Safety design reviews

Perform electrical safety design reviews of new equipment. 

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At this phase no technical hurdles are anticipated. Future actions include conducting a safety design review (HazOps analysis), establishing an activity-based target date for a critical design review, and generating a system level functional specification document which will help define the research boundaries for this project. 

Plot plan, layout, area classification, pressure relief and fire safety design reviews are crucial to make revamp projects safer... 

The applied lean concepts as discussed in this book relate to the safety design review provisions in ZIO, and a chapter on lean concepts follows the design chapter. 

Identify and control hazards in the design process and when changes are made in operations—which requires that safety design reviews be made for new and altered facilities and equipment. 

Checklists are easy to use and provide a cost-effective way to identify customarily recognized hazards. Nevertheless, the quality of checklists is dependent on the experience of the people who develop them. Furthermore, they must be crafted to suit particular needs. If a checklist is not complete, the analysis may not identify some hazardous situations. An example of a checklist for machinery design is provided in Addendum B at the end of this chapter. A checklist for general design purposes appears in Chapter 13, Safety Design Reviews. Both serve as resources for those who choose to build their own checklists. 

Having written and stressed that the most effective and economical way to minimize risks is to have the hazards from which they derive addressed in the design process, I commend the drafters of ZIO for including the safety design review provisions in the standard. If it becomes the norm for employers to include these provisions in their safety and health management systems, injuries and illnesses will be substantially reduced. 

A safety design review process will not be effective until the participants in the review team have acquired knowledge of hazards and risks and agreed on the risk assessment methods and risk assessment matrix to be used. Chapter 7, A Primer on Hazard Analysis and Risk Assessment, serves as a basis for the education of team members. Also, a safety design review process can be successfiilly applied only if senior management has been convinced of its value. 

Much was made in Chapter 12, Hierarchy of Controls The Safety Decision Hierarchy, of the need to design work methods so that they were not error-provocative or overly stressful. Safety design reviews should not be Umited to the facility, equipment, and processes, that is—the hardware. They should also limit the hazards and risks in the work methods prescribed, taking into consideration the capabilities and limitations of the workers so that the risks of injury and damage are at a practicable minimum. 

Crucial to the success of the UAW-GM joint process was the inclusion of the hourly skilled trades and production personnel, who were extensively involved in the task-based risk assessments. This involvement was based on the premise that the person who does a job every day has intimate knowledge of it and can make meaningful contributions on how a job or process can be changed to make it safer. (The TABRA process has matured now, internally developed computer-based software is used in the safety design review process and for recordkeeping.)... 

A SAFETY DESIGN REVIEW AND OPERATIONS REQUIREMENTS GUIDE... 

An Internet search on design reviews will yield many results, but only a few address safety considerations. Enter safety design reviews into any search engine, and you will find that the literature on safety design reviews is scarce. That is one reason why outlines of several safety design processes as they are applied by individual companies or a combination of companies are included in this chapter. 

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