Post on 02-Jan-2016
transcript
Managing Environmental Aspects
An Integrated FMEA Approach
Why do we Assess Risk?
It’s our job Ensure compliance Protect our assets Balance our concerns Drive improvement
Why Integrate?
Incorporate risk as part of “big picture” Common tools provide for:
– Decreased Training Needs– Increased Skill– Improved Interaction
More Eyes = More Opportunities for Improvement
When we don’t integrate…
Conflicting information in different areas We risk focusing on trees instead of the forest We may initiate projects with conflicting goals We may find ourselves competing for vital
resources
Goals for this Session:
Identify potential environmental impacts using a process approach
Analyze environmental risks in light of multiple business objectives
Define appropriate control measures Formulate strategic improvement projects
Borrowing from the Quality Toolbox
“Go with the flow”- process flow diagrams Find the flaws - FMEA Create a game plan - SOPs, etc. Summarize Controls - Control Plan Reduce Risk - CI Process
…Review & Repeat!
Process Flow Diagrams
What do we have? (inputs)
Where/Why? (process) What’s left? (outputs,
waste) How do we control? Who do we train? How can we reduce?
CGL Process Section
Utility Process OutputsInputs
Coil From EntrySectionPF-08
PDI Info
Coil advancesthrough Cleaner
SOP-UT-01
Process Water
Caustic Cleaner
Wastewater toWWTPF-14
Coil advances toFurnace
SOP-PR-01
Gas:Natural Gas, Nitrogen,
Hydrogen
Coil advances toPot WI-PR-01
Coil advancesthrough air knivesand baffle plates
SOP-PR-03
GA?
Coil through EdgeBurners
Coil through GalvRig SOP-PR-05
Electricity
Cooling SolutionCtg Wt OK?
Coil throughQuench
Coil through SPM(on if rqd)
SOP-PR-02
Coil through TL(on if rqd)
SOP-PR-04
Coil throughstenciler (on if rqd)
WI-PR-06
Coil through RollCoater (on if rqd)
WI-UT-02
Roll CoaterChemicals
Stenciler Ink
Coil To ExitInspection
PF-10
Rolling Solution
Rags to HazWaste Disposal
50-foot Records
ZincAdd ZincWI-PR-02
Yes
No
AutoControlLoop
NOX emissions
Equipment TimeBased Data
(from various)
Pot Sample to LabWI-LB-23
Take Sample
Dross
See Control Plan for Monitoringand Measurement Requirements
Line StopOccurs
See Environmental FMEAfor Significant Aspects
Assess the Risk - FMEA
Lay out the process steps Identify hazards and effects for each action Assess the risk = Severity / Probability Summarize Controls Prioritize Actions - the power of FMEA
Karen’s Kwik Lube
Welcome to the Kwik Lube Krew! Your job today will be to:
– Map the Kwik Lube process– Identify potential environmental impacts– Assess their various risks– Draft a game plan for improvement
Let’s Begin…
Process Map - Reminders
All inputs captured (information, materials, tools, equipment)
All steps clear All outputs captured (final product, information, wastes) The cross-functional model
Identifying Hazards/Aspects
Aspects can include any solid, liquid or gas added to, used in, created by, or left over as the result of a process that has the potential to impact the environment
Aspects must include elements that may not be under our direct control, but over which we can be expected to have an influence (e.g., work of contractors, etc.).
Consider plans for process changes and improvements
Identifying Effects/Impacts
Impacts May Include: emissions to air releases to water or land use of raw materials or natural resources use/emission of energy creation of waste Safety would include motion, energy, chemicals,
etc.
Severity
Score Effect Severity – Environmental Impact
10 Catastrophic Irreparable damage to environment or living beings
9 Critical Spill, release, incident resulting in major remedy costs, fines, prison
7 Significant Spill, release, or incident resulting in moderate remedy costs and/or potential fines
5 Marginal Spill, release, or incident resulting in minor remedy costs, no penalties
3 Minor Environmental impact not regulated / no potential to exceed requirements
1 Positive Provides net environmental benefit
Severity - Other Elements
Score Effect Severity – Personnel Severity – Property
10 Catastrophic Multiple Deaths Catastrophic damage to equipment
9 Critical Death Major damage to equipment / Significant delay
7 Significant Major injury, disabling illness
Minor damage to equipment / Significant delay
5 Marginal Lost time injury or illness
Equipment damage unlikely / Minor delay
3 Minor Minor Injury, First Aid, Near Miss
Equipment damage improbable
1 Positive Promotes / improves health
None
Severity - Other Elements
Score Effect Severity – Resource Consumption/Waste Generation
Severity – Public Concerns
10 Catastrophic Destruction of resources or uncontrolled release of hazardous waste resulting in irreparable damage
Regulatory intervention, shut-down of operations
9 Critical Endangerment of resources or uncontrolled release of hazardous waste repairable over a number of years
Permanent public disfavor / disruption to operations
7 Significant Resource consumption exceeds industry standards. Waste streams of excessive quantity and/or hazardous nature.
Public protest / disruption to plant operations
5 Marginal Resource consumption at or below industry standards. Waste reduction / lean efforts have minimized waste streams.
Public disfavor
3 Minor Resource consumption at or below industry standards. Waste streams are recycled or reused.
Public concern (local)
1 Positive Provides resource recovery Improves Public Perception
Probability
Ranking Effect Probability
10 Frequent Occurrence almost certain in exposure interval
9 Probable Quite likely to occur in exposure interval
7 Occasional May occur in exposure interval
5 Remote Not likely to occur in exposure interval
3 Improbable So unlikely it can be assumed occurrence may not be expected
1 Impossible Redundant/fail-safe engineering controls in place
Risk = S x P
ProbabilityS
E
V
E
R
I
T
Y
10 9 7 5 3 1
10 High
9
7 Med
5
3 Low
1
Controls
Controlling Conditions– Engineering Controls– Pre-treatment Systems– Housekeeping
Controlling Behavior– Controlled Practices (SOPs, Work Instructions)– Training & Communication– Behavior Modification
Control
Ranking Effect Control
10 Almost Impossible
Control is non-existent, non-functioning, or impossible to achieve
9 Slight Control is subject to human error or misuse, no supervision provided. Includes general awareness training.
7 Low Control is subject to human error or misuse; activity is supervised. Includes general awareness training.
5 Medium Engineering controls isolate risk during proper use (e.g., guarding), no verification measures in place.
3 High Engineering controls isolate risk during proper use (e.g., guarding), verification measures in place.
1 Almost Certain Interlocks or other measures prevent the bodily contact with hazard at all time.
RPN
Risk Prioritization Number S x P x C
– Multiplication helps stratify hazards
Relative Measure of Risk - relies on:– Well-defined criteria– Consistent Application
Determining Significance
Define the criteria– Severity– Risk
Avoid “lines in the sand” Continual improvement should drive change
How can we improve?
Focus on THE PROCESS– Modify process to change or eliminate step– Reduce Severity– Reduce Probability– Institute or Improve Control
Use ALL the tools - P2, Lean, 6-sigma, 5-S
Ideas??
Integration
Cross-functional Approach Adding Safety Adding Quality
– Process versus Product
Continual Improvement Programs
Questions??
kmreaume@worthingtonindustries.com