WCM审核标准

WORLDCLASSMANUFACTURINGPLANTAUDIT&EVALUATIONGUIDE1Dr.HajimeYamashinaProfessorEmeritus,KyotoUniversityMemberofRSAMemberofRoyalSwedishAcademyofEngineeringSciencesNewAuditGuideSeptember,20092Thescoreisdeterminedbythislevelasinthecasewherecustomersseeourquality.Step66610TechnicalPillarsStep710ManagerialissuesFinalTargetStepStep444Step3Step2Step13Step5Step2Countermeasures(ListingallandhorizontalexpansionassessmentStep61.Safety(plant-wide)Step7FullyimplementedsafetymanagementManagementinitiatedSelf-initiated4Analysisofaccidents(Analysisofcauses)Step1Step3Settingtentativestandardsforsafetysafetyproblems)(CountermeasuresRiskatthesimilarareas)Step4Generalinspectionforsafety(Trainandgrowpeopleinsuchawaythattheycareforsafety)Step5Autonomousinspection(Predictivecountermeasuresagainstsafetyproblems)ReactivePreventiveProactiveAutonomoussafetystandards(*Overallinspectionofsafetylevels*Reevaluationifsafetycontrol)TeaminitiatedStepCountermeasuresReactive1AccidentanalysisandcountermeasuresIncidentanalysisandcountermeasuresPreventive2-5HorizontalexpansionofcountermeasuresVisualdemonstration(simulation,video,etc.)ofaccidentstoalertpeopleaboutsafety,CompliancewiththesafetylegalregulationsSafetyriskassessment*ManagementSMAT,SafetyauditRootcauseanalysisofincidentswithspecialemphasisonnearmissesandunsafeactsSelf-initiatedsafetyactivitiesProactive6-7TeaminitiatedsafetyactivitiesSystemtomakepeoplenotabletomakemistakes5Safety(Reactive)1.5G6Heinrichpyramid6.S-Matrix7.Managementinitiatedsafety2.5W+1H,5Why10.Emergencyplan3.7WCMtools9.Basicsafetystandards4.Knowledge8.SafetyStep15.TheprincipleofSafety(Reactive)1.5G2.5W+1H,5Why3.7WCMtools4.Knowledgeofallsafetylegalrequirementsandcompanystandardsandcomplianceanalysis5.TheprincipleofHeinrichpyramid6.S–matrix77.Managementinitiatedsafetyactivities8.Safetystep1:Accidentanalysis*,safetyRCAofinjuryincidentsandtheircountermeasures9.Basicsafetystandardsforpedestrianization,controlofvehicles,workatheight,machinerysafetyguarding,etc.10.Emergencyplanandfacilitiesforaccident,fire,explosion,etc.ManyfactorsAccidentStructureFR1Linear23LotofAccidentanalysisFactorsFrequencyRateEvolutionTime8FRFrequencyveryfrequentAccidentanalysis1Permanent2Sporadicorepisodic3ExceptionalActivityProblemAnticipateDetectionSpecific,habitual,linkwithjobTechnicalfailureEasyConnected,secondarynoinhabitualOrganisational,misfitbetweenactivitiesDifficultNotconnectedwithjobGapanddriftaccumulationVerydifficultMeansofdetectionCheckinspectionJobAnalysisWorstcaseAuditsGapDetectionTime9ReactivePreventiveProactiveAAVeryhighnumberofaccidents,medicaltreatments,firstaidsVeryhighpotentialVeryhighrisk*AHighHighpotentialHighriskBMediumMediumpotentialMediumriskCLowLowpotentialLowriskClassificationofareas101.Safetystep22.Safetystandardsgapanalysismatrix9.EffectiveSafety(Preventive)10.Occupationalhealthcheckup3.SafetyResponsibility5.SafetyRCA7.SafetyStep46.Incidenttrendanalysis11reporting4.SafetyStep38.SafetyStep5Safety(Preventive)1.Safetystep2:Safetystandardizationandhorizontalexpansion2.Safetystandardsgapanalysis3.Safetyresponsibilitymatrix,safetycommunicationsystem,greencross4.Safetystep3:Visualsafetystandards,PPE,Riskassessment*5.SafetyRCAinclusiveofnearmissesandunsafeacts+TWTTPandsuitablecountermeasures6.Incidenttrendanalysis127.Safetystep4:Periodicsafetyauditsbyseniormanagement**,Manage-mentSMAT,shiftmanagerSMAT8.Safetystep5:OperatorSMAT9.Effectivereportingofnon-injuriesincidents10.Occupationalhealthcheckupandfollowup*Note:Firerisks,earthquakes,thunders,typhoons,hurricanes,mobileequipment,safetyguarding,firstaidboxes,noise,irrespirabledust,harmfuldust,explosiveatmosphere,mechanicalrisks(fallingfromaheight,slipping,fallingover,stabs,cuts,grazes,particlesprojections,blows,impacts,crushing,fallofmanipulatedobjects),electricalrisks,electromagneticwaves,vibration,ergonomics,illuminations,overloads,materialhandling,VOC(volatileorganiccompounds),CO,O3,hazardousmaterials,chemicalmaterials,thermalrisk(heat,fire,cold),gasses(vapors),radiation(non-ion,ion),asbestos,etc.13**AuditsandguidancebyseniormanagementhaveanimportantplaceinallWCMactivities,includingsafety.Regularauditskeeppeopleandorganizationsontheirtoesandhelpraisetechnicalstandards.Preparelistsofaudititemsthatrelatetosafety,health,andpollution;clarifyevaluationstandpointsandlevels;andestablishasystemof(atleast)everyfourmonthson-siteauditsbyseniormanagers.Thisisindispensableforeliminatingaccidents.Safety(Proactive)1.Safetystep62.SafetyRCA+…10.Employeesatisfaction3.Systemtocreatemotivation9.Bodyage4.Intrinsicsafetydesignforequipment5.Intrinsicsafetydesignforworkshop146.Safetystep78.Healthadvice7.HealthcampaignSafety(Proactive)1.Safetystep6:Teaminitiatedsafetyactivities2.SafetyRCA+TWTTP+humanerroridentificationatoneofthreephases(perception,judgmentandaction)anditspropercountermeasures3.Systemtocreatemotivationtorecordallkindsofnearmisses,unsafeconditionandacts.154.Intrinsicsafetydesignforequipmentandprocess5.Intrinsicsafetydesignforworkshopandplant6.Safetystep7:Systemtomakepeoplenotabletomakemist