Ohs Ah 18001 Overview

8/14/2019 Ohs Ah 18001 Overview

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The World Leader in High Performance Signal Processing Solutions

OHSAS 18001 Overview

Ron Scholtz- REA, CHMM

Manager- Environmental/SafetyAnalog Devices, Inc.


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Background

ADIs Silicon Valley semiconductor manufacturing operations totalaround 900 employees.

This operation had a very high accident and lost work day ratearound 10 years ago.

As many as 70 OSHA recordable accidents per year (130 plus total

claims per year) with workers compensation costs over $400,000per year.

Twice as many workers compensation claims as another ADImanufacturing site with twice as many employees.

Reactive vs. proactive Hired full time occupational health nurse

Implemented management safety committee Focus on ergonomic issues, training, exercises

Implemented ISO 14001

Accident rates improved, but were still above industry benchmarks.

ADI chose to implement OHSAS 18001 corporate-wide.


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What is OHSAS 18001?

OHSAS 18001: Occupational Health and Safety AssessmentSeries (OHSAS).

Developed by the British Standards Institute.

Voluntary standard for developing an occupational health andsafety management system (HSMS).

Enables an organization to more proactively control healthand safety risks and improve performance.

Developed in response to demands for a recognizable OHSmanagement system that compliments the ISO 14001

environmental management system.There is currently no comparable ISO related HSMS standard

available.


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What Are The Requirements?

The 18001 standard features the following key elements:OH&S Policy Statement

Planning

Implementation and Operation

Checking and Corrective Action

Management Review

Continual Improvement

The OHSAS 18001 elements are very similar to the ISO 14001

elements.


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ISO 18001 vs. ISO 14001 Elements

Management Review4.6Management Review4.6

Internal AuditAudit

Control of RecordsRecords and Record Management

Evaluation of Compliance,

Corrective Action and Preventative Action

Accidents, Incidents, Non-Conformances

And Corrective and Preventative Action

Monitoring and MeasurementPerformance Measurement and Monitoring

Checking and Corrective Action4.5Checking and Corrective Action4.5Emergency Preparedness and ResponseEmergency Preparedness and Response

Operational ControlOperational Control

Control of DocumentsDocument and Data Control

DocumentationDocumentation

CommunicationConsultation and Communication

Competence, Training, AwarenessTraining, Awareness, Competence

Resources, Roles, Responsibility, AuthorityStructure and ResponsibilityImplementation and Operation4.4Implementation and Operation4.4

Environmental Management ProgramsOH&S Management Programs

Objectives, Targets, and ProgramsObjectives

Legal and Other RequirementsLegal and Other Requirements

Environmental AspectsHazard Identification and Risk Assessment

Planning4.3Planning4.3

Environmental Policy4.2OH&S Policy4.2

ISO 14001:2004OHSAS 18001:1999


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Policy Statement

Includes a commitment to continual improvement

Includes a commitment to at least comply with current OH&Slegislation

Must be documented, implemented, and maintained

Must be communicated to all employees

Must be available to interested parties

Must be reviewed periodically to ensure it is still relevant


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Example Combined EH&S Policy

Analog Devices, Inc. and its employees are committed toprotecting the environment and the health & safetyof fellowemployees, customers, and the public

by endeavoring to adhere to stringent regulatory andindustry standards across all our facilities, encouraging

pollution prevention, and striving towards continualimprovement. Analog seeks to go beyond compliance withregulatory standards in order to achieve a standard of

excellence in environmental, health and safety managementpractices, as an integral part of its total quality managementsystem.


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Hazard Identification and Risk Assessment

A risk assessment process needs to be developed andimplemented.

ADI developed a process that looks at different job positions-Homogenous Exposure Groups (HEG).

A Job Hazard Analysis (JHA) is conducted by a core team

for each HEG.An employee representing the HEG is interviewed to better

understand their jobs and the hazards involved.

JHA forms are used to score the identified hazards.

Hazards with scores above a cut point are considered

significant.An additional safety analysis is performed on significant

hazards to determine needed improvements.

When all JHAs are completed, they will be revisited andrevised based on improvements made.


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Job Hazard Analysis Process Forms

Checksheet for Conducting a Job Hazard Analysis

HEG: ____________________________________ Evaluator : ____________________________________ Date: __________________

Step by Step Work Tasks Routine

Task?

How

Often?

Production Equipment

Used?

Types of

Che micals/Gases Used?

List Hazards

Involved

Other/Comments

YESNO

YESNO

YESNO

YES

NO

YESNO

YES

NO

Page ___ of ___

See separate presentation for other JHA forms


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Legal and Other Requirements

Develop a comprehensive list of legislation and regulationsthat apply to your operations.Add hyperlinks to regulations

Develop a comprehensive list of permits, reports, and fees

and their due dates.Compliance calendar- automate

Need to communicate relevant information to employees-training, postings, website.

Other Requirements:FM Global

SEMI StandardsOHSAS 18001ANSI Industry BenchmarkingVPP


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Objectives and Targets

Goals that result in continuous improvement in the Healthand Safety Management System.

