Health and Safety in High Risk Industries: Risk Management Report

This report critically analyzes the impact of risk management in plant maintenance within high-risk industries, focusing on several key areas. It begins by exploring the risk management process, including hazard identification, risk assessment, and control measures, emphasizing the importance of plant design, procurement management, and effective communication in minimizing health hazards. The report then delves into reliability engineering principles, examining system reliability concepts and analysis techniques like Event Tree Analysis and Markov Models. Furthermore, it discusses strategic management principles in plant commissioning, highlighting the identification of hazardous areas and the importance of involving operators and maintenance staff. The report also emphasizes the role of health and safety by design, safer designs, and the implementation of safety management systems. The document concludes with a critical analysis of various risks, including manual handling, storage systems, and in-house transport, along with an evaluation of the roles of risk management, planning, procurement, supervision, design, and communication. This detailed analysis provides insights into improving quality of life and minimizing health hazards in high-risk environments, supported by figures and references.

PRS 4552
Health and Safety within High Risk
Industries
Module Leader: Dr David Thomas
Student Name:
Student ID:
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Table of Contents
1. Introduction.................................................................................................................5
2. Risk Management in Plant Maintenance....................................................................5
2.1. Identifying Hazards...............................................................................................6
2.2. Assessing the risks...............................................................................................6
2.3. Controlling Risks...................................................................................................6
2.4. Maintaining and Reviewing Risk Control Measures.............................................6
3. Reliability Engineering Principles for Plant Maintenance...........................................7
3.1. Reliability Engineering Principles.........................................................................7
3.2. System Reliability Concepts.................................................................................7
3.3. System Reliability Analysis...................................................................................7
3.3.1. Event Tree Analysis.......................................................................................7
3.3.2. Markov Model................................................................................................8
4. Strategic Management Principles in the Commissioning of Plants............................8
4.1. Identify Machine/Process.....................................................................................8
4.2. Gather Proper Individuals and Machines in Use..................................................8
4.3. Identify Hazardous Areas of the Equipment........................................................9
5. Maintaining Health and Safety by Design...................................................................9
5.1. Safer Designs for Mitigating Health and Safety Risks.........................................9
5.2. Implementation of Safety and Health Management System in Plant Facilities. 10
6. Critical Analysis:........................................................................................................10
6.1. Risk of manual handling transport:.....................................................................11
6.2. Risk of Storage System......................................................................................11
6.3. In House Transport and Mechanical Handling Risks.........................................11
Risk Prevention of in House Handling and Transport..................................................11
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7. Evaluation.................................................................................................................12
7.1. Role of Risk Management..................................................................................12
7.2. Role of Planning.................................................................................................13
7.3. Role of the Procurement....................................................................................13
7.4. Role of Ongoing Supervision.............................................................................14
7.5. Role of Design....................................................................................................14
7.6. Role of Communication......................................................................................14
8. Conclusion................................................................................................................14
9. References................................................................................................................15
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List of Figures
Figure 1-Health and Safety by Design..............................................................................9
Figure 2-Role of Management in Risk Mitigation............................................................12
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1.Introduction
When dealing with the plant facilities safety is one of the most important factors to
consider. By evaluating the danger. By evaluating the risk in preliminary planning
phase, security in configuration seeks to prevent any harm or injury. Safety measures
such as proper management system, communication, better equipment design helps in
reducing the possibilities of risk involvement (Chemweno et al., 2018). This study aims
to critically analyze the impact of risk management in plant maintenance. Moreover, the
objectives of this study include; to analyze several impacts such as plant and equipment
design, procurement management, communication can help in improving the quality of
life and minimizing the health hazards in high risk activities. To improve assessment,
problem solving, and testing in relation to the physical and tragic threats posed by the
nature and use of facilities, plant, devices, and common procedures, as well as the skills
to encourage corrective and assertive risk management performance indicators in high
risk environments.
2.Risk Management in Plant Maintenance
The five fundamental activities or processes make up the risk management process:
identify and evaluate malfunction threats, implement controls, and make strategic
choices. Implementing the control strategies, and supervision and evaluation of the
processes. Any equipment, instrument, devices, container, device or anything fitting or
linked to any of these items, is referred to as a plant. Various working elements that are
used for performing operations in the plant are escalators, elevators, computers,
cranes, automobiles, trolleys, hand tools all of which need maintenance in order to
prevent any risk inside the plant (Velayutham and Ismail, 2018). Various steps are
involved in managing the risk with the power plants are:
2.1. Identifying Hazards
Finding all of the objects and circumstances that might potentially harm individuals is
part of identifying risks (Walsh and Morgan, 2005). Plant-related hazards are most
commonly caused by:
1. The plant in its whole. For instance, dangers related to forklift’s movement,
electronic devices, pneumatic and mechanical sources of power, movable
components, load carrying capability, and worker safety would all be hazards.
