# Presentation: 741676

## Work Controls Manager Workshop

*Chris Johnson, Al Boerner & Steve Coleman*
*April 15, 2008*

## Workshop Overview

- Bldg 555 Mercury Cleanup Lessons Learned
- Work Coordination / Work Complexity Update
- Web Requisition Update
- Work Planning and Control (WP&C) Training Course Update
- Integrated Safety Management (ISM) Performance Measures
- WP&C Effectiveness Review – August 2008
- Feedback/Open Discussion on WP&C Issues and Concerns

## Bldg 555 Mercury Cleanup Lessons Learned

- If a procedure exists – Reference the SOP on the Work Permit & review the steps in the pre-job briefing (Note any deviations from procedure due to job situations/conditions.)
- Workers can have different PPE, but must always meet minimum prescribed (however it does allow the auditor to raise the issue and open it up for discussion).
- Auditors can sometimes get in the way of safe work practices. On the job it was noted that the auditor was distracting the worker during job performance.

## Work Coordination / Complexity

- DOE ISM Inspection Team believed the graded approach document used for categorizing work into low, moderate or high levels was exceptional.  However, there was no guidance on work complexity and coordination.
- Proposed changes to the graded approach document was forwarded to several Work Control Managers and Coordinators for review and comment
- After several iterations – April 1st minor revisions to the subject area went active
- Work Control Managers must flowdown revised guidance to Work Control Coordinators

## Slide 5

## Web Requisition Changes

- Defined “Manual/Hand Delivery” and separated it from “Installation”
- Placed “Warranty Work” as a separate type of on-site work and it doesn’t need review from the WCC to pin Requisition
- Added “Construction” as a separate type of on-site work and if selected, process the requisition differently from other types of on-site work (includes associated controls).
- Reworded the Plant Engineering question to include only “Hoisting and Rigging” services
- Expanded Radio Frequency (Rf) wireless device question
- Added question on deliverable goods outside US

## Work Planning & Control Training

- Jim Nemeth from the Training & Qualification Office is working on the WP&C Web based course.  The revised course will include:
- Scenario based activities
- Integration of the various JTA course information
- Hazard analysis & Control techniques
- Pre-job briefings, Change control, etc...
- The final draft will be forwarded to Work Control Managers for review and comment – 4th quarter of FY 2008

## ISM Performance Measures

- In the FY08 BSA/BNL Contract – As part of BNL’s annual declaration, a set of performance measures (due 3/31/2008) was required to be developed for ISM Effectiveness determination (Performance Evaluation & Measurement Plan [PEMP] Target 5.2.1.5).
- The 4 Process and outcome measures:
- Work Planning Breakdown – establish a baseline to identify the percent of worker planned, prescribed and permit planned work.  Analyze to determine if consistent with risk levels (through assessments, RARs, ORPS, NTS, etc...)
- Evaluate unsafe behaviors (observations) to determine correlation to ISM core functions *(leading indicator)*
- Evaluate the ratio of work planning and control problems identified to the total number ORPS, NTS, RARs, Injury & Illness *(lagging indicator)*
- Work planning problems that causes facility downtime (e.g., inadvertent shutdown of systems or processes) - report from maintenance management *(lagging indicator)*

## WP&C Effectiveness Review

- A number of existing actions in the ISM/Safety Improvement Project Plan address WP&C findings identified in the 2005 ISM Readiness Review – those actions include:
- Creating a culture “all work is planned” and develop supporting procedures & methodologies – recently implemented worker planned, prescribed and permit planned work
- Integrate human performance factors and principles into the WP&C Management System
- During the week of August 11th, 2008 – effectiveness review team (DOE-BHSO, BNL IO Office & PNNL IO Office) will consider the following criteria:
- Appropriateness of corrective actions
- Implementation effectiveness
- Performance Improvement
- Follow-up/Assurance

