Achieving Excellence in OH&S performance through OH&S Management Systems

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Achieving Excellence in OH&S performance
through
OH&S Management Systems
9
Quality of Auditing and Certification
Presented by : M G Singhal

How Accidents/Incidents occur
Management
Commitment
Machines, Tools
& tackles
10
Employees
exposed to risk
Management
System
Work
Environment
Materials including
waste generated
from process
Legal framework

OHSAS 18001 - OH&S performance in industry !
• Based on the audit and certification of thousand of
company’s OHSAS 18001:2007 management systems
by UL-DQS India,since last several years, it is seen that
a few companies have really used the standard for
achieving excellent results in OH&S performance,
whereas a large number of them still are not meeting the
expectations of the managements.
11
expectations of the managements.
• Let us examine the areas where companies could use
the requirements of this standard, in a more focused
manner and make substantial improvement in their
OH&S performance

4.1 General Requirements
Use ISO 18002:2008 Guidelines for the
implementation of OHSAS 18001:2007, to
design, develop , document ,implement and
continually improve your OHSAS 18001:2007
Management system
12
Management system
Integrate your OH&S management system
activities with daily operational management
activities rather then keeping it as a stand alone
system .

• Ensure that the OHS policy is a shared document of the
entire management team rather then produced by one or two
individuals and approved by the top management
•Ensure that every statement given in the policy document is
deployed at the operational level and can be verified during
the internal audits
4.2. Policy
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the internal audits
•Is the policy and its essence understood properly by all
employees and are they clear about their role and
responsibilities.
•Is a formal system put in place to ensure that all instances of
continual improvement ,both in Management System and the
OH&S performance ,are tracked and shared with all
employees, as it is one of the key requirement of the standard

Have you ensured that all activities, processes,
machines and materials are covered for HIRA
assessment
Have you ensured that all relevant abnormal and
emergency situations are also captured while
4.3.1 Hazard identification, risk assessment and
determining controls
emergency situations are also captured while
conducting HIRA
Is it ensured that hazards related to all aspects of
operations viz. Man, Machine, Material, Method and
work environment are captured in HIRA
Ensure that all possible control measures required to
bring down the risk level are captured in the HIRA
document

4.3.1 Hazard identification, risk assessment
and determining controls
Occupational Health and Safety :
Are the hazards ,on account of changes or
modification in the processes , captured for risk
assessment and control.
Have you considered the human capabilities and
their compatibilities with work place design,
processes, installations, machinery and work
processes, installations, machinery and work
organization.
Do you always revisit the HIRA of an activity, if an
accident/incident occurs or a new hazard is
identified
Have you developed a formal system to influence
employee’s unsafe behavior

4.3.1Hazrds identification, risk assessment and
determining controls.
While determining controls to reduce risk levels, do
you follow the risk control hierarchy viz:
Elimination
Substitution
Engineering controls
Signage /warnings and or administrative controls
Signage /warnings and or administrative controls
PPE’s
Note:1) Have you ever attempted to select and display
all safety signs and posters etc, as per standard
signs given in ISO: 7010:2011
2) Have you referred OHSAS 18002 ‘’ guidelines
on HIRA’’ for designing your procedure for HIRA

Tragedy of a young life lost at a project site

Tragedy of a young life lost at a project site
Company: An Indian Multinational Company
Site: Brownfield expansion project site
When: About 5 years back
What happened: Fall from a floor opening from a height of
35 Meters
Employee: A semi-skilled contractor employee
(helper of a welder)
Direct Cause: No HIRA done of site before starting work
Root cause: No training to contractor on HIRA

4.3.2 legal and other requirements
Develop a formal system to ensure that all
line Managers/Engineers/Supervisors are
fully aware about the legal requirements
applicable to their activities/operations,
rather then remaining dependent on the
safety coordinator or HR department
safety coordinator or HR department

4.3.3 Objectives and programs
It is observed that only a few objectives and
programs are taken at the MR level and very
little periodic review is done. OHSAS 18001
requires that OH&S objectives and management
programs should be taken at all relevant
programs should be taken at all relevant
functions and levels .
This is a tool which can greatly help in brining in
continual improvements ,if objectives and
programs are taken by all departments, as and
when an area of improvement is identified

4.4.1 Resources, roles, responsibility,
accountability and authority
Appointment of Management Appointee: Even
though the standard permits appointment of MR
from top management team , this function has been
relegated to Managers in the middle management
level, over a period of time . Having a member from
top management team ,as MR has its advantages
Responsibilities of Line Management, Managers
and members of top management team: The
management must very clearly specify the
expectation from each person and their objectives
on OHS in their areas, should be clearly defined,
documented and reviewed

Some of the expectations of Management from
supervisors
Ensure that there are no accidents in your
area
You will be held responsible for any injuries in
your department
your department
Let us all achieve zero accidents this year
Ensure there is no NC in your department in
this audit .

A typical examples of management's expectations
A top boss to a Safety Manager- You are responsible for safety.
Why are the accidents increasing in the plant!

