IMPROVE THE SENSIVITY OF DANGER FOR ACHIEVING ZERO ACCIDENT K Y - KIKEN YOCHI ( JAPANESE WORD) KIKEN - DANGER YOCHI - PREDICTION

1. K-Y CALL
Prepared By
Md Aminul Islam
Reliability Engineer
SADAF-SABIC.

2. PURPOSE
TO IMPROVE THE SENSIVITY OF
DANGER FOR ACHIEVING ZERO
ACCIDENT

3. INTRODUCTION
K Y - KIKEN YOCHI ( JAPANESE WORD)
KIKEN - DANGER
YOCHI - PREDICTION
IN 1982 SUMIMOTO METAL PLANT AT
JAPAN COMPLIED THIS SAFETY PLAN
FOR THEIR WORKER IN EACH WORK
PLACES THROUGH PDCA CYCLE

4. DEFINATION
KIKEN YOCHI -- IT IS A PROCEDURE FOR
ON-THE-SPOT RISK ASSESSMENT IN
WORK PLACE. THE GROUP OF WORKER
FOR EACH WORK WILL DISCUSS AMONG
THEMSELVES ABOUT THE HAZARD AND
RISK AND PLANNED FOR
COUNTERMEASURE & ACTION PLAN
BEFORE START ANY WORK.

5. HOW TO IMPLEMENT
a) IDENTIFY THE POTENTIAL RISK AT THE
WORK SPOT WITH ALL THE WORKER. b)
SELECT THE HAZARD / RISK PRIORITY WISE
ACCORDING TO SERIOUSNESS. c)
PROPOSED COUNTERMEASURE PLAN d)
ACTION TAKEN.
WHY TO IMPLEMENT
TO ELIMINATE THE RISK & UNSAFE
ACT.
WHEN TO IMPLEMENT
EVERYDAY BEFORE START OF ANY WORK.

6. WORK FLOW DIAGRAM
WORK
PLAN
WPS
ISSUE
JSA & SOP BRIEFING
AMONG THE
WORKER
GATHER
AT WORK
PLACE
KY
DISCUSSION
AT SITE
RECORDED IN
TOOLBOX
MEETING
&SAFETY
MEASURE
TAKEN
JOB EXCUTED 5-S
COMPLETED
WPS HAND
OVER

7. VARIOUS STEPS FOR SAFETY
AT WORK PLACE
a)TOOL BOX MEETING.
b) SOP - STANDARD OPERATION
PROCEDURE.
c) SAFETY NOTICE.
d) HATTO HIARI .
e) KY.
f) JSA -JOB SAFETY ANALYSIS.

8. RELATION WITH K-Y AND
OTHER SEFETY PROCEDURE
1. TOOL BOX MEETING.- AFTER K-Y, ALL THE
SAFETY MEASURE/PPE TO BE SELECT IN THE
TOOL BOX MEETING.
2.SOP- IT DESCRIBE THE STEPS TO BE
FOLLOWED & TO BE CONSIDER BEFORE K-Y.
3. SAFETY NOTICE- IT IS A GENERAL
INFORMATION FOR EQUIPMENT,ENVIRONMENT
FOR THAT PARTICULAR AREA & WHICH TO BE
CONSIDER WITH K-Y.
4. JSA- IT BRIEFING THE SAFETY STEPS TO BE
FOLLOWED AS PER SOP & WHICH TO BE
INCLUDED IN K-Y FINDINGS.

9. GUIDE LINE FOR K-Y
ANALYSIS
1. TECHNICALLY.- a) WORKIBILITY. b) HEALTH
HAZARD. c) ACCIDENT PROBABILITY.
2. HARMFULL SUBSTANCE.-a) ORGANIC
SOLVENTS. b) DUST. c) RADIATION. d) GASES.
3. WORKING ENVIRONMENT.-
a)VENTILATION. b) NOISE. c) TEMPERATUR.
d) POSTURE.
4. WORKING DISPLAY.- a) HOT JOB. b)
CONFINED SPACE WORK. c) FRAGILE ROOF.

10. DESCRIPTION FOR RISK
ANALYSIS ON FINDINGS.
1. WORKIBILITY/ ACCIDENT PROBABILITY --
OPERATIONALAREA/ ROATATING EQUIPMENT /
WORKING AT HEIGHT.
2. HEALTH HAZARD-- FALL/BURN/ELECTRIC SHOCK/ GAS
POISENED.
3. ORGANIC SOLVENT / DUST / NOISE / GASE / RADIATION
TEMPERATURE-- EFFECT ON HUMAN BODY.
4. HOT JOB.-- FIRE
5.POSTURE -- DIFFICULT TO WORK
6. CONFINED SPACE JOB / VENTILATION -- OXYGEN
DEFFICIENCY.
7. FRAGILE ROOF -- BREAK / FALL

11. BENEFITS OF K-Y
1. EVERY DAY PRACTICE FOR EACH WORK.
2. ON THE SPOT ACTIVITES GATHER DETAILS
KNOWLEDGE OF PROBLEM.
3. PARTICIPATION & INVOLVMENT OF ALL
WORKER.
4. AVOIDING UNSAFE ACT.
5. ON THE SPOT COUNTERMEASURE WILL
PREVENT CHANCES OF ACCIDENT.
6. SELF DEVELOPMENT & DISIPLINE AT WORK
PLACE.

