Prevention through Design (PtD) - Mills.pdfLiberty Mutual Insurance Lean Construction Institute 2...

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Lean Construction Institute

Prevention through Design (PtD)

By Michael Mills, Kevin Coen, Dan Lavoie, Gary Cunningham Liberty Mutual Insurance

Lean Construction Institute Liberty Mutual Insurance 2

Objec&ves ReviewthebenefitsofPreven1onthroughDesign(PtD)

DiscusshowPtDandLeancomplimenteachother.

BecomefamiliarwithhowtoestablishaPtDProcess

Iden1fyandmanagepoten1alrisksofcollabora1vePtDprocesses

What is Preven&on through Design?

It’saPROCESS

Addressessafetyandhealthneeds

Duringthedesignstage

An1cipatesandpreventsorminimizeshazardsandrisks

Bydesigningouttherisk!

Benefits of Preven&on through Design

CostSavings• DesignOutRisk• ReduceInjuryCosts

EmployeeAcceptance• InvolvedinProcess• Collabora1ononSolu1ons

ImprovedEfficiencies• EliminateInefficientProcesses• ReduceComponents

PtD = ROI

Similar to Lean

Focusesonelimina1ngWastewhichleadstoRisk.

Collaborateprocessthatinvolvesfrontlineworkers.

EngageseveryoneinthebuildingprocessfromArchitectstoContractors.

Demonstrateaddi1onalvaluetoOwnersofcollabora1onwithContractors.

CaneliminaterisktoOwner’semployeesaswellasContractoremployees.

An Overview of the Process

Plan•  DevelopaPtDProjectPlan

Assess•  ConductRiskAssessment

Design•  DevelopDesignExpecta1onsforRiskReduc1on(DERR)

Review•  ConductDesignReview

Verify• MonitorConstruc1on/Installa1on/ProcessChangeandVerify

Learn•  ReviewProjectandDocumentLessonsLearned

EliminateInjuries

DevelopPtDProjectPlan

•  EstablishscopeofthePtDPlan•  Iden1fykeystakeholdersanddefineresponsibili1es

•  EstablishaDesignReviewTeam• Determineexper1seneededfrominternalandexternalsources

Plan and Track

Sample Tracking Sheet to Monitor PtD Project Progress

Design Review Team

• Management:bothuppermanagementandlinesupervision•  Employees• Architects,designers,andengineers•  Safetyandhealthprofessionals•  Contractors•  Suppliersofequipment,machineryortools• Othersasneeded,suchasIndustrialHygienist,Purchasing,orLegalCounsel

•  InsuranceBroker

ASSESS

ConductRiskAssessment

•  SelectRiskAssessmentmethod•  ConductRiskAssessmentofplannedprocessoropera1ons

•  Priori1zerisks

Insurance Broker

•  CommercialGeneralLiability:GeneralContractor(GC)•  Trigger:BodilyInjury(BI)/PropertyDamage(PD)arisingfromanoccurrence

•  CG2243–fullprofessionalliabilityexclusion•  CG2279–excludesprofessionalservices(exceptmeansandmethods)

•  CG2280–offerslimiteddesignrelatederrors

•  Professional:Designer/Engineering•  Trigger:Negligence/StandardofCare,doesn’tneedoccurrence•  Doesnotcoverconstruc1onmeansandmethods(temporaryjobsitestructures)

•  “OtherInsurance”clause

Risk Assessment Process

Sample Process from ANSI/ASSE Z590.3 – 2011

Risk Assessment

• AssessExis1ngandFutureBuildings,StructuresorProcesses•  Choosetheriskassessmenttool.• Meetwithkeystakeholderstoiden1fytasksandhazards.• Determineiftraininginhowtoperformariskassessmentisneeded.

•  Reviewplanstoiden1fytasksandhazards.•  Brainstormtoan1cipatesourcesofhighestrisk.•  Setpriori1esforriskstotargetforreduc1on.

Iden&fying Tasks and Corresponding Hazards

• Useasystemsapproach•  Examine:

•  Plansandspecifica1ons•  Workexpecta1onsandwaste•  Commonbehaviorsandwaste•  Similarbuildingsoropera1ons(includinglosshistory,riskassessmentsandjobhazardanalyses)

•  Maintenanceproceduresandwaste•  Relevantcodes,standardsandregula1ons

•  Interviewcurrentorintendedusers

Brainstorm Future Hazards

•  Buildinganewplant,tankswillbeinstalledtofeedtheproduc1onprocess.

Task:1.  Workersneedtoclimbto

thetopofthetanktomeasurefluidinsidefromthetop.

Risks:•  FallsfromHeightswhileclimbingandworking/takingreadingsontopoftank.

Assessing the Risks

• Questions to consider •  What aspect of the technology or activity produces waste

and risk? •  What action or inaction causes risk? •  Where are the potential sources of high severity injuries?

•  High/low pressure or temperature, work at elevation, unplanned energy release, hazardous material release, etc.

•  Any standard controls for common risks without performing detailed Risk Assessment (e.g. parapet or guardrail at roof perimeter)?

From ANSI/ASSE Z590.3 – 2011 PtD Guidelines for Addressing Occupational Hazards and Risks in Design and Redesign.

DevelopNewControls

DesignFallArrestSystem

andAnchorPoints

Eliminatethehazardbychangingaprocess

Cantheneedforworkersto

accessthetanktopbeeliminated?

Canthefallhazardbeeliminatedthruworkprocess

change?

Canweengineerorguardagainstthehazard?

