Tom Barnes
Compliance Specialists, Inc.
In the most recent Management Pulse survey, members were asked to respond to questions regarding the use of work instructions and job safety analysis.
Of the 136 respondents, about 67%, or two thirds, had fewer than 25 employees. An operation with a small number of workers makes it much more difficult to marshal the resources to write site specific work instructions and properly do job safety analysis. It is, however, no less important that even the smaller service centers have these important documents and utilize them in the day-to-day operations of the facility.
Job Safety Analysis
The survey revealed that 45 respondents, or one-third of the 136, were not familiar with the Job Safety Analysis (JSA) process.
It simply breaks down any task into individual elements from start to finish to identify potential hazards associated with each step in the process. For example, let’s look at the Vacuum Pressure Impregnation (VPI) process in a typical motor service center. The steps you would want to evaluate include:
- Moving the part from another location to the VPI tank
- Preparing the part to be placed into the VPI vessel
- Opening the VPI tank
- Placing the part into the tank
- Closing the tank
- Running the VPI process
- Reopening the tank
- Removing the part from the tank
- Moving the part from the tank to the bake oven
Each step is evaluated for potential hazards, methods to avoid those hazards, and even the Personal Protective Equipment (PPE) required to perform each task. Once completed, then training of all applicable employees can be completed to help minimize the risk of the hazards identified.
Work instructions
In regard to work instructions, more than 75% of the respondents noted that they maintain work instructions for processes and/or the use of equipment. For this 75%, it’s important to assure that the work instructions are available for use and all applicable personnel have been trained on the instructions and that the training is properly documented. For the 25% who do not currently maintain such work instructions, it is highly recommended that they be developed and implemented.
Importance of process
Of the 136 respondents, more than 57% of the service centers are not currently performing and/or documenting the JSA process. It is highly recommended that all service centers develop a JSA process, as developing such a process and conducting training on the results will not only provide for a safer workplace, it will help to eliminate potential injuries and provide some good legal protection should an injury occur.
Finally, in regard to whether customizable JSAs and work instruction templates would be beneficial, the overwhelming response to those questions was yes, they would be helpful.
To the members who participated in this recent survey, the Management Services Committee thanks you.
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