TOOLS USED TO IMPROVE OPERATIONAL SAFETY IN JOHNS MANVILLE GLASS PLANTS

摘要

Johns Manville (JM) has a long-standing core value of safety at its operations around the world. As focused as the company has been on ensuring a safe work environment for its people, in the mid-1990s the need to balance regulatory compliance, employee engagement, and risk elimination led to a 15-year effort to modernize safety processes. This change process resulted in a safety program delivering a sustainable step-change in improved safety performance. Ultimately, the changes resulted in the development and refinement of formalized safety tools and approaches proven effective at identifying risk, and enabling the company to modify designs and reduce the potential for incident occurrence. Three of the most effective tools in managing risk associated with glass manufacturing operations include Management of Change (MOC), Process Hazard Analysis (PHA), and Technical Inquiry (TI). The MOC process provides a structured approach to evaluating many dimensions of potential risk associated with critical processes prior to making a physical change. In cases where the results of an MOC analysis suggest significant risk, a variety of PHA tools were developed to identify and correct probable failure modes in order to arrive at an acceptable risk profile. In situations where desired outcomes are not achieved and significant safety incidents have occurred, the TI process is employed to maximize learning and minimize the potential for a repeat of a loss event by effectively identifying and correcting root causes.