12. K-Y CALL
MAIN / TOP PRIORITY ACTION PLAN AS PER K-Y
FINDINGS FOR A PARTICULAR JOB TO BE
CONSIDER AS A K-Y CALL FOR THAT
PARTICULAR WORK.
A COMMON K-Y CALLALSO MAY BE CONSIDER
FOR DEPARTMENT WISE AS PER PREVIOUS
EXPERIENCE / AS PER GENERAL WORK
ACTIVITY.
IT CAN BE WEEKLY / MONTHLY / YEARLY AND
TO BE CALL / TAKING AS A OATH BEFORE START
THE DAILY ACTIVITY.

13. MECHANICAL K-Y CALL
………...EXAMPLE…………….
MONDAY-CONFIRM SAFETY TREATMENT BEFORE EXECUTE
ANY JOB AT SITE.
TUESDAY- ALWASYS USE TESTED TOOLS & TACLES IN
EXECUSION OF JOB.
WEDNESSDAY- DO NOT SHORT CUT IN OVERHAULING JOB.
THRUSDAY- ALWAYS USE SOP & JSA IN REGISTERED RISK
JOB.
FRIDAY-DO NOT MOVE UNDER LOAD LIFTING AREA.
SATURDAY- ALWAYS USE PROPER PPE.
SUNDAY-DON’T HIDE ANY MISTAKE.

14. MECHANICAL K-Y CALL
………...FOR-2008…………….
MONDAY-USE FLASHBACK ARRESTER IN GAS CUTTING
SET.
TUESDAY- CONFIRM UNDERGROUND CABLE & PIPE
BEFORE EXCAVATION.
WEDNESSDAY- DON’T THROW ANY OBJECT FROM HEIGHT.
THRUSDAY- DON’T WORK ON AUTO START MACHINE
FRIDAY-USE FULL BODY HARNESS FOR HEIGHT JOB.
SATURDAY- USE OF MASK IS COMPULSORY IN DUST
GENERATING JOB.
SUNDAY- DON’T USE LOOSE UNIFORM AT MACHINE SHOP
AREA.

15. K-Y TRAINING EXAMPLES & ANALYSIS FOR
SELF IMPROVEMENT.
EXAMPLE-2
CONDITION - A PERSON IS
SETTING SLEEPER &
SIGNALING TO CRANE.
UNSAFE FINDINGS.-
1. HEAVY LOAD MAY FALL ON HIS
HAND DUE TO SIGNALING &
PLACING SLEEPER AT A SAME
TIME & DIRECTION.
2. WHILE GETTING BACK, THE
BACK SIDE SLEEPER MAY HIT HIS
LEG & GETTING INJURED.
CORRECTIVE MEASURES.
1. PLACING & SIGNALING SHOULD
NOT BE AT A TIME. 2.
SAME PERSON SHOULD NOT DO
PLACING & SIGNALING.
K-Y CALL - DO NOT WORK UNDER LOADING CRANE.

16. K-Y TRAINING EXAMPLES& ANALYSIS FOR
SELF IMPROVEMENT.
EXAMPLE-3
CONDITION-A PERSON IS DOING
PAINTING IN UNDERGROUND TANK
UNSAFE FINDINGS--
1. RESCUE FACILITY NOT
AVAILABLE SUCH AS SEFETY
BELT,LADDER WITH THE MAN.
2. VOC PREVENTION FACILITY
SUCH AS AIR LINE MASK,
VENTILATOR NOT PRESENT.
3. PAINTING CONTAINER MAY
DROP AS IT NEAR BY OPENING.
CORRECTIVE MEASURE--
1. CONFINED SPACE PAINTING
PROCEDURE TO BE FOLLOWED .
2.SPOTTER SHOULD PRESENT.
3.NO MATERIAL KEEP NEAR
OPENING.
K-Y CALL- FOLLOW CONFINED SPACE PAINTING PROCEDURE.

17. K-Y TRAINING EXAMPLES & ANALYSIS FOR
SELF IMPROVEMENT.
EXAMPLE-4
CONDITION- GRINDING WORK IN
TABLE GRINDING MACHINE
UNSAFE FINDINGS-
1.PPE NOT USE SUCH AS HAND
GLOVES,GOGGLES, MASK.
2. WHEEL COVER NOT FOUND IN
GRINDING MACHINE.
3. MANY MATERIALS LAYING ON
WORKING TABLE WHICH MAY
FALL ON LEG.
CORRECTIVE MEASURE-
1. PPE SHOULD BE USED IN
GRIDING MACHINE WORK.
2. GRINDING WHEEL COVER TO
BE FIXED FOR PROTECTION OF
SPARK & BROKEN PIECE.
3. WORKING TABLE SHOULD BE
KEPT CLEANED.
K-Y CALL- PROPER PPE TO BE USED IN MACHINE WORK.