2. What the plant is used for and where it is utilized. The type of weights that a forklift
carries, the volume of the region in which it is utilized, and the elevation or uniformity
of the surface.
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2.2. Assessing the risks
A risk assessment considers what may occur if individuals gets subjected to a hazard
as well as the chance that it will occur (Cango, Caron, and Mancini, 2002). A risk
analysis can assist in determining the following aspects:
1. How serious a threat is
2. Whether or if present controls are sufficient
3. What steps can be taken to minimize the risk
4. How quick the measures shall be taken
If the risk causes and prevention methods are already known then the risk assessment
isn’t essential.
2.3. Controlling Risks
According to (Sellick, 2006) the methods for reducing plant-related dangers are listed
from the greatest degree of security and dependability to the lowest. The hierarchy of
hazard mitigation is the name given to this classification. The required responsibility
holders work their way up this structure to select the measure that completely eliminates
or, if that is not possible, reduces the risk of harm.
2.4. Maintaining and Reviewing Risk Control Measures
Control procedures must be implemented to ensure that employees and others are
protected from the risks associated with the plant facility (Bridges and Tew, 2008).
Security controls must include:
1. Appropriate for the purpose
2. Appropriate for the kind and nature of the job
3. Properly established set up, and utilized
The control measures which have been adopted must be evaluated and, if required,
updated to ensure that they are working as intended and they have not created any
novel risks.
3.Reliability Engineering Principles for Plant
Maintenance
Production and other commercial endeavors executives and designers are
progressively putting a reliability factor into their operational and strategic objectives and
processes. This tendency has an impact on a variety of domains, including equipment
design and procurement, plant operations, and plant maintenance (Hashe and
Mamatlepa, 2020). Moreover, reliability engineering which has its roots in the aviation
sector has traditionally been centered on ensuring product reliability. These approaches
are increasingly being used to ensure the production dependability of industrial
amenities and technology frequently as a lean manufacturing accelerator.
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3.1. Reliability Engineering Principles
The lifespan and reliability of components, goods, and processes are the subject of
reliability engineering. More importantly it is about risk management. Engineers use a
wide range of quantitative approaches in reliability engineering to analyze better the
failure mechanisms and trends of these components, goods, and systems. Product
durability and reliability confirmation have always been the emphasis of reliability
engineering (O’Connor and Kleyner, 2012).
Many reliability engineering principles are utilized to produce judgements on how to
enhance and optimize equipment in order to meet the minimum necessary system
dependability. A few of them are discussed below:
3.2. System Reliability Concepts
A system is a group of interconnected components that cooperate through some driving
mechanism. The chance that an engineering system will execute a required activity
adequately for its planned life given specified technical and environmental
circumstances is described as dependability in this respect. Many parameters such as
Mean Time to Failure (MTTF) and Mean Time to Recovery, may be specified to assess
and evaluate the dependability qualities of a system (MTTR) (Pham, 2006).
3.3. System Reliability Analysis
For the functional connections of elements, subsystems, and the overall system, there
are several mathematical and analytical models. Failure Modes and Effects Analysis
(FMEA), Event Tree Analysis (ETA), Fault Tree Analysis (FTA), Monte Carlo simulation,
and Markov Models (Lisnianski, Frenkel and Ding, 2010).
3.3.1. Event Tree Analysis
According to (Metzroth, 2011) event trees are the branching graphs that depict the
different potential sequences of plant circumstances (with associated estimated
likelihood) as a result of the proper functioning or breakdown of safety systems meant to
prevent or reduce the effects of incident. Previous failure information or conceptual
models such as RBD or FTA can be used to calculate the failure risk of various
defense-in-depth levels. Numerous plant systems can be exposed to sever conditions
such as a result of triggering events which might be extrinsic or intrinsic. As a result a
PRA approach can predict the probability and severity of any incidents caused by a
system failure or an operating error.
3.3.2. Markov Model
Markov models are recursion judgement trees that are used to describe circumstances
that happen frequently over period or predicted things that occurred over time. A
Markov model for a particular system includes a sequence of the service’s potential
states, transitional pathways between those states, and rate variables for those
transformations. Each measurable of a Markov model is generally represented visually
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as a circular shape, with arrows showing the transformation pathways between states
for a solitary element with just two states: success (no measurable damage) and failure
(no detectable harm). These technologies can help in mitigating occurrences of risks
(Gupta, Tiwari and Sharma, 2009).
