Sample Written Program For

Job Safety Analysis

Table of Contents Part Introduction........................................................................................ Selecting Jobs for Analysis................................................................ Involving the Employee ..................................................................... Conducting the Job Safety Analysis .................................................. Breaking Down the Job ..................................................................... Identify Hazards ................................................................................ Recommending Safe Procedures and Protection ............................. Revising the Job Safety Analysis ...................................................... Job Safety Analysis Training Guide ................................................... Group Exercise .................................................................................. Job Safety Analysis Blank Form ........................................................ Sample Job Safety Analysis .............................................................. Sample Job Safety Analysis Grinding Castings................................. Sample Job Safety Analysis .............................................................. 1 3 4 5 7 8 10 12 13 14 15 17 19 20

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Introduction

Job-related injuries and fatalities occur every day in the workplace. These injuries often occur because employees are not trained in the proper job procedure. One way to prevent workplace injuries is to establish proper job procedures and train all employees in safer and more efficient work methods. Establishing proper job procedures is one of the benefits of conducting a job safety analysis carefully studying and recording each step of a job, identifying existing or potential job hazards (both safety and health), and determining the best way to perform the job or to reduce or eliminate these hazards. Improved job methods can reduce costs resulting from employee absenteeism and workers compensation, and can often lead to increased productivity. This booklet explains what a job safety analysis is and contains guidelines for conducting your own step-by-step analysis. A sample of a completed job safety analysis and a blank job safety analysis form are included at the back of this booklet.

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Although this booklet is designed for use by supervisors, employees also are encouraged to use the information contained in this booklet to analyze their own jobs, be aware of workplace hazards, and report any hazardous conditions to their supervisors.

Is the worker wearing personal protective clothing and equipment, including safety harnesses that are appropriate for the job?

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Selecting Jobs for Analysis

A job safety analysis can be performed for all jobs in the workplace, whether the job task is Aspecial@ (non-routine) or routine. Even one-step-jobs such as those in which only a button is pressed can and perhaps should be analyzed by evaluating surrounding work conditions. To determine which jobs should be analyzed first, review your job injury and illness reports. Obviously,

a job safety analysis should be conducted first for jobs with the highest rates of disabling injuries and illnesses.
Also, jobs where Aclose calls@ or near misses@ have occurred should be given priority. Analyses of new jobs and jobs where changes have been made in processes and procedures should follow. Eventually, a job safety analysis should be conducted and made available to employees for all jobs in the workplace.

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Involving the Employee

Once you have selected a job for analysis, discuss the procedure with the employee performing the job and explain its purpose. Point out that you are studying the job itself, not checking on the employee=s job performance. Involve the employee in all phases of the analysis from reviewing the job steps and procedures to discussing potential hazards and recommended solutions. You also should talk to other workers who have performed the same job.

Are lockout procedures used for machinery deactivation during maintenance procedures?

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Conducting the Job Safety Analysis

Before actually beginning the job safety analysis, take a look at the general conditions under which the job is performed and develop a checklist. Below are some sample questions you might ask. Are there materials on the floor that could trip a worker? Is lighting adequate? Are there any live electrical hazards at the jobsite? Are there any chemical, physical, biological, or radiation .hazards associated with the job or likely to develop? Are tools including hand tools, machines, and equipment In need of repair? Is there excessive noise in the work area, hindering worker communication or causing hearing loss? Are job procedures known and are they followed or modified? Are emergency exits clearly marked? Are trucks or motorized vehicles properly equipped with brakes, overhead guards, backup signals, horns, steering gear, and identification, as necessary? Are all employees operating vehicles and equipment properly trained and authorized? Are employees wearing proper personal protective equipment for the jobs they are performing? Have any employees complained of headaches, breathing problems, dizziness, or strong odors? Is ventilation adequate, especially in confined or enclosed spaces? Have tests been made for oxygen deficiency and toxic fumes in confined spaces before entry? Are work stations and tools designed to prevent back and wrist injuries? Are employees trained in the event of a fire, explosion, or toxic gas release?

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Naturally this list is by no means complete because each worksite has its own requirements and environmental conditions. You should add your own questions to the list. You also might take photographs of the workplace, if appropriate, for use in making a more detailed analysis of the work environment.

Is the worker wearing clothing or jewelry that could get caught in the machinery or otherwise cause a hazard?

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Breaking Down the Job

Nearly every job can be broken down into job tasks or steps. In the first part of the job safety analysis, list each step of the job in order of occurrence as you watch the employee performing the job. Be sure to record enough information to describe each job action, but do not make the breakdown too detailed. Later, go over the job steps with the employee. Figure 1 shows a worker performing the basic job steps for grinding iron castings.

Figure 1. Grinding Castings: Job Steps 1. Reach into metal box to right of machine, grasp casting, and carry to wheel. 2. Push casting against wheel to grind off burr. 3. Place finished casting in box to Left of machine.

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Identify Hazards

After you have recorded the job steps, next examine each step to determine the hazards that exist or that might occur. Ask yourself these kinds of questions. ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Are there hazards that would require the use of personal protective clothing and equipment that are appropriate for the job? Are work positions, machinery, pits or holes, and hazardous operations adequately guarded? Are lockout procedures used for machinery deactivation as required? Is the worker wearing clothing or jewelry, or have long hair that could get caught in the machinery or otherwise cause a hazard? Are there fixed objects that may cause injury, such as sharp edges? Is the flow of work organized (e.g., Is the worker required to make movements that are too rapid)? Can the worker get caught in or between moving parts? Can the worker be injured by reaching over moving machinery parts or materials? Is the worker at any time in an off-balance position? Is the worker positioned to the machine in a way that is potentially dangerous? Is the worker required to make movements that could lead to or cause hand or foot injuries, or strain from lifting the hazards of repetitive motions? Can the worker be struck by an object or lean against or strike a machine part of object? Can the worker fall from one level to another? Can the worker be injured from lifting or pulling objects, or from carrying heavy objects? Do environmental hazards (dust, chemicals, radiation, welding rays, heat, or excessive noise) result from the performance of the job?

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Identify Hazards

Repeat the job observation as often as necessary until all hazards have been identified. Figure 2 shows basic job steps for grinding iron castings and any existing or potential hazards.

Figure 2. Grinding Castings: Hazards 1. Strike hand on edge. of metal box or casting; cut hand on burr. Drop casting on toes. 2. Strike hand against wheel. Flying sparks, dust, or chips. Wheel breakage. Not enough of wheel guarded. No dust removal system. Sleeves could get caught in machinery. 3. Strike hand against metal box or castings.

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Recommending Safe Procedures and Protection

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After you have listed each hazard or potential hazard and have reviewed them with the employee performing the job, determine whether the job could be performed in another way to eliminate the hazards, such as combining steps or changing the sequence, or whether safety equipment and precautions are needed to control the hazards. An alternative or additional procedure is to videotape the worker performing his or her job and analyze the job procedures. If safer and better job steps can be used, list each new step, such as describing a new method for disposing of material. List exactly what the worker needs to know to perform the job using a new method. Do not make general statements about the procedure, such as ABe Careful.@ Be as specific as you can in your recommendations. You may wish to set up a training program using the job safety analysis to retrain your employees in the new procedures, especially if they are working with highly toxic substances or in hazardous situations. (Some OSHA standards require that formal training programs be established for employees.) If no new procedure can be developed, determine whether any physical changes such as redesigning equipment, changing tools, adding machine guards, personal protective equipment, or ventilation will eliminate or reduce the danger. If hazards are still present, try to reduce the necessity for performing the job or the frequency of performing it. Go over the recommendations with all employees performing the job. Their ideas about the hazards and proposed recommendations may be valuable. Be sure that they understand what they are required to do and the reasons for the changes in the job procedures.

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Recommending Safe Procedures and Protection

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Figure 3 identifies the basic job steps for grinding iron castings and recommendations for new steps and protective measures.

Figure 3. Grinding Castings: New Procedure or Protection 1. Provide gloves and foot protection. 2. Provide larger guard over wheel. Install local exhaust system. Provide safety goggles. Instruct worker to wear short or tight-fitting sleeves. 3. Provide for removal of completed stock.

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Revising the Job Safety Analysis

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A job safety analysis can do much toward reducing accidents and injuries in the workplace, but it is only effective if it is reviewed and updated periodically. Even if no changes have been made in a job, hazards that were missed in an earlier analysis could be detected. If an illness or injury occurs on a specific job, the job safety analysis should be reviewed immediately to determine whether changes are needed in the job procedure. In addition, if a Aclose call@ or Anear miss@ has resulted from an employee=s failure to follow job procedures, this should be discussed with all employees performing the job. Any time a job hazard analysis is revised, training in the new job methods, procedures, or protective measures should be provided to all employees affected by the changes. A job safety analysis also can be used to train effectively new employees on the steps and job hazards.

The information and suggestions contained in this material have been developed from sources believed to be reliable. However, Frankenmuth accepts no legal responsibility for the correctness or completeness of this material, or its application to specific factual situations.

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JOB SAFETY ANALYSIS TRAINING GUIDE

Job Title: Equipment: Department: Required Personal Protective Equipment (PPE): JOB STEPS Break down the job into its basic steps, e.g., what is done first, what is done next, and so on. You can do this by: 1. 2. 3. 4. Observing the job Discussing it with the operator Drawing on your knowledge of job A combination of the three POTENTIAL HAZARDS For each step, ask yourself what accidents could happen to the employee doing the job. You can get the answers by: 1. 2. 3. 4. observing the job. discussing it with the operator recalling past accidents a combination of the three RECOMMENDED SAFE JOB PROCEDURES For each potential accident or hazard, ask yourself what safeguards should be provided for the employee and how should the employee do the job step to avoid the potential accident, or what should they do or not do to avoid the accident. You can get your answers by: 1. observing the job for leads 2. discussing precautions with experienced job operators 3. drawing on your experience 4. a combination of the three Be sure to describe specifically the provided safeguards and precautions an employee must use. Don=t leave out important details. Number each separate recommended precaution with the same number you gave the potential accident (see center column) that the precaution seeks to avoid. Use simple do or don=t statements to explain recommended precautions as if you were talking to the employee. For example: ALift with your legs, not your back.@ Avoid generalities such as, ABe careful,@ ABe alert,@ ATake caution,@ etc. Trainee=s Name: Trainer=s Name: Four-Step Instruction Completed? Prepare the Worker . . . . . . . . . . . . Trainer=s Initials Present the Operation . . . . . . . . . . Trainer=s Initials Try Out Performance . . . . . . . . . . .Trainer=s Initials Follow Up . . . . . . . . . . . . . . . . . . . .Trainer=s Initials Training Date: Trainer=s Signature: Page: of JSA No. Date: Analysis by: New Revised

Supervisor: Approved by:

Record the steps in their normal order of occurrence. Describe what is done, not the details of how it is done. Usually three or four words are sufficient to describe each basic job step. For example, the first basic job step in using a pressurized water fire extinguisher would be: 1. Remove the extinguisher from the wall bracket.

Ask yourself; can he/she be struck by or contacted by anything; could they strike against or come in contact with anything; could the employee be caught in, on, or between anything; can they fall; be over exerted; or be exposed to anything injurious such as gas, radiation, welding rays, etc.? For example, acid burns, fumes.

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Comments:

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GROUP EXERCISE JOB SCENARIO Work in groups using the following information to create a JSA. When the class has finished, we will discuss the project. #CINCINNATI HYDRAULIC PRESS BRAKE IN THE METAL FORMING DEPARTMENT #THE JOB HAS JUST BEEN SET UP, THESE ARE THE FIRST PIECES OF A 1,200 PIECE PRODUCTION RUN #ONE WORKER IS REQUIRED TO DO THIS JOB #THE PRESS BRAKE IS ACTUATED AND SAFEGUARDED BY 2-HAND CONTROLS SECURED TO FRONT OF PRESS BRAKE ABOUT 48 INCHES FROM THE FLOOR. #ONE PALLET OF BLANKS IS DELIVERED BY HILO, SET ON WORKBENCH ABOUT 40 INCHES HIGH 4 STACKS, 250 BLANKS PER STACK ARE SECURED BY BANDING TO THE PALLET #THE BLANKS ARE 6 INCH x 12 INCH METAL AND WEIGHT ABOUT 2 POUNDS #THE OPERATION CONSISTS OF MAKING ONE 90 DEGREE BEND LENGTHWISE IN THE BLANK #THE DIE FIXTURE HOLDS THE PART SECURELY IN DIE #FINISHED PARTS ARE STACKED IN A PARTS BIN SET ON THE FLOOR

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JOB SAFETY ANALYSIS

Job Title: Equipment: Department: Required Personal Protective Equipment (PPE): JOB STEPS POTENTIAL HAZARDS RECOMMENDED SAFE JOB PROCEDURES Page: 1 of 2 Supervisor: JSA No. ____ Date: Analysis by: Reviewed by: ____New ____Revised

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JOB SAFETY ANALYSIS

Job Title: Equipment: Department: Required Personal Protective Equipment (PPE) JOB STEPS POTENTIAL HAZARDS RECOMMENDED SAFE JOB PROCEDURES Page: 2 of 2 Supervisor: Approved by: JSA No. Date: Analysis by: New Revised

Trainee=s Name: Trainer=s Name: Four-Step Instruction Completed? Prepare the Worker . . . . . . . . . . . . .Trainer=s Initials Present the Operation . . . . . . . . . . .Trainer=s Initials Try Out Performance . . . . . . . . . . . .Trainer=s Initials Follow Up . . . . . . . . . . . . . . . . . . . . .Trainer=s Initials

Training Date: Trainer=s Signature:

Comments: Page 16

SAMPLE JOB SAFETY ANALYSIS

Job Title: MACHINE OPERATOR Equipment: CINCINNATI PRESS BRAKE Department: METAL FORMING

Page: 1 of 2 Supervisor: James Smith Approved by: Rhonda Ames

JSA No. 103

Date:

7-7-00

x New
Revised

Analysis by: James Smith and Louis Andres, Operator

Required Personal Protective Equipment (PPE): Heavy gloves, Kevlar sleeves, safety glasses w/side shields, heavy work boot (steel toe optional). JOB STEPS POTENTIAL HAZARDS RECOMMENDED SAFE JOB PROCEDURES

1. Turn on press brake

Parts: tools, debris, electric shock Inside/outside press brake, floor area Flying pieces/slip, trip, fall Point of operation Crush or amputate Finger, hand Moving Hilo and stationary parts Struck by or crushed between Hilo and Press brake or table Sharp edges and release of coiled energy Lacerations Hands, arms, face, eyes Sharp edges and long, loose banding Lacerations/trip, fall Hands, arms, face, eyes Sharp edges Lacerations, cuts Hands, fingers

Good housekeeping; check area is clear of tools, parts, debris. Check flex cords for damage and exposed wiring. Wear PPE. Check operating selector - single stroke. Test controlsconcurrent, anti-tie-down, anti-repeat, no bridging, protected from accidental activation. Test stop control. Move out of way while Hilo is delivering parts so body is not in pinch point. Use proper cutting tool.

2. Test 2-hand controls

3. Receive parts

4. Cut banding

5. Discard banding

Wind up banding and deposit into-drum. Observe for tripping on loose bands. Grasp along edges. Pull blank toward you.

6. Remove blank from stack

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Job Title: MACHINE OPERATOR Equipment: CINCINNATI PRESS BRAKE Department: METAL FORMING

Page: 2 of 2 Supervisor: James Smith

JSA No. 103

Date: 7-7-00

X New Revised

Analysis by: James Smith Reviewed by: Jane Martin

Required Personal Protective Equipment (PPE): Heavy gloves, Kevlar sleeves, safety glasses w/side shields, heavy work boot (steel toe optional, face shield (steps 4 and 5). JOB STEPS POTENTIAL HAZARDS Same as #6 Part can fall from fixture Point of operation, struck by metal debris Amputation, lacerations Fingers, hands, eyes Same as #6 Bending to floor level, handling metal parts Strain, sprain, cuts, lacerations Back, shoulder, fingers, hands RECOMMENDED SAFE JOB PROCEDURES Locate securely in fixture Use 2-hand control safeguards to actuate

7. 8.

Put blank in fixture Actuate press brake

9.

Remove formed part Place part in bin on floor

Same as #6 Use safe lifting techniques. (See Comments) (Short-term solution until work station is adapted according to good ergonomic guidelines) Training Date: Trainer=s Signature:

10.

Trainee=s Name: Trainer=s Name: Four-Step Instruction Completed? Prepare the Worker. . . . . . . . . . . . . . . . Trainer=s Initials Present the Operation . . . . . . . . . . . . . . Trainer=s Initials Try Out Performance. . . . . . . . . . . . . . . Trainer=s Initials Follow Up . . . . . . . . . . . . . . . . . . . . . . . Trainer=s Initials

Comments: Refer to Safe Back Training@ module.

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SAMPLE JOB SAFETY ANALYSIS GRINDING CASTINGS

STEP

HAZARD

CAUSE

PREVENTIVE MEASURE

1. Reach into right box and select casting

Strike hand on wheel

Box is located beneath wheel Corners of casters are sharp Box too low

Relocate and select casting side of wheel Require wearing of leather gloves Place box on pallet Require wearing of safety shoes Provide larger guard with tongue guard and work rest Check rpm rating of wheel Inspect wheel for cracks Require wearing of eye goggles Provide local exhaust system

Tear hand on corner of casters 2. Grasp casting, lift and position Strain shoulder/elbow by lifting with elbow extended Drop casting on toe during positioning 3. Push casting against wheel and grind burr Strike hand against wheel

Slips from hand

Wheel guard is too small

Wheel explodes

Incorrect wheel installed Cracked wheel

Flying sparks/chips

Wheel friction with caster Dust from caster metal and wheel material Loose sleeves

Respirable dust

Sleeves caught in machinery 4. Place finished casting into box Strike hand on castings

Require tight or short sleeves

Buildup of completed stock

Remove completed stock routinely

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SAMPLE JOB SAFETY ANALYSIS

JOB TITLE (AND NUMER IF APPLICABLE): STOCK LOADING TITLE OF PERSON WHO DOES JOB: LOADER COMPANY/ORGANIZATION: METAL FABRICATING CORP. PLANT/LOCATION: CHICAGO PAGE 1 JSA NO. 103 DATE: 1-1-95 SUPERVISOR: JAMES SMITH DEPARTMENT: PACKAGING NEW REVISED ANALYSIS BY: JAMES SMITH REVIEWED BY: JOHN MARTIN APPROVED BY: JOE BOTTAN RECOMMENDED ACTION OR PROCEDURE 1a. USE PALMAR GRIP, GRASP BOTTOM WITH ONE HAND ON BOTTOM FRONT CORNER AND OTHER HAND ON TOP OPPOSITE CORNER OF OTHER END. KEEP ONE ELBOW INTO SIDE. TURN BODY INSTEAD OF TWISTING.

REQUIRED AND/OR RECOMMENDED PERSONAL PROTECTIVE EQUIPMENT: GLOVES, SAFETY SHOES, SAFETY GLASSES, HARD HATS SEQUENCE OF BASIC JOB STEPS 1. REMOVE BOX FROM CONVEYOR AND PLACE ON TRUCK. POTENTIAL HAZARDS 1a. HEAVY BOXES & IMPROPER HAND PLACEMEN OR HANDLING METHOD. (MASHED FINGERS, HIT ELBOWS, STRAINS).

1b. SPLINTERS (PUNCTURES). 1c. HEAVY BOXES, POOR GRIP, & IMPROPER SHOES (FOOT INJURIES). 1d. UNGUARDED V-BELT (HAND INJURIES). 1e. TRUCK PARKED TOO CLOSE OR TOO FAR FROM WORK AREA. (STRAINS, BOXES

1b. WEAR GLOVES. 1c. WEAR HARD TOE SHOES.

1d. GUARD V-BELT WITH ENCLOSURE AND KEEP IN PLACE.

1e. PARK TRUCK AT A DISTANCE AWAY FROM TH NOT REQUIRED TO TWIST THE BODY AND SO THAT YOU HAVE CROPPED ENOUGH ON WORKING FEET, SLIPS/ ROOM TRIPS/FALLS). TO AVOID BUMPING INTO THE CONVEYOR OR TRUCK.

* NATIONAL SAFETY COUNCIL SAMPLE JOB SAFETY ANALYSIS

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JOB SAFETY ANALYSIS SAMPLE Page 2

JOB TITLE (and number if applicable): STOCK LOADING TITLE OF PERSON WHO DOES JOB: LOADER COMPANY/ORGANIZATION: METAL FABRICATING CORP. PLANT/LOCATION: CHICAGO PAGE 2 OF 4 JSA NO. 103 DATE: 1-1-95 SUPERVISOR: JAMES SMITH DEPARTMENT: PACKAGING X NEW REVISED ANALYSIS BY: JAMES SMITH REVIEWED BY: JOHN MARTIN APPROVED BY: JOE BATTON

REQUIRED AND/OR RECOMMENDED PERSONAL PROTECTIVE EQUIPMENT: GLOVES, SAFETY SHOES, SAFETY GLASSES, HARD HATS SEQUENCE OF BASIC JOB STEPS CONT=D FROM PAGE 1. 2. PUSH LOADED TRUCK. POTENTIAL HAZARDS 1f. OBJECTS ON FLOOR. (SLIPS/TRIPS/FALLS). 2a. OVERLOADED TRUCK & WORN CASTERS (STRAINS WHILE (PUSHING).

RECOMMENDED ACTION OR PROCEDURE 1f. OBSERVE AREA FOR SLIPPING 2a. IF TRUCK WILL NOT MOVE BY USING BODY WEIGHT AGAINST IT, GET POWERED EQUIPMENT, REMOVE PART OF LOAD, OR SECURE ASSISTANCE. 2b. KEEP HANDS ON END OF TRUCK.

AND TRIPP

2b. HANDS ON SIDE OF TRUCK. 2c. PULLING TRUCK (RUN OVER FOOT). 2d. BOXES STACKED TOO HIGH & UNBALANCED. (FOOT INJURIES). 2e. OBJECTS ON FLOOR. (SLIPS/TRIPS/FALLS).

2c. PUSH, NEVER PULL.

2d. STACK BOXES ORDERLY & NO HIGHER THAN NORMAL EYE LEVEL. 2e. OBSERVE FOR SLIPPING/ TRIPPING HAZARD WHEN TRAVELING.

* NATIONAL SAFETY COUNCIL JOB SAFETY ANALYSIS

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