Intranet solution for safety management

UGL-UNICCO white paper discusses strategies to integrate safety management systems

04/16/2008


 

By Marc Wendell, CSP, CHMM

UGL-UNICCO Director

Safety, Health & Environmental director

Managing business risks, including SH&E, has always been a UGL-UNICCO priority. This is evidenced in numerous safety awards received from industry groups and our customers over the years, as well as our continuously improving OSHA incidence rates and reductions in Workers Compensation loss rates. Yet, the job is never done when it comes to safety %%MDASSML%% it requires ongoing commitment and continuous improvement. In 2005, UNICCO began looking for new ways to improve safety performance. This brief article outlines key features of USafe, a solution aimed at helping UNICCO integrate its Safety Management System into business decision-making processes.

UNICCO’s Safety Management System conforms to the Plan-Do-Check-Act (PDCA) cycle advocated by international management system standards, e.g., ISO 14001 and OHSAS 18001. There are two key features to such management systems:

 

  1. Planning & Implementation %%MDASSML%% To identify safety and other business risks and implement risk controls early in the planning stages of work;

  2. Evaluation & Corrective Action %%MDASSML%% To evaluate work, investigate deviations (e.g., safety/quality incidents), and manage corrective actions.

    1.  

      At UNICCO, these activities were mainly being managed on paper. With thousands of sites in the U.S. and Canada, it was not easy for UNICCO to translate a myriad of safety/risk assessments and incident investigations into improved performance. To solve this problem we initiated a collaborative team effort between our operations, safety, and Information Technology departments. With the primary purpose of further improving SH&E performance (i.e., reducing incident frequency, severity and cost), the project focused on standardizing, automating and facilitating the integration of the following existing SH&E tasks and business processes:

      #1. Conduct risk reviews of prospective jobs and integrate reviews into business plans;

      #2. Conduct risk reviews and periodic compliance inspections of existing job sites;

      #3. Create an incident “dashboard” for accessing incident reports and investigations,

      analyzing causal trends, and managing corrective action plans;

      #4. Facilitate compliance with OSHA recordkeeping requirements, including generation of paper OSHA Form 301 (Incident Report), 300 (Log) and 300A (Summary);

      #5. Track performance metrics, including OSHA incidence rates and progress on risk reviews and inspections, across multiple levels of management structure.

      In researching available applications, the team found many “point” solutions that covered inspections, or incident management, or forms/reporting. These applications did not, however, provide an integrated solution for the full spectrum of facilities services that UNICCO provides. To remedy the situation, UNICCO brought in IBM and its new “Workplace Forms” technology, an electronic forms-based business process management software and service. This approach allowed UNICCO to build on the success of its existing business processes and forms.

      The UNICCO/IBM team created forms that automate the capture and processing of SH&E information, including risk reviews, inspections, and incident investigations. This sped up transactions, increased operational efficiency, and made the information more amenable to business decision making. Now managers are doing a better job of identifying business risks, incorporating risk controls/costs into business decision making, reporting/investigating incidents, and meeting SH&E metrics. They are also spending less time performing these activities.

      The solution is housed on the company intranet site: myUNICCO.com. Incidents, risk reviews, and site inspections are uploaded directly to USafe through the myUNICCO.com portal. In addition to the prescribed forms, the solution also allows for the uploading of images, e.g., photos, drawings, medical reports and workers’ compensation documents. USafe is now the central file for all such forms.

      If an incident is OSHA Recordable, the system automatically updates the site OSHA Log and Form 300A. The solution thereby facilitates maintenance of OSHA Logs, automates OSHA recordkeeping tasks, and helps assure regulatory compliance, while reducing demands on administrative personnel. As well, the solution is designed specifically to support Operations personnel. An understanding of safety terminology is not required.

      Action items from incident investigations, risk reviews, and inspections are structured into Corrective Action Plans, allowing operations personnel to manage and track actions online. If an action date is missed, USafe sends “trigger” notices to those responsible and, if specified in the system, to their management.

      Now that USafe is deployed, we are further on our way to improving safety performance. Good safety practices make sense. It’s good for our employees, it’s good for our customer relations and it makes good business sense.



Top Plant
The Top Plant program honors outstanding manufacturing facilities in North America.
Product of the Year
The Product of the Year program recognizes products newly released in the manufacturing industries.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
October 2018
Tools vs. sensors, functional safety, compressor rental, an operational network of maintenance and safety
September 2018
2018 Engineering Leaders under 40, Women in Engineering, Six ways to reduce waste in manufacturing, and Four robot implementation challenges.
July/Aug
GAMS preview, 2018 Mid-Year Report, EAM and Safety
October 2018
2018 Product of the Year; Subsurface data methodologies; Digital twins; Well lifecycle data
August 2018
SCADA standardization, capital expenditures, data-driven drilling and execution
June 2018
Machine learning, produced water benefits, programming cavity pumps
Spring 2018
Burners for heat-treating furnaces, CHP, dryers, gas humidification, and more
October 2018
Complex upgrades for system integrators; Process control safety and compliance
September 2018
Effective process analytics; Four reasons why LTE networks are not IIoT ready

Annual Salary Survey

After two years of economic concerns, manufacturing leaders once again have homed in on the single biggest issue facing their operations:

It's the workers—or more specifically, the lack of workers.

The 2017 Plant Engineering Salary Survey looks at not just what plant managers make, but what they think. As they look across their plants today, plant managers say they don’t have the operational depth to take on the new technologies and new challenges of global manufacturing.

Read more: 2017 Salary Survey

The Maintenance and Reliability Coach's blog
Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
One Voice for Manufacturing
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Maintenance and Reliability Professionals Blog
The Society for Maintenance and Reliability Professionals an organization devoted...
Machine Safety
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
Research Analyst Blog
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Marshall on Maintenance
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
Lachance on CMMS
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
Material Handling
This digital report explains how everything from conveyors and robots to automatic picking systems and digital orders have evolved to keep pace with the speed of change in the supply chain.
Electrical Safety Update
This digital report explains how plant engineers need to take greater care when it comes to electrical safety incidents on the plant floor.
IIoT: Machines, Equipment, & Asset Management
Articles in this digital report highlight technologies that enable Industrial Internet of Things, IIoT-related products and strategies.
Randy Steele
Maintenance Manager; California Oils Corp.
Matthew J. Woo, PE, RCDD, LEED AP BD+C
Associate, Electrical Engineering; Wood Harbinger
Randy Oliver
Control Systems Engineer; Robert Bosch Corp.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
Design of Safe and Reliable Hydraulic Systems for Subsea Applications
This eGuide explains how the operation of hydraulic systems for subsea applications requires the user to consider additional aspects because of the unique conditions that apply to the setting
click me