Work Controls Manager Workshop

1
Work Controls Manager Workshop

• Chris Johnson, Al Boerner Steve Coleman
• April 15, 2008

2
Workshop Overview

• Bldg 555 Mercury Cleanup Lessons Learned
• Work Coordination / Work Complexity Update
• Web Requisition Update
• Work Planning and Control (WPC) Training Course
  Update
• Integrated Safety Management (ISM) Performance
  Measures
• WPC Effectiveness Review August 2008
• Feedback/Open Discussion on WPC Issues and
  Concerns

3
Bldg 555 Mercury Cleanup Lessons Learned

• If a procedure exists Reference the SOP on the
  Work Permit review the steps in the pre-job
  briefing (Note any deviations from procedure due
  to job situations/conditions.)
• Workers can have different PPE, but must always
  meet minimum prescribed (however it does allow
  the auditor to raise the issue and open it up for
  discussion).
• Auditors can sometimes get in the way of safe
  work practices. On the job it was noted that the
  auditor was distracting the worker during job
  performance.

4
Work Coordination / Complexity

• DOE ISM Inspection Team believed the graded
  approach document used for categorizing work into
  low, moderate or high levels was exceptional.
  However, there was no guidance on work complexity
  and coordination.
• Proposed changes to the graded approach document
  was forwarded to several Work Control Managers
  and Coordinators for review and comment
• After several iterations April 1st minor
  revisions to the subject area went active
• Work Control Managers must flowdown revised
  guidance to Work Control Coordinators

5
(No Transcript)
6
Web Requisition Changes

• Defined Manual/Hand Delivery and separated it
  from Installation
• Placed Warranty Work as a separate type of
  on-site work and it doesnt need review from the
  WCC to pin Requisition
• Added Construction as a separate type of
  on-site work and if selected, process the
  requisition differently from other types of
  on-site work (includes associated controls).
• Reworded the Plant Engineering question to
  include only Hoisting and Rigging services
• Expanded Radio Frequency (Rf) wireless device
  question
• Added question on deliverable goods outside US

7
Work Planning Control Training

• Jim Nemeth from the Training Qualification
  Office is working on the WPC Web based course.
  The revised course will include
• Scenario based activities
• Integration of the various JTA course information
• Hazard analysis Control techniques
• Pre-job briefings, Change control, etc
• The final draft will be forwarded to Work Control
  Managers for review and comment 4th quarter of
  FY 2008

8
ISM Performance Measures

• In the FY08 BSA/BNL Contract As part of BNLs
  annual declaration, a set of performance measures
  (due 3/31/2008) was required to be developed for
  ISM Effectiveness determination (Performance
  Evaluation Measurement Plan PEMP Target
  5.2.1.5).
• The 4 Process and outcome measures
• Work Planning Breakdown establish a baseline to
  identify the percent of worker planned,
  prescribed and permit planned work. Analyze to
  determine if consistent with risk levels (through
  assessments, RARs, ORPS, NTS, etc)
• Evaluate unsafe behaviors (observations) to
  determine correlation to ISM core functions
  (leading indicator)
• Evaluate the ratio of work planning and control
  problems identified to the total number ORPS,
  NTS, RARs, Injury Illness (lagging indicator)
• Work planning problems that causes facility
  downtime (e.g., inadvertent shutdown of systems
  or processes) - report from maintenance
  management (lagging indicator)

9
WPC Effectiveness Review

• A number of existing actions in the ISM/Safety
  Improvement Project Plan address WPC findings
  identified in the 2005 ISM Readiness Review
  those actions include
• Creating a culture all work is planned and
  develop supporting procedures methodologies
  recently implemented worker planned, prescribed
  and permit planned work
• Integrate human performance factors and
  principles into the WPC Management System
• During the week of August 11th, 2008
  effectiveness review team (DOE-BHSO, BNL IO
  Office PNNL IO Office) will consider the
  following criteria
• Appropriateness of corrective actions
• Implementation effectiveness
• Performance Improvement
• Follow-up/Assurance

10
Summary/Questions/Comments

• Work Control Manager Actions
• Flowdown work complexity and coordination
  guidance to WCCs and forward an email to Chris
  Johnson and/or Steve Coleman stating so.
• Flowdown Web Requisition changes to WCCs
• Identify the of worker planned, prescribed and
  permit planned work in respective
  Departments/Divisions (for example 60 worker
  planned, 35 prescribed and 5 permit planned)
  and forward to Chris Johnson and Steve Coleman.
• WPC Issues and Concerns?