## Summary/Questions/Comments

**Work Control Manager Actions**
- Flowdown work complexity and coordination guidance to WCCs and forward an email to Chris Johnson and/or Steve Coleman stating so.
- Flowdown Web Requisition changes to WCCs
- Identify the % of worker planned, prescribed and permit planned work in respective Departments/Divisions (for example: 60% worker planned, 35% prescribed and 5% permit planned) and forward to Chris Johnson and Steve Coleman.
**WP&C Issues and Concerns?**

## Work Planning & Controlfor Work Control Coordinators

**Chris Johnson**
**April, 2008**

## Work Planning & Control for  Work Control Coordinators

- What’s Changed in Work Planning & Control Subject Area
- Three-Tiered Work Planning Format
- When & How to Use Each Kind
- Complexity and Work Coordination for Work Permits applying the Graded Approach

## Work Planning & Control Changes

- WCM / WCC Qualification – Local, Dept. Decision
- BTMS Training ++ Local Knowledge Requirements / Hazard Recognition
- Planning Levels
- New Guidance / Instructions – Exhibits & Forms
- Change Control
- ISM Flowdown to Contractors / Vendors
- Visitor Notification
- Work Observations

## Three-Tiered Work Planning Format

- Worker Planned Work
- Prescribed Work
- Permit Planned Work

## Worker Planned Work

- Formerly “Skill-of-the-Craft”
- Typically Low Hazard – Routine Work
- Characteristics of Worker Planned Work
- Employees Current on JTA
- JRAs have been completed for Hazards of Task
- Employee has Approval for Task on Qualification Matrix
- Worker-Qualified from OJT, Other Site Experience, Degree, Certified License, Etc.
- Planning Done Immediately Before Work is Performed
- Worker to Consider:
- Hazards, Critical Steps, Failure Scenario, Likely Errors, OK to Proceed, Change Control

## Prescribed Work

- Pre-Approved Work Plan or Procedure Written by Others
- Task is Important Enough, Done Frequently Enough, or has a Hazard that Calls for a Specific Procedure
- Could be One-Time Procedure or Done in Advance
- Pre-Planning should Dictate Training, PPE, Equipment, Tools, Access Requirements, or Special Instructions

_**Caution**_**: Since this work is “pre-planned”, attention must be given to any changed conditions or new location hazards**.

## Permit Planned Work

- Thorough Hazard Analysis Checklist
- Gets the Most People Involved – Including Subject Matter Experts
- High Visibility to Workforce
- Planning is Usually done Close in Time to Work Effort – But Duration Could be Long so Changing Conditions and/or Scope Requires Vigilance (WCC)
- Best “Buy In” by Planners, Supervisors, Experts, & Workers
- Has Mechanism to Obtain Feedback

## Permit Planned Work / Graded App

- _Environment, Safety, Security, & Health Risk_
- Low – Little chance of negative outcome if workers do what they are suppose to do. Few, if any, preventive measures required.
- Moderate – Risks are present that require specific action or prevention strategy to ensure mitigation.
- High – Without effectively employing hazard mitigation strategies, a negative outcome is likely.

**Strategies should be employed in the following order:**
**Replace/Eliminate Hazard ******** Engineering Controls ******** Administrative Controls ******** PPE**

## Permit Planned Work / Graded App

- _Complexity Level_
- Low – Task sequence is not significant.  Minimal interactions between personnel required.
- Moderate – Task sequence is significant.  Frequent interactions among personnel required.
- High – Continuous interdependency among personnel required. elements. Plan demands input & discussion from as many experts as can be utilized. Pay considerable attention to starting conditions, watch for & manage emergence. (Plan well up front – watch for changing conditions.)

## Permit Planned Work / Graded App

- _Work Coordination_
- Low – No more than 3 functional groups within one Dept/Div. Minimal coordination from support groups.
- Moderate – More then 3 functional groups involved. Work requires close coordination with support groups.
- High - More than 6 functional groups within one department or combination of Dept/Div. or outside contractors performing work requireing  frequent support systems to assist in risk mitigation. Hand off points require particularly in-depth planning.