Consider the following factors:Legal and Other Requirements

Hazards and RisksViews of Interested Parties

Example Objectives and Targets:Reductions in Incident Rate

Reductions in Severity Rate

Reductions in Types of Emergency Responses (example: Odors)Emergency Preparedness- Completion of planned training, drills,

and equipment inspections

Implementation of New Safety Programs (example: Heat Stress)

Must be measurable where possible


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Targets and Objectives: ExampleObjective: Ensure compliance with EH&S and Other Requirements Target: Maintain 100% compliance with EH&S permit and

operating requirementsResult Metrics: Submittal of permits, fees and reports on time (Goal 100%) Completion of all required life safety inspections on time (Goal 100%) Regulatory inspections with no violation notices/fines (Goal: 100%) EMS/HSMS Surveillance Audits with no Major Findings (Goal: 100%) Address FM Global Recommendations within completion plan (Goal: 100%)

Process Measurements: Compliance Calendar monthly completion (Goal: 100%) Life Safety Calendar monthly completion (Goal: 100%) Compliance inspections completed on-time (Goal: 100%) Corrective Action Requests completed on-time (Goal: 100%)

Improvement Projects: Corporate compliance audit (Goal: 100% AIs addressed)

Owner: Environmental/Safety


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Targets and Objectives: ExampleObjective: Reduce the numbers and severity of accidents Target: Reduce the 2006 OSHA recordable accident rate to 0.9 or below (SIA industry

rate) Meet or exceed the 2005 ADSiV OSHA recordable accident rate and severity

rate

Result Metrics:

Number of OSHA recordable accidents per month (Goal: Zero) Number of Lost Work Days per month (Goal: Zero)

Process Measurements: Number of overdue accident reports (Goal: Zero) Number of overdue AIR corrective actions (Goal: Zero) Number of Job Hazard Analysis completed per quarter (Goal: 4) Number of overdue JHA corrective actions/improvements (Goal: Zero)

Number of employees with overdue/not completed safety training (Goal: Zero) Improvement Projects: Fab microscope PMM team Job hazard analysis program implementation Implement Heat Stress safety program for Chem Techs and Maintenance

Owner: Environmental/Safety, Health Services, Safety Committee


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Implementation and Operation

TrainingOHSAS 18001 Awareness- employees and management

OSHA Required Training- Forklift, Respirator, LOTO, etc.

Training Records- need to be complete

Communication

External Communications- customers, agencies, public Internal Communications- safety alerts, posters, safety suggestions

Operational ControlsOperations and activities with identified risks that need controls

Written procedures- controlled documents

ADI- Silicon Valley maintains over 100 EHS related specifications

Procedures are audited- make sure you do what the procedure says!

Emergency Preparedness Procedures for responding to emergencies that will prevent injuries

Review and periodically test procedures


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Checking and Corrective Action

Performance Measurement and MonitoringObjectives and Targets

Proactive Measures

Reactive Measures- including near misses

Accidents, Incidents, Non-Conformances Investigation of accidents, incidents and non-conformances

Initiation and completion of corrective and preventative actions-close the loop

Audit

Internal audit program to ensure the HSMS meets OHSAS 18001Conducted by personnel independent of the activity being audited

Compliance Audits- required by regulations (Confined Space,Respirator, Forklift, LOTO, etc.)


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Management Review

Top management needs to review the HSMS at predeterminedintervals (example: quarterly)

Excellent way for getting top management feedback andsupport for key projects

Establish a set agenda for the reviews:Objectives and Targets Update

Regulatory Issues

Audit and Regulatory Inspection Results

Communications

Action Items From Last Review

Management reviews need to documented:Meeting minutes with attendees

Hand-outs

PowerPoint slides


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Benefits of OHSAS 18001

Gives a structured approach to managing an EHS Department

Allows for standardization within companies that havemultiple sites

Increased regulatory compliance

Potential cost savings- workers compensation, manufacturingdisruptions

Systematically plan, control, and monitor operations throughoperational controls

Top management involvement

Increased employee awareness and involvementPositive image with customers

Positive image with stakeholders (stockholders)


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Why Bother With Registration?

Its really up to top management just how far they want to gowith a HSMSValue added

Bare minimum

Take beyond OHSAS 18001Why third party registration?Provides independent verification of HSMS effectiveness

Demonstrates transparency

Regular surveillance audits helps to keep the focus

Auditor recommendations can lead to opportunities for furtherHSMS improvement

Registration certificate satisfies many customer surveys


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OHSAS 18001 Registration Process

Apply for 18001With Registrar

Perform GapAnalysis

vs. Standard

CloseGaps

Identified

Pre-AssessmentAudit ByRegistrar

AddressPre-AssessmentAudit Findings

RegistrationAudit

AddressRegistration

Audit Findings

Yes

No

Yes

No

Project Monitor:Are All Gaps

Addressed?

Reschedule

Pre-AssessmentAudit

Project Monitor:Major

Findings?

RescheduleRegistration Audit


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Example Implementation Schedule

8/25/048/24/047. Pre-Assessment audit with Eagle

9/7/048/25/048. Address findings from Pre-Assessment Audit

9/10/049/8/049. Registration audit with Eagle

5/28/044/26/046. 18001 Awareness training

4/26/044/12/045. Finalize Objectives and Targets

8/23/044/12/044. Internal Auditing of all 18001 elements

8/23/044/5/043. Address other deficiencies from gap analysis

8/23/044/5/042. Implement Job Hazard Analysis

3/31/043/1/041. Perform gap analysisFinishStartTask


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Some Lessons Learned

If your facility is already ISO 9001 certified, many of theneeded elements are already in place

If you can implement ISO 14001 and OHSAS 18001 at thesame time, some redundant work can be avoided

Policy statementOperational controls

Combined EMS and HSMS manuals

Use your Injury and Illness Prevention Plan (IIPP) as yourHealth and Safety Management System Manual

Give yourself time to adequately implement- 9 to 12 months

Consider a corporate-wide registration vs. individual facilities

ANSI Z10 Standard


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We Have Come a Long Way!

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#OSHAACCIDENTS

OSHA Accidents 30 37 23 19 7 6

FY2000 FY2001 FY2002 FY2003 FY2004 FY2005

Zero lost work days in FY 2005!


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The World Leader in High Performance Signal Processing Solutions

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Ohs Ah 18001 Overview

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