Safe_Design_Manufacture_Import_and_Supply_of_Plant.doc

Actions and prevent operator errors ensuring plant

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actions and prevent operator errors ensuring plant design is fail safe at least to the level of reliability/safety integrity level as determined by the plant risk assessment layout of the work stations, for example, the position of the worker in relation to plant controls instrumentation required at each work station or cabin, and the layout of this instrumentation the specific devices, tools or controls the operator and support people will need to perform their jobs safely the options available to enable quick recovery or to maintain the safety and integrity of the system in the event of operator error or plant failure and the means available to access the operator in the event that assistance is required environmental conditions that will tend to impair operator performance, for example, long periods where the operator engages in physical or repetitive activity or inactivity in a hot or cold environment separation of persons, including the operator, from entrapment as a result of plant operation i.e. being caught between the plant and other objects in operation. You should also take into account predictable human behaviour and never presume those who use or maintain plant have a full or continuous appreciation of essential safety features. Where there is a likelihood of operator error, higher order control measures should be incorporated into the design. For example: A driver used a tractor to haul a hydraulically operated tilt-up trailer loaded with grain. The gear lever of the tractor was positioned close to the control lever which operated the tip-up SAFE WORK AUSTRALIA MEMBERS’ MEETING 6 30 SEPTEMBER 2010 PAGE 23 OF 52
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mechanism of the trailer. While underway, the driver’s arm moved the control lever slightly so the trailer tray began to lift. The trailer rose and eventually overturned. 4.3 Reasonably foreseeable misuse Sometimes plant may be used for applications other than those for which it was designed and originally intended, for example where an excavator is used to lift and transport concrete pipes. When designing plant the risk of reasonably foreseeable misuse should be assessed and appropriate control measures incorporated in the design. 4.4 Minimising human error Human or worker error is not always the result of carelessness or negligence. The desire for extra speed, increased production and making tasks easier are some of the main reasons why guards are bypassed or removed. Workers may also use unsafe practices to overcome poor plant design or become bored and distracted with repetitious work, which may cause loss of concentration. In designing plant, designers should be aware of the factors contributing to human error, including: forgetfulness workers’ diligence to ‘get the job done’ or to ‘find a better way’ capacity to understand information ergonomics psychological or cultural environment habit fatigue level of training.
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