Designawaytomeasurelevelsfromtheground.

Changethedesignofthetanktops.ElevaDonRiskiseliminated.

Designguardrailsfor

thetanktop

Redesign to Eliminate Risk

•  Redesignoftanks/processtointegratemeasurementsystemswithgaugesatgroundlevelsothatworkerscantakemeasurementswithoutneedtoaccesstopoftanks.•  Process/equipmentchangeeliminatestheneedforthepartofthetaskthathasrisk.

•  Climbingandtopoftankmeasurementnolongerdonesinceworkersdon’tneedtobeateleva1ontoperformtask.

Workersmustperiodicallyclimbto

accesstopoftankstotakemeasurementsfromtopof

tanks.Collaborate with the customer to work on both risk and waste!

DESIGN

DevelopDesignExpecta1onsforRiskReduc1on(DERR)

• UsetheHierarchyofControlstoselectthemosteffectriskreduc1onstrategies.

• DevelopDesignExpecta1onstoaddresspriori1esfromtheRiskAssessment.

• ProvidetoArchitects/Designersforinclusioninprojectdesignplanning.

• CommunicateguidanceonPtDprocessexpecta1ons.

DERR – What Can Be Done to Reduce Risk

•  Createsaguidefordesigners,architects,engineers:

•  Whatyouwanttosee(ornotsee)incurrentandfuturedesignstoreducerisk.

•  Considerthelifecycleofwhatisbeingdesigned:

•  Construc1on,use,maintenanceanddisposal.

•  UsetheHierarchyofControlstoselectmosteffec1vesolu1ons.

Example DERR’s

• Designcomponentsthatcanbepre-fabricatedoff-siteoronthegroundtoavoidassemblingorerec1ngatheightsandtoreduceworkerexposuretofallsfromheights.1

DesigntoReduceRiskDuringConstruc1on

• Walkwaysurfacesshallbeslipresistantunderexpectedenvironmentalcondi1onsanduse.2• Designchemicalprocessestobeconductedinclosedsystems,wherefeasible.3

DesigntoReduceRiskforAllUsers

• Wherefeasible,systemsshallbedesignedtoavoidconfinedspaceentry.3• Designthestructuresothatmaintenancecanbeperformedatgroundlevelorsafelyfromthestructure,forexample,posi1oningair-condi1oningunitsandlijplantatgroundlevel.1

DesigntoReduceRiskforMaintenance

1 Safe Design of Structures: Code of Practice July 2012 Safe Work Australia 2 ASTM: F1637 − 13 - Standard Practice for Safe Walking Surfaces 3 ANSI/ASSE Z590.3 – 2011 - Prevention through Design Guidelines

REVIEW

ConductDesignReview

•  ReviewDrawings/Plans/ProcessDesignsforimprovementopportuni1es.

• VerifyplanadherencetoDERR.•  Communicatevariances.• Developalterna1vecontrolplanswithvendors.

Roof Fall Risk Elimination

• A design review revealed no guardrails or safe access to the roof.

• No guardrail designed around the Green Roof.

• Workers access the roof through a window to perform maintenance.

Prevention through Design

VERIFY

MonitorConstruc1on/Installa1onProcessChangeandVerify

• MonitorandverifyImplementa1onofexpecta1ons.

• Addressneedsthatariseforchange.•  Ensureeffec1vecommunica1onwithvendors.

Monitor Construc&on •  Drain Pipe location was

identified as a risk factor during the Design Review and location was redesigned to eliminate the trip/fall hazard.

•  Design changes were not communicated.

•  During the monitoring of construction the issue was found and corrected.

ReviewProjectandDocumentLessonsLearned

•  ReviewtheoverallPtDprocessforimprovements.

• UpdatetheDERR’sforuseonFutureProjects.

• DiscussLessonsLearnedandwhatcanbedonetoeliminateorreducemissedopportuni1esonfutureprojects.

Lessons Learned •  LessonLearned-postconstruc1onchangescanbecostly.

•  DesignReviewTeamlearnedthevaultcoverswereslipperyatonefinishedentrance.

•  Matsplacedonthemtocutdownonslipfallexposureblockedrequiredven1ng.

•  Workingwiththeu1lityandDesignReviewTeam,thesizeofthecoverswasreduced,thevaultrelocatedandthemetalcoverstreatedwithaslipresistantmaterial.

Renova&on

•  YoumayhaveasmallerDesignReviewTeam.•  Encourageemployeesimpactedbytherenova1ontopar1cipate.•  Takeadvantageoftheknowledgeandexperienceoffrontlineworkers.

•  Takethislessonslearnedfromcurrentsitestoyourrenova1ons.•  Usetheopportunitytocorrectissuesthatproducerisk.

Servicing lighting can be costly and high risk.

Design to reduce risk during maintenance.

Evaluate All Risk

• Have your Design Review Team look at all aspects of the design both contractor and owner employee exposures.

•  It could save lives, dollars and prevent a liability incident.

Roadmap to Risk Reduc&on

Summary

•  PtDcanprovideROIwithcostsavings,improvedefficiencyandreducedinjures.

•  Startearlyinthedesignphaseforbestresults.•  Focusonthehighestrisks.• UsetheHierarchyofControlsformosteffec1vesolu1ons.• Defineandcommunicateexpecta1onsfordesignsthatwillreducerisk.

Ques&ons and Comments

Prevention through Design (PtD) - Mills.pdfLiberty Mutual Insurance Lean Construction Institute 2...

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