4.Strategic Management Principles in the
Commissioning of Plants
Commissioning is a high-risk job that puts individuals, buildings, equipment, and
commodities at danger. Engineers and specialists engaged in the commissioning
should have clear responsibilities and authorities. There should be no ambiguity
regarding who is responsible (Lawry and Pons, 2013). The accuracy of key choices and
the speed with which they are implemented have a significant impact on future growth.
Project risk arises in the areas of health security, and the surroundings, all of which
have an impact on the project’s total cost and effectiveness. Several strategies that are
followed during the commissioning of plants keeping in mind the product and equipment
safety.
4.1. Identify Machine/Process
According to (Leonesio, Bianchi and Brondi, 2006) recognizing activities that involve
some sort of protecting is generally the simplest phase during the commissioning of
plant facilities as these applications are most commonly revealed through incidents and
near misses. An examination of a facility’s incident history will quickly aid in the
detection of potentially dangerous situations. During the commissioning process plant
facilities typically address high-risk equipment initially, then work on their way down the
line to lower-risk activities until all of the machines get to an acceptable level risk.
4.2. Gather Proper Individuals and Machines in Use
For two reasons, getting input from operators and maintenance staff during the
equipment safety process is essential. Initially, because these personnel operate on and
across the equipment on regular basis, they are more likely to notice risks that might
otherwise go unnoticed by others who are not as familiar with the equipment’s day-to-
day operations (Lake et al., 2017). Secondly, gaining information regarding the
equipment from such persons is critical. If a safety system is built and the individuals
who will have to use it are unhappy, and their opinions are not addressed at the design
and development phase, the safety system may not fulfill their needs or prohibit them
from doing certain duties.
Similarly, end users change equipment to manufacture particular components based on
consumer and stakeholder demands because many equipment are similar in design.
Even though machines are identical in design, they may be quickly modified to
drastically vary the degree of risk they pose.
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4.3. Identify Hazardous Areas of the Equipment
This method, also referred as task/hazard strategy, generates a comprehensive
inventory of all potentially dangerous circumstances. Initially, all of the activities are
identified that can be performed throughout the equipment lifespan. During the
commissioning of the power plant all areas of the equipment which can be harmful for
the workers are recognized and then appropriate measures are taken in order to
eliminate those hazardous areas (Bottrill, Cheyne, and Vijayaraghavan, 2005).
5.Maintaining Health and Safety by Design
The method of controlling health and safety hazards throughout the lifetime of facilities,
plants, equipment, and other goods is known as “Health and Safety by Design”. From
the commencement of the design phase, designers are in privileged phase to create
work healthy and safe (Jonathan and Mbogo, 2016).
Figure 1-Health and Safety by Design
5.1. Safer Designs for Mitigating Health and Safety Risks
According to Kletz and Amyotte (2010) to mitigate risks, dangers must first be
recognized, followed by an assessment of the risk and a determination of whether it can
be tolerated or not. Safe design is including prevention strategies in early stages of the
design phase in order to avoid or, if this is not feasible, reduce hazards to health and
safety throughout the plant’s lifespan. Safe designing starts with the development
process, when decision regarding design, materials, and manufacturing techniques are
decided. During the early stages of commissioning process there is a better possibility
of designing out risks or including risk control methods that are acceptable with the
product’s original design idea and perceived ideas. Moreover, plant design is a time
consuming process. After the first control measures have been included into the design,
it should be examined to see if there are any lingering hazards and whether modifying
the design can mitigate or reduce them. Plant and equipment maintenance is performed
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to prevent issues from occurring, to correct defects, and to ensure that equipment is
operating properly.
5.2. Implementation of Safety and Health Management System
in Plant Facilities
According to Ghobeity et al., (2011) a safety and health management system is a
component of an organization’s overall management program that contains:
1. The practice of hazard and health prevention management
2. The duties of the plant management officials
3. The techniques, processes, and tools for establishing, adopting, evaluating, and
sustaining a work health and safety policy.
The workplace should have devise a strategy to implement the safety statement and
health policy. For the strategy to be implemented, an efficient organizational culture and
mechanisms need to be put in the place. All management and workers should have
health and safety goals and strategies. Plant should establish the competencies and
institutional support needed and security legislation goals, and objectives for successful
delivery. Not just to avoid incidents, but to operate reliably and maintain their long-term
health.
