DRH, 05/09/03, Slide 1

Methodology for applying HF analysis

or

A Human Factors Toolkit

Debby Hallett, Ciba Specialty Chemicals

DRH, 05/09/03, Slide 2

Introduction…• Purpose of presentation:

– Share experiences of developing and using the “Human Factors Toolkit”

• Contents:– Ciba Specialty Chemicals & it’s requirements– Overview of methodology– Examples of applying the method– Problems encountered (& overcome)

DRH, 05/09/03, Slide 3

Ciba Specialty Chemicals & it’s requirements

DRH, 05/09/03, Slide 4

Ciba Specialty Chemicals…• Globally:

– 20,000 employees– 64 production sites– 25 countries

• Bradford, UK site:– 1,200 employees– Top tier COMAH site

• Human Factors at Ciba Specialty Chemicals:– Wide range of projects involve HF– 3 year history of specific HF work

DRH, 05/09/03, Slide 5

Ciba Human Factors “History”…• 2000: submitted COMAH Safety Report

– Considered Technical control measures– Improvement plan on Human Factors agreed

• 2000 – 2001: Various individual assessments on lone working, manloading and Human Factors DNV

• 2001: Developed HF assessment technique: Ciba/DNV• 2002: Pilot assessment – Grimsby site Ciba/DNV• 2002: Assessment – Bead, Bradford site Ciba/DNV• 2003: Assessment – Maintenance Ciba• 2003: Assessment – R2000 Control room Ciba/DNV• 2003: Assessment – Project Diamond Ciba

DRH, 05/09/03, Slide 6

Ciba’s objectives:• COMAH (Seveso) compliance…demonstration of:

– Evaluation of potential human error– Effectiveness of human interventions required to maintain

control

• Establish awareness of human factors:– Line Management– Engineering design

• Technology transfer:– Develop internal HF assessment methodology– Apply to all types of activities on site– Suitable for use by non-HF professionals– Complement other risk assessment techniques

DRH, 05/09/03, Slide 7

Overview of Methodology

DRH, 05/09/03, Slide 8

Incorporate relevant results into Safety Report

Major Accident Hazard scenarios identified from

COMAH Safety Report

Task inventory & criticality assessment

Observational data

Identify critical tasks

Error analysisTask analysis (HTA & concurrent)

Qualitatively assess critical tasks and potential errors

Staffing assessment

Alarm & Procedure checklists

Evaluate the safeguards

Identify risk control strategies

Before Assessment

Assessment

After Assessment

Human Factors Method to Support COMAH

DRH, 05/09/03, Slide 9

Examples of applying the method

DRH, 05/09/03, Slide 10

1) Maintenance activities• Manual task:

– Breaking and making gasketted joints

• Toolkit worked well:– Easy to identify task steps, errors & consequences– Easy to generate recommendations

• Example - handover incomplete job to next shift– Error: fail to communicate task status– Consequence:

• Gaskets missing/untightened - leak of hazardous substance– Recommendations:

• Maintenance operatives handover job personally• Use job sheet to record status

DRH, 05/09/03, Slide 11

2) Automated continuous plant• General control room duties difficult to assess

• Selected a manual task, and looked at links to control room activities

– e.g., communications, data entry & decision making

• Example – taking sample of reactor contents– Error: fail to circulation valve on sample cooler– Consequence:

• Unrepresentative sample taken - status of reactor unknown• Potential runaway reaction

– Recommendations:• Ensure all operators understand importance of sampling• Improve labelling of valves• Investigate linking valves to sample point

DRH, 05/09/03, Slide 12

3) Design phase of new plant• Multi-disciplinary team established during design phase• Applied methodology to proposed design:

– Identified how plant will operate– Identified design problems before too late– Identified manning levels– Most importantly…ensured employee involvement

• Example – connect road tanker to off-load point– Error: driver connects to wrong point– Consequence:

• Incompatible substance into storage tank - exothermic reaction– Recommendations:

• Tanker drivers not allowed on site unaccompanied• 2 x paperwork checks• Off-load points locked

DRH, 05/09/03, Slide 13

Problems encountered (& overcome)

DRH, 05/09/03, Slide 14

Key learning points…• Consultants requirements Ciba’s:

– Unused data removed from process– Role of Task Inventory?– Training modified: less academic, more pragmatic

• Select the right assessment team:– Key people = experienced operators– Manager/supervisor also required (reality check)– Must be available for whole assessment

• Time intensive process:– Moved some steps outside assessment timetable– Ensure assessment scope is realistic– Facilitator observe task(s) before assessment– Smarter recording (reduce time to ‘write-up’)

DRH, 05/09/03, Slide 15

Key learning points (cont)…• Costs involved:

– Move to Ciba Specialty Chemicals led assessments– DNV provide support as required

• Staffing assessment:– Diagrams told us what we suspected – not specific enough– Concurrent task analysis = more useful

DRH, 05/09/03, Slide 16

Conclusions…1) Methodology meets Ciba’s requirements:• COMAH Compliance:

– “Reality check” on current practice– Identifies deficiencies/opportunities

• Raised HF awareness within Ciba Specialty Chemicals• Technology Transfer:

– Simple method (but time consuming)– Suitable for wide variety of activities– Compliments other RA techniques

2) Most important parts of process:– Team selection– Setting scope– Concurrent task analysis– Smart recording

DRH, 05/09/03, Slide 17

• Continue assessment programme:– Incorporate into design process– Roll-out to remaining production areas

• Development of best practice document– Continue Technology Transfer to other Ciba Specialty

Chemicals EHS professionals

• Link to other business initiatives e.g. quality

Way forward…