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

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


PLAN

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

No

DesignFallArrestSystem

andAnchorPoints

Yes

Eliminatethehazardbychangingaprocess

Cantheneedforworkersto

accessthetanktopbeeliminated?

Canthefallhazardbeeliminatedthruworkprocess

change?

Canweengineerorguardagainstthehazard?

Designawaytomeasurelevelsfromtheground.

Changethedesignofthetanktops.ElevaDonRiskiseliminated.

No

No

Designguardrailsfor

thetanktop

Yes

Yes


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.


LEARN

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.


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