6.Critical Analysis:
According to Reason, (2016), almost all workplaces engage in some form of in-house
handling of material and transportation (movement and storage of items), whether
automated or manual. Moreover, falls, slips and trips, car and pedestrians accidents,
falling items, musculoskeletal problems, and other hazards are associated with these
activities. Marchet et al. (2014) stated that in big warehouses in the logistic industry,
automated systems like autonomous guided trucks and digital order picking pose
particular hazards, like the problems of cognitive ergonomics. Boysen et al. (2015)
expressed the risks of transportation and stated that deliveries, moving products,
storage, dispatching and other warehousing and workplace transportation operations
occur in nearly every workplace. There is also the logistic industry, which includes
operations like container receiving, transportation, and logistics centers. Analyzing and
recognizing the hazards involved with in-house transportation and handling of materials
is critical for avoiding accidents and health issues. The measures of prevention must be
adopted based on the assessment of risk.
6.1. Risk of manual handling transport:
Goode et al. (2014) stated that workplace injuries are frequently caused by manual
material transport. Moreover, the way of job design and materials are handled, and the
physical characteristics and condition of individual employees are all factors in manual
material transfer accidents. The features of cargo, the physical effort required to move it
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as well as the need for handling activity are all the risk factors in manual handling of
materials. Klussmann et al. (2017) expressed that the mishaps involving transfers of
material like falling the material from height and injuries caused by collapsing and falling
items, cause more significant injuries to employees and the physical climate than the
other accident of workplace.
6.2. Risk of Storage System
Derbal et al. (2014) revealed that the aisles and (pallet) racks are commonly used in the
rooms of storage and warehouses to store items. To avoid falling objects and collapse,
these systems of racking must be probably maintained and installed. There is a
maximum safe load of work for all racking systems that must not be increased.
According to Derbal et al. (2014), EN 15512; systems of adjustable pallet racking, steel
statistic storage systems structural designs principles is one of many EN standards that
offer technical criteria for the installation and design of storage systems. Furthermore,
the websites of Shelving European Materials Handling Federation and FEM racking has
further information.
6.3. In House Transport and Mechanical Handling Risks
According to Ivanov et al. (2017) transport and vehicle systems, like conveyors, are
used to carry out mechanical transfers, workers are also exposed to the significant risk
of mechanical transfers. Pallet stackers, pedestrian-controlled pallet trucks, forklift
trucks and reach trucks, and other vehicles are the main examples of vehicles of in-
house transport. Moreover, to overcome mechanical handling risks, vehicles may also
be equipped with automatic transmission automatic guided vehicles). Choi et al. (2016)
revealed that the interplay between the car poses and pedestrians is the greatest risk.
While transportation, forklift drivers are frequently engaged in accidents like vehicle
overturns, falls from trucks, collisions with objects, and so on. Accidents are more likely
when there are insufficient warning and training signs, poor vehicle maintenance,
insufficient illumination, and a lack of space.
Risk Prevention of in House Handling and Transport
Yang et al. (2018) depicted many essential precautions to take while dealing with in
house material handling and transportation such as if at all possible, avoiding the
danger by conducting the assessment of the risk of potentially hazardous actions which
must not be avoided, taking the steps to lessen the likelihood of harm. It implies that
when in-house transportation necessitates physical handling, these activities must be
organized in such a way as to reduce carry distances, minimize the weight of the load
and overcome the frequency of tasks of manual handling. Huang et al. (2019) stated
further suitable technological equipment and lifting aids must be supplied, and the
environment must be maintained and planned to reduce the risks associated with
manual handling (even good indoor air quality, sufficient visibility, and non-slippery
floors).
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Yang et al. (2018) stated that employers are responsible for providing a safe
environment of working and employees are responsible for adhering to their safety
regulations of the workplace, according to European legislation. Technical solutions and
Ergonomics, task-specific training, collaborations with all actors in the environment or
workplace, workplace, and organizational measures are all methods for avoiding in-
house transportation risks. Cooperation, organizational measures, training, technical
devices, Ergonomics of material transfers are the subchapter of all of these. In today’s
evolving corporate world, safety concerns around in-house transportation and material
handling are becoming increasingly important. Product life cycles are shorter than they
have ever been, and the current tendency is to change damaged and broken things with
new ones rather than repairing the old ones.
