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Anneliese1973  
#1 Posted : 04 October 2016 15:49:51(UTC)
Rank: Forum user
Anneliese1973

I work in a relatively low risk manufacturing company. Within Production, we have 3 teams, assembly, upholstery and sewing.  Minimal machinery (sewing/cutting machines, spray booths, compressed air, staple guns, screwdrivers, knives etc).  We have a H&S Induction process where we have some training documents for how to clean the spray booth, how to use the compactor.

My query is over the general tasks - Upholstering a product, Assembling a product (many different products) - Should we have a method statement which details how to carry out these activities? - My concern is that someone recently had an accident which could so nearly have been a nasty eye injury, where he chose to use the wrong tool to remove a bung which had got stuck.  Now the individual was trained in the correct way to do it, but chose to use the nearest tool to him.  However, we dont have anything documented which states the correct way to do it - So had he had a major eye accident, how would we have been able to prove that he was trained properly - I am wondering whether this activity would warrant a documented SSOW/Method Statement, or whether this would be overkill. I would appreciate some advice as I'm really struggling with this

Thanks

RayRapp  
#2 Posted : 04 October 2016 16:37:45(UTC)
Rank: Super forum user
RayRapp

Rather than a Method Statement you should have a suite of Risk Assessments which identify the significant risks arising from your work activities. The RAs should identify the controls needed to eliminate or reduce the risks through training, instruction, supervision, PPE, etc.

Management could devise a set of work instructions to assist with the control of the aforementioned risks and ensure all personnel are properly trained and familar with the work instructions. 

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Anneliese1973 on 05/10/2016(UTC)
RayRapp  
#3 Posted : 04 October 2016 16:41:44(UTC)
Rank: Super forum user
RayRapp

Should have mentioned that RAs or work instructions may not prevent people from doing what they should, or ignoring their training and getting injured. This is what is called 'human behaviour' and has to be tackled in  different ways.

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Anneliese1973 on 05/10/2016(UTC)
gerrysharpe  
#4 Posted : 05 October 2016 07:14:18(UTC)
Rank: Super forum user
gerrysharpe

Originally Posted by: Anneliese1973 Go to Quoted Post

However, we dont have anything documented which states the correct way to do it - So had he had a major eye accident, how would we have been able to prove that he was trained properly - I am wondering whether this activity would warrant a documented SSOW/Method Statement, or whether this would be overkill. I would appreciate some advice as I'm really struggling with this

Thanks

I think it would be more appropriate to maintain a training manual where people have been trained correctly by a competant person and then entered into the training matrix, which also shows any further training or improvements.

When you get a new member of staff comes in, how do you let them know how to get the job done?? is it something they do themselves or do you actually show them? Do they come to you as untrained or fully skilled? 

Apart from the Risk assesments which you should do, having a training register is the next phase to show that the employee has been taught to work in the correct fashion with a bid to prevent poor working practices and injuries.

Having said that a review of training should be carried out say every 6 months with an audit to see if further requirements are needed as there will no doublt be some cutting corner incidents which can occur over a period of time, especially with repetition work.

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Anneliese1973 on 05/10/2016(UTC)
A Kurdziel  
#5 Posted : 05 October 2016 08:08:35(UTC)
Rank: Super forum user
A Kurdziel

Yes you need to document what you are doing-you can call it an SOP or SSOW, a method statement or whatever but unless you are a one man band essentially you need some sort of documentation. But… this needs to be a realistic document describing what you actually do as oppose to what you say you do or think you do. It should describe who does what and how, using what sort of equipment. The risk assessment is a process (not a piece of paperwork) applied to the method statement or whatever, where you decide whether the method statement is appropriate and controls the risk adequately.  The documentation does not need to be complicated. It should be easily understandable by the users. It could consist of pictures or even a video but it should describe what you expect the users to actually do.

Using James Reason’s Swiss Chess model, I’d say that the first layer of cheese is the method statement. The next layer is the employee’s competence, so they understand what they are doing and can they safely fill in any gaps using their knowledge, experience etc. or they know when to say ‘I  don’t know’ and pass it up to their functional  managers.  You need to be checking for this competence. The next layer is the role of the functional managers-they can support the frontline people and help them fill in the gaps. Finally the top layer is the strategic managers/executives who are largely responsible for the overall culture of the organisation. These are guys who say ‘let’s do it and get everybody home in one piece at the end of the day’ and mean it by supporting a positive H&S culture. So H&S in a nutshell!