11
Work Planning Controlfor Work Control
Coordinators
Chris Johnson April, 2008
12
Work Planning Control for Work Control
Coordinators

• Whats Changed in Work Planning Control Subject
  Area
• Three-Tiered Work Planning Format
• When How to Use Each Kind
• Complexity and Work Coordination for Work Permits
  applying the Graded Approach

13
Work Planning Control Changes

• WCM / WCC Qualification Local, Dept. Decision
• BTMS Training Local Knowledge Requirements /
  Hazard Recognition
• Planning Levels
• New Guidance / Instructions Exhibits Forms
• Change Control
• ISM Flowdown to Contractors / Vendors
• Visitor Notification
• Work Observations

14
Three-Tiered Work Planning Format

• Worker Planned Work
• Prescribed Work
• Permit Planned Work

15
Worker Planned Work

• Formerly Skill-of-the-Craft
• Typically Low Hazard Routine Work
• Characteristics of Worker Planned Work
• Employees Current on JTA
• JRAs have been completed for Hazards of Task
• Employee has Approval for Task on Qualification
  Matrix
• Worker-Qualified from OJT, Other Site Experience,
  Degree, Certified License, Etc.
• Planning Done Immediately Before Work is
  Performed
• Worker to Consider
• Hazards, Critical Steps, Failure Scenario, Likely
  Errors, OK to Proceed, Change Control

16
Prescribed Work

• Pre-Approved Work Plan or Procedure Written by
  Others
• Task is Important Enough, Done Frequently Enough,
  or has a Hazard that Calls for a Specific
  Procedure
• Could be One-Time Procedure or Done in Advance
• Pre-Planning should Dictate Training, PPE,
  Equipment, Tools, Access Requirements, or Special
  Instructions

Caution Since this work is pre-planned,
attention must be given to any changed conditions
or new location hazards.
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Permit Planned Work

• Thorough Hazard Analysis Checklist
• Gets the Most People Involved Including Subject
  Matter Experts
• High Visibility to Workforce
• Planning is Usually done Close in Time to Work
  Effort But Duration Could be Long so Changing
  Conditions and/or Scope Requires Vigilance (WCC)
• Best Buy In by Planners, Supervisors, Experts,
  Workers
• Has Mechanism to Obtain Feedback

18
Permit Planned Work / Graded App

• Environment, Safety, Security, Health Risk
• Low Little chance of negative outcome if
  workers do what they are suppose to do. Few, if
  any, preventive measures required.
• Moderate Risks are present that require
  specific action or prevention strategy to ensure
  mitigation.
• High Without effectively employing hazard
  mitigation strategies, a negative outcome is
  likely.

Strategies should be employed in the following
order Replace/Eliminate Hazard ? Engineering
Controls ? Administrative Controls ? PPE
19
Permit Planned Work / Graded App

• Complexity Level
• Low Task sequence is not significant. Minimal
  interactions between personnel required.
• Moderate Task sequence is significant.
  Frequent interactions among personnel required.
• High Continuous interdependency among personnel
  required. elements. Plan demands input
  discussion from as many experts as can be
  utilized. Pay considerable attention to starting
  conditions, watch for manage emergence. (Plan
  well up front watch for changing conditions.)

20
Permit Planned Work / Graded App

• Work Coordination
• Low No more than 3 functional groups within one
  Dept/Div. Minimal coordination from support
  groups.
• Moderate More then 3 functional groups
  involved. Work requires close coordination with
  support groups.
• High - More than 6 functional groups within one
  department or combination of Dept/Div. or outside
  contractors performing work requireing frequent
  support systems to assist in risk mitigation.
  Hand off points require particularly in-depth
  planning.