4.4.2 Competence, Training and Awareness
With increasing trend in industry on engagement
of contract workers, even in core operational
activities, the competence of people performing
various tasks is not to the desired level. This has
a serious potential for accidents/incidents.
The core competence for each function should be
clearly defined, mapped and continually
The core competence for each function should be
clearly defined, mapped and continually
enhanced.
The training of employees with respect to the
OHS hazards in their respective work areas
,should be ensured before they are engaged for
the job including the hazards associated with
handling of dangerous substances and
hazardous chemicals

4.4.3 Communication, participation and consultation
Even though, there are documented procedure for
communication, participation and consultation of
employees in safety ,management, the experience tells
us that this is an area which has a huge potential for
improvement. Remember that OHS is a people related
subject and their involvement will have very positive
effect on the safety performance.
effect on the safety performance.
Create a forum where employees are talked to every day
in the morning for few minutes to ensure important
communication ,consultation and involvement ,besides
the formal forums like safety committees, safety
promotional activities etc
Involve employees in HIRA and for any changes
/proposed changes in management system or in the
operational issues, where they have intimate knowledge
of machines and processes

4.4.6 Operational Control
One of the key requirement to ensure operational excellence
and to control OHS risks is that ,the standard operating
practices should be clearly defined, documented and
implemented. These SOP’s should be based either on the
manufacturer’s guidelines or should meet any National or
international standards. To clarify this ,a few examples of some
of the National standards(BIS) are given below ,for controlling
OH&S risks:
OH&S risks:
IS 11461 : 1985 Code of practice for compressors safety
IS 13367 : 1992 Code of practice – Safe use of cranes
IS 4357 : 1974 Methods for stability testing of forklift trucks (first
revision)
IS 7155 : 1986 – 1994 Code of recommended practice for
conveyor safety – Part 1 to 8

4.4.6 Operational Control
IS 4912 : 1978 Safety requirements for floor and
wall openings, railings and toe boards (first
revision)
IS 7689 :1989 Guide for control of undesirable
static electricity (first revision)
static electricity (first revision)
There are National standards (BIS) for safe
operation ,and maintenance ,inspection and
testing of almost all types of activities,
equipments and machinery. The need is to
identify these standards ,get copies and use
them for formulating SOP’s

4.4..7 Emergency preparedness and
response
Generally, it is seen that most of the plants
identify emergency only related to ‘Fire’.
There is a need to identify other emergency
situations also depending on the nature of
operation, the type of hazardous material in use
operation, the type of hazardous material in use
and the extent of controls.
During the testing of the procedures to handle
the identified emergencies, an effort to reduce
the response time for each type of emergency
situation ,will go a long way in controlling the
emergency, in its early stages.

Emergency preparedness and response
A trained employee ready to handle an emergency of Leakage
of Chlorine from a cylinder

4.5.1 Performance Monitoring and Measurement
It is generally seen that in most of the organizations, only some reactive
data are monitored by the safety Coordinator or the MR
It will greatly help in knowing the performance level of OHS if all
departments maintain both reactive data and proactive data ,month over
month . This can become a basis for continual improvement
Reactive Data: Number of accidents/Incidents AFR; ASR; Man days
Lost etc
Proactive data:
i. OHS Training provided to the employees
ii. Involvement of employees in OHS( involvement in HIRA; Accident
investigation; Corrective &preventive actions: Changes brought in
management system or the work place)
iii. No of new management programs taken and the old programs
satisfactorily completed
iv. No of safety committee meetings held; % attendance and the Number
of issues identified related to OH&S

Monitoring of Proactive OHS data:
No of corrective actions taken
Number of NC’s closed effectively
No of unsafe conditions identified and corrected
No of employees contacted for influencing their safety
No of employees contacted for influencing their safety
behavior
Use of PPE’s( Head protection; eyes protection: ear
protection; respiratory protection; Foot protection; Special
PPE’s for welders; working at height; confined space entry
and handling hot substances etc.)
No of medical examination done including special check
up like Audiometry and LFT etc)
Monthly hygiene index

Monitoring and measurement of chlorine leakage by a hand held meter

4.5.3. Accident investigation, Non-Conformity,
Corrective and Preventive action
The effectiveness of corrective action recommended by
incident investigation teams must be reviewed .
A critical analysis of various accidents/incidents /non-
conformities ,over a period of time month on month and
year on year basis should be used to identify repetitive
type of issues, for taking corrective action
type of issues, for taking corrective action
Fining out non-conformities only during the internal audits
serves very little purpose . There should be a procedure to
identify and correct the non-conformities on a regular
basis.
HIRA must be reviewed after every incident, identification
of non-conformity and after taking corrective/preventive
actions

4.5.5 Internal Audit
This is a very powerful tool but the experience tells us that
the quality of internal auditing is far from satisfactory in
several companies.
Ensure that the internal auditors are trained in line with
guidelines given in ‘’ISO 19011:2011Guidelines for quality
and/or environmental management systems auditing’’
Ensure that after every internal audit, a thorough review is
Ensure that after every internal audit, a thorough review is
done to check the quality of auditing and proposed corrective
and preventive action.
A detailed analysis of all NC’s will reveal the areas which
need focused attention. If necessary special audits can be
done for such areas of concern

4.6 Management Review
• This is another powerful tool which can bring in
considerable improvements through a detailed
review of performance of management system
of each department
• All departments must be asked to present the
detailed data on their performance in OH&S in
detailed data on their performance in OH&S in
MRC
• All proposed improvement in MRC must be
tracked till such time, they are effectively
implemented

Reality check
Remember, any management
system is as good as the efforts put
in by the people, operating and
maintaining it.
maintaining it.
The performance of the system
(Poor, Average, Good or Excellent)
depends entirely on management

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Achieving Excellence in OH&S performance through OH&S Management Systems

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