18. K-Y TRAINING PHOTOGRAPHS & ANALYSIS FOR
SELF IMPROVEMENT.
CASE-1
CONDITION - UNDER GROUND
EXCAVATION IN PLANT AREA.
UNSAFE FINDINGS-
1. UNDER GROUND CABLE & PIPE
EXISTS IN EXCAVATION AREA.
2.NO BARRICADING / NOTICE
ARROUND EXCAVATION AREA.
3.GUMBOOT NOT USED IN SLUSH
EXCAVATION AREA.
CORRECTIVE MEASURES-
1. NOTICE BOARD FOR
UNDERGROUND PIPE & CABLE TO
BE DISPLAY BEFORE STARTING THE
EXCAVATION.
2. BARRICATION TO BE DONE.
4. TEMPORARY SUPPORT / COVER
TO BE PROVIDED FOR PIPE / CABLE.
K-Y CALL- CONFIRM UNDERGROUND FACILITIES LAYOUT
BEFORE WORK.

19. K-Y TRAINING PHOTOGRAPHS & ANALYSIS FOR
SELF IMPROVEMENT.
CASE-2
CONDITION- PAINTING
WORK IN PLANT AREA
UNSAFE FINDINGS.-
1. NO SCAFFOLDING, PAINETR IS DOING
PAINT IN HANGING POSITION. 2.
SAFETY BELT NOT USED THOUGH HE
WEAR FULL BODY HARNESS.
CORRECTIVE MEASURES.
1. SCAFFOLDING FOR HEIGHT JOB
SHOULD BE DONE AS MCPI STANDARD.
2. PROPER PPE & THEIR USE TO BE
MAINTAINED.
3. PAINT COTAINER TO BE KEPT NEAR
BY SO THAT HANDLING WILL BE EASY
& PAINT DROPS WILL BE MINIMUM.
K-Y CALL - USE SCAFFOLDING FOR HEIGHT JOB

20. K-Y TRAINING PHOTOGRAPHS & ANALYSIS FOR
SELF IMPROVEMENT.
CASE-3
CONDITION- PAINTING WORK
NEAR ROATATING MACHINE.
UNSAFE FINDINGS.-
1. THE PAINTER IS RESTING
HAND ON ROATATING SHAFT
COVER WHICH MAY SLIP &
CAUSED TO TOUCH ON SHAFT
AND ACCIDENT MAY HAPPEN.
2. PAINT DROPS MAY FALL ON
ROATATING PARTS & CAUSED
DAMAGED OR MAY CAUSED
FIRE DUE TO HEAT OF
FLAMMABLE MATERIAL.
CORRECTIVE MEASURES .--
1. NO PAINT , NO TOUCH ON
ROATATING MACHINES PART.
2. CARE SHOULD BE TAKEN ON
AUTO START MACHINE ALSO.
K-Y CALL - NO PAINT NO TOUCH ON ROATATING EQUIPMENT.

21. K-Y TRAINING PHOTOGRAPHS & ANALYSIS FOR
SELF IMPROVEMENT.
CASE-4
CONDITION- A PERSON IS
DOING SCAFFOLDING FOR
COMPRESSOR DUCT .
UNSAFE FINDINGS.
1. SCAFFOLDING STANDARD NOT
MAINTAIN,LONG HORIZINTAL PIPE
BEND & ANY TIME IT WILL FALL.
2. PLATFORM JALLI FIXED WITH
COIRSTRING, WHICH MAY CUT
AND FALL ANY TIME.
3. HAND RAIL / GUARD PIPE NOT
AVAILABLE.
CORRECTIVE MEASURES--
1. SCAFFOLDING TO BE MADE AS
PER MCPI STANDARD.
2. MINIMUM 2 PERSON REQUIRED
FOR HANDLING THE HEAVE TYPE
PLTFORM JALLI.
K-Y CALL - SCAFFOLDING STANDARD TO BE MAINTAIN.

22. K-Y CALLAT SITE BY CONTRACTOR EMPLOYEE

23. K- Y CALLAT SITE BY MECHANICAL MEMBER

24. CONCLUSION
FIND OUT THE PROBLEM IN EACH OF
OUR DAILY ACTIVITY TO APPLY THE
PREVENTION ACTION THROUGH TBM /
JSA / K-Y FOR MINIMISE THE HAZARD /
RISK / ACCIDENT & ALSO CONTINUAL
MONITORING FOR IMPOROVEMENT
OF OURSELVES & OUR SUPPORTING
CONTRACTOR.