Huang et al. (2019) stated high-risk companies use sub-contractors and even the tiniest
pieces may need to be moved from one location to another for manufacturing. Because
there are so many different materials, it is difficult to know how to treat them all. Many
items need specialized shipping. This emphasizes the need of doing a more thorough
and targeted risk assessment in order to identify the OSH hazards associated with the
different types of materials. Material handling and internal transportation must be done
safely and in accordance with ergonomic guidelines, since these may assist to mitigate
musculoskeletal diseases. The usage of transfer devices is critical in reducing the
overexertion of worker. The musculoskeletal system of human is put under the most
stress while lifting, carrying, pushing and pulling. Manual transfer aids that help with
lifting or reduce the requirement to carry weight must also be considered until they are
sound ergonomically, mechanical instruments and devices may decrease the physical
risk of over exertion.
7.Evaluation
7.1. Role of Risk Management
Risk management on projects is the process that involves the assessment of risk as
well as reduction plan of the risk. The main role of management is the identification of
possible risk and appraisal of the potential effect of risk. The goal of the risk mitigation
strategy is to reduce or eliminate the effect of the risk events.
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Figure 2-Role of Management in Risk Mitigation
7.2. Role of Planning
Risk planning is the process of recognizing, managing, and prioritizing risks; the
effective accomplishment of these essential success elements is jeopardized by risk
occurrence. As a result, risk planning entails identifying and prioritizing the most critical
risk occurrence ahead of time, as well as establishing suitable risk response plans
Naeem et al. (2018). Risks are unknown while planning the endeavor since they have
not happened yet. However, some of the dangers or risks that a person plans for may
ultimately occur, and he has to deal with them. According to Gonzalez-Mathiesen et al.
(2021), risk management on projects is the process that involves the risk reduction plan.
Moreover, the identification of possible risk and the appraisal of the potential effect of
risk are both parts of risk assessment. The goal of a risk mitigation strategy is to
eliminate or reduce the impact of risk events, which are occurrences that have a
negative influence on the industries. Identifying risk requires both discipline and
creativity. The brainstorming meetings are part of the creative process, and the team is
required to make a list of everything that may go wrong.
7.3. Role of the Procurement
According to Pereira et al. (2014) when it comes to supplier risk reduction, procurement
professionals may keep an eye on a variety of things. Sandeep Singh, Genpact’s Vice
President of services of supply chain and procurement, discusses his experiences with
these variables. While evaluating the financial situation of supplier or risk regarding
bankruptcy, procurement experts may pay particular attention to the following factors of
the high-risk company:
1. Information of finance such as revenue growth; negative cash flow; liquidity.
2. Staff and managerial-related events like important management members’
resignations or unusual turnover of the employee.
3. Suits like those in which the provider is being sued for debt collection.
4. Longer term order delinquencies or poor services or product quality.
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7.4. Role of Ongoing Supervision
Peled-Avram, (2017) stated the ongoing supervision creates profiles of risk, tracks and
conducts the assessment and indicators of risk to systematically quantify, identify and
monitor risks, assessing the likelihood of occurrence and the possible effect. It allows
them to better identify the upcoming and existing risks and focus precious resources to
the industries, suppliers, and product which pose the highest threat to the supervisory
goals. Risk-based techniques necessitate the mental change away from compliance-
based methods. Rather than doing one size fits all checks on the providers that how
they follow regulations and avoid hazards on the regular basis, risk-based supervisors
examine how providers manage risks through continuous intelligence conversation and
collection with the industry.
7.5. Role of Design
According to Akdeniz (2014) design of high risk industries or design risk management is
the method for designers to show that their designs may be built, maintained, and
utilized, and finally destroyed without endangering the health, safety, or well-being of
people involved in the building process or others who can be affected by projects.
7.6. Role of Communication
According to Ceric (2014) the subject of health and safety is no exception. An absence
of clarity in communication may stymie not only the full adoption of a health and safety
system, but it can also contribute to an unsafe environment where accidents and
diseases are more common.
8.Conclusion
The prevention of risk is very essential for the management of any organization in order
to ensure safe and productive outcomes. In current study different aspects such as the
communication, procurement, risk assessment techniques and many other have been
analyzed and it was concluded that risk analysis factor such as risk identification is the
most import aspect when dealing with high risk organizations. The advantages of
improved facility safety necessitates deliberate efforts to establish the data bases,
analytical methodologies, and organizational motivation required to encourage risk
analysis usage. Moreover, reliability engineering principles are considered as one of the
most important aspects in generating efficient outcomes. Furthermore, it was seen that
risk analysis in plant management encourages a beneficial way of understanding about
how facility failures to operate as expected might endanger operational efficiency, public
health, security, and financial expenditures. Risk analysis may help in enhancing the
value creation to produce more balanced risk mitigation at all phases of development.
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