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Anneliese1973 on 05/10/2016(UTC)
chris42  
#6 Posted : 05 October 2016 08:32:34(UTC)
Rank: Super forum user
chris42

I think it can be any of the things mentioned above by RayRapp, GerrySharpe or A Kurdziel. The work instruction / method statement states how the task should be done (and perhaps how it should not be done). However, the training will also do the same, but I would ensure that the training is documented in terms of what they should and should not do as well. So a hard copy if you like of the training content, and version control (in case it evolves). In essence they are all the same document! I think it would be extremely useful should a serious accident happen, that you can show documented evidence that they were informed, instructed, trained and if necessary reprimanded by supervision for not doing as told. Put yourself in the shoes of the enforcement authority, what would you want to see to prove the story being told of “they knew not to do it”. Chris
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gerrysharpe on 05/10/2016(UTC), Anneliese1973 on 05/10/2016(UTC)
Anneliese1973  
#7 Posted : 05 October 2016 09:09:12(UTC)
Rank: Forum user
Anneliese1973

Thanks for your comments. Just responding to some of the questions you've raised, we do have Risk Assessments in place for each of the 3 work areas mentioned. They do cover the hazards in each area, but don't drill into detail such as how we control someone using the wrong tool for a job. We also now have a skills matrix which grades each individual on their skill level over time and ability to carry out tasks. Individuals do going through a training period when they first join (unskilled - assembly & skilled - upholsterers), but there is nothing to document what they are shown during this training. We have an Induction sign-off form, which covers Management System training, spray booth cleaning, compactor use, manual handing training. But doesn't cover every aspect of their role, such as how to use a sewing machine, how to upholster/staple fabric to a frame. In your experience, how do most companies document that they have trained people in the basic tasks within their role - I think the key issue here is tool use, I know people are shown how to carry out tasks, which tool to use etc - but we don't have any documented procedures etc. Where I'm struggling is drilling into this detail feels like overkill on one hand, but without it we have nothing documented to evidence someone was shown what to do. Would the introduction of a toolbox training session as part of their Induction, covering all the tools they will need to use in their job (how to use, when to use etc) which is signed by both trainer and trainee to confirm they've had the training and received their toolbox - Would that work as part of a SSOW?
sadlass  
#8 Posted : 05 October 2016 10:10:44(UTC)
Rank: Forum user
sadlass

Video the correct procedures / processes using a competent (and co-operative) worker.

Select key parts to either screen grab, or go back and take still shots.

Compile these as part of training / procedure manual, aimed specifically at workers (don't muddle up with risk assessment findings or other management guff). You can show video but it may not be the best way. Still shots allow for notes, arrows, highlighting etc. 

Make this the induction & training process and have competency 'signed off' by supervisors.

Supervisors to supervise (I know - really!) all work activities and correct any observed mis-application or mis-underhearing (!). Retrain where necessary.

Job done.

People will still 'do their own thing' occasionally - you will never be able to prevent everything. Once you have done everything 'reasonably practicable' yet something as you say goes wrong - that is where your insurance kicks in.

You will find little on 'method statements' on HSE website, as these are just refined forms of SSOW / SOPs and their proliferation is down to the construction industry and contractor management as much as anything.

I do not think this is necessary or appropriate in this case.

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Anneliese1973 on 05/10/2016(UTC)
A Kurdziel  
#9 Posted : 05 October 2016 10:13:32(UTC)
Rank: Super forum user
A Kurdziel

A toolbox talk is great both as training as a sort of method statement but you need to double check or better still the local manager needs to double check. So that a week after the toolbox talk the manager drops in and has an informal look and asks the question “ that tool box talk last week…good wasn’t it? You aright with what it was on about…what tool to use for what job? “Yes, no problems” “yeah we don’t want any accidents. Good stuff”. This is the sort of thing that Tim Marsh goes on about when he mentions “taking and walking safety” by managers. It does not sound like much but it is really important. Documentation by itself and all the training in the world don’t close the H&S loop...it needs that human touch. Records good- touchy feely stuff is the icing on the cake, which makes it digestible.
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Anneliese1973 on 05/10/2016(UTC)
andybz  
#10 Posted : 06 October 2016 12:54:03(UTC)
Rank: Super forum user
andybz

Anneliesse By asking "how would we have been able to prove that he was trained properly" it implies that you are most interested in blaming the individual for having an accident.  I presume that is not really your intention.

Assuming you actually want to prevent these types of accident you really need to understand why did the incident occur? I am assuming that this was a routine task for the person.  Was this the first time that this person had used the wrong tool or do they do it regularly?  Is this the only person who would do this or would everyone?

You say the person had been trained properly, so more training will not be the answer.  Writing down how to do the task may help with ensuring consistency in training, but if the person is performing the task every day/continually, they will not be reading any instructions. Again, use of video may help with training, but as before it appears that training was not actually the problem.

As above, the answer will depend on if this was a routine or one-off event.

WatsonD  
#11 Posted : 06 October 2016 14:02:18(UTC)
Rank: Super forum user
WatsonD

Originally Posted by: andybz Go to Quoted Post

Anneliesse By asking "how would we have been able to prove that he was trained properly" it implies that you are most interested in blaming the individual for having an accident.

No it doesn't! It shows that Anneliese is concerned that her company is not recording the training they are providing fortheir emplyees as effectively as they could and is looking for suggestions from other professionals.

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Anneliese1973 on 19/10/2016(UTC)
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