A Simple Way to do Risk Assessments

Recently I’ve done dozens of Task Based Risk Assessments (TaBRA) for clients, and the experience always reinforces for me the importance of worker input and the relative speed in which an assessment can be performed.

My approach, which embraces lean thinking to gain the perspective of the worker, is much more detailed than a job safety analysis.

For example, one JSA had 11 total operator steps, with one being for clearing a jam. Risk assessment from the perspective of the worker began with, “I’m your kid… What part of your job has the greatest risk of injury?” It was clearing jams. While this task was one step in JSA, TaBRA showed 18 steps with 22 task hazard pairs for clearing jams – and one of the steps had a very high risk of a fall. That hazard was overlooked because JSA does not get into the detail that TaBRA does.

Now, you can’t do TaBRA for every job – it would be overwhelming. It is a tool to help answer questions, whether for minor servicing vs. LOTO or to answer if you need more guarding. The first level of risk assessment comes from the worker.

After introducing myself and what we wish to do, I ask, “If I were a close friend or relative, what element of your job poses the greatest risk of me being injured?” It doesn’t take long for the worker to identify the specific task element. We then walk through every step, including those like “place the machine in manual.” There is no discussion of hazards or risk until the worker has gone through all steps of the task. It is evident that workers get into a rhythm of doing familiar work. . Discussion about variables because of changes in product, machine malfunction, etc., identify possible concerns that a JSA is not designed to pick up.

The TaBRAs showed that most hazards were not from machine motion. They were the slips, trips, fall, strains, struck by a hand tool, etc. and typical of injuries borne out by the OSHA recordable cases where engineering safeguards do not apply. As I put together a presentation on the lower of controls using lean thinking for standardized work (instructions, visual controls, pictures at the point where work is done), I pondered this question:

Since workers typically train other new workers why not forgo doing JSA and just ask the worker(s) what they need to assist in their training efforts. Again, it’s not just posting words or lengthy procedures. The question for an experienced worker might be, “I am a new kid on this job. What would help you to train me to do the job flawlessly and safely?”

