynamic and fast-moving world, the search for professional and personal success becomes constant and, given this volatile scenario, continuous learning becomes an essential skill.

Commercially or politically sensitive information in lessons learnt are unlikely to be circulated to all stakeholders, hence, industry regulator may be best placed to ensure cross-learning for relevant industry, while protecting privacy and balance of interests.

Ensuring personnel safety goes beyond mere continuous improvement; it demands an initial focus on implementing the most robust safety system right from the start. One crucial aspect I've discovered is the necessity of integrating redundant systems. Instead of solely depending on a couple of safety devices, establish a comprehensive network of detection, prevention, and emergency stopping/shut-off devices

Safety and risk management is the first pillar for the success of any Business and it comes by Top Down approach. Understanding the concept of safe operations and investing time and money on it, is the biggest intangible asset. Having safe travels environment and educating employees to follow the same without any compromise, will lead to much higher return then just investing in tangible Operational assets. Safety does not mean only people and plant safety, but it includes environmental safety also. Being entrepreneur comes with lot of social responsibility and maintaining 380degree safety is first step towards risk management.

It can only be achieved by Improving the mindset. Whatever you do, Whatever the System you follow either ISO, OSHMS , PMRs etc etc. There will always be Risks. To overcome this 3 steps are necessary 1. Risk/Hazard Identification (Concept of Hiyari Hato) - Can only be achieved with Trainings and develop people to Think out of the box. Motivate people by giving them importance or compensations rather investing soo much on systems initially 2. Risk Reduction Planning - Once risk is identified, Score it. And Develop a plan for its reduction with some temporary Measures at the day of identification 3. Audit and Followup - That is the most difficult step, to Sustain, but can be achieved by Visualizing the Main, Process and Sub KPIs on daily basis

Innovation for safety proposed from grass roots may see unjustified push-back from leaders in particualr business. To overcome it, one requires closer collaboration on innovation technology in incubators supported by governemt or industry co-regulated funds. In 1959, the Volvo engineer Nils Bohlin invented and shared with permission of managers the design of three-point seatbelt. Innovation of significance for safety could be shared, with apt support from industry body and government.

May be there have addressed the following The crucial part is about the safety by design which includes the measures what relevant legislation requirement and industrial best practices. That’s the safest and most effective ways to eliminate the hazards. Consideration not only include the hazards in operation but also maintenance situations. Feedback from users is also another good way to obtain the info which the operators encountered at work.

Employee are required to make safety consciousness a culture by ensuring there is behavioral observation of there work area. Quick risk assessment must be done before any job done while safety must not be for only

The challenge of risk management does nit restrict to manufacturing sector. The challenge spread across all sectors, Risk management is just an system, guidelines for the management team. To have the system works, the stakeholders must be proactive, leading and not reacting.

* It's for us. The Customer happens to get a (full / partial) copy to fulfill their requirements, but the exercise is for us. * Team Effort: This is not something an heroic engineer or area does on their own. * Discipline - Follow the sequence, don't play dumb or dream.

First of, do a comprehensive hazard/risk analysis of all the manufacturing processes and then identity mitigation for those hazards. Staff training is very crucial in ensuring that they can identify hazards/risks, contain or eliminate them in their day to day activities.

1. The first step is establishment of functional, customized and supported safety and risk management system with feedback route, that covers all the operations and system. Functional: There are good number of organizations that have risk management system that is not truly reflecting the safety and risk inherent to the organization's activities, because it is just in place as regulatory requirements. Customized: The risk management system should be specifically designed for your organization and its activities. Supported: All the required resources should the put in place and regularly maintain. Feedback: Very important for verifying effectiveness and recommending improvement.