All modern manufacturing facilities use principles that “all accidents are preventable,” but sometimes incidents or accidents can still happen.
Gathering as much data as possible and analyzing it to prevent a recurrence is essential.
Investigation Report
Let’s review the first part – [ Incident Reporting ] A. To be completed by the COMMUNICATOR AT THE TIME OF INCIDENT.
![Safety 4M Analysis](https://leanmanufacturing.online/wp-content/uploads/2018/04/Safety-Health-and-Environment-Incedent-Report-1024x805.png)
All fields in the report’s first part (A) are self-explanatory. Let’s review “The incident / Accident Description and Evaluations sections.
Description
Create a detailed explanation of the area/part of the equipment, what happened, and who and how – attach a diagram or picture applicable in the “Attachment” sheet only.
Evaluations
All evaluation sections must be filled to get a Hazard Rating Number (HRN), suggesting a future course of action.
Degree of Possible Harm
- 0.1 —> Scratch or bruise;
- 0.5 —> Laceration or mild ill health effect;
- 1 —> Break of a minor bone or minor temporary occupational illness;
- 2 —> Break of a major bone or minor permanent occupational illness;
- 4 —> Loss of one limb, one eye, or serious temporary occupational illness;
- 8 —> Loss of limbs, eyes, or serious permanent occupational illness;
- 15 —> Fatality.
Likelihood of Occurrence
- 0 —> Impossible cannot happen;
- 0.1 —> Almost impossible possible in extreme circumstances;
- 0.5 —> Highly unlikely though conceivable;
- 1 —> Unlikely but could occur;
- 2 —> Possible but unusual;
- 5 —> Even chance could happen;
- 8 —> Probable not surprised;
- 10 —> Likely to be expected;
- 15 —> Certain no doubt.
Frequency of Exposure
- 0.1 —> Infrequently;
- 0.2 —> Annually;
- 1 —> Monthly;
- 1.5 —> Weekly;
- 2.5 —> Daily;
- 4 —> Hourly;
- 5 —> Constantly.
Number of Personnel
- 1 —> 1-2 persons;
- 2 —> 3-7 persons;
- 4 —> 8-15 persons;
- 8 —> 16-50 persons;
- 12 —-> >50 persons.
Hazard Rating Number (HRN)
HRN = DPH * Likelihood * FOE * NOP
- HRN range 1-3, the risk is minimal – No need to make any changes;
- HRN range 3-9, the risk is still low- review existing measures;
- HRN range 10-15, the risk is medium – control measures need to be reviewed;
- HRN range 16-20, the risk is HIGH – future activity could be stopped;
- HRN higher than 25, EXTREME risk – not recommend restarting activity.
Investigation Part using Cap-Do Cycle
![5W2H phenomenon tool](https://leanmanufacturing.online/wp-content/uploads/2018/04/Safety-Health-and-Environment-Incident-Investigation-1024x439.png)
Start 1st stage of investigation by determining the phenomenon using 5W2H analysis. After it’s done, use the 2nd stage to find the root cause using a hybrid of RCA and 4M Analysis.
![4M Analysis in Lean Six Sigma](https://leanmanufacturing.online/wp-content/uploads/2018/04/Root-Cause-Analysis-and-4M-Fishbone-1024x624.png)
Finally, after finding a single of multiple causes, proceed to stage 3 and create an action plan of countermeasure with the assignment of the responsible person and completion timeframe.
![Investigation action plan](https://leanmanufacturing.online/wp-content/uploads/2018/04/Proposed-countermeasures-action-plan-with-responsible-persons-and-timeframe-1024x296.png)
The last section is used to verify and close the Incident Report
![Health and Safety report closure](https://leanmanufacturing.online/wp-content/uploads/2018/04/Verification-and-closure-of-SHE-incident-1024x251.png)
If your company requires the template mentioned above, you can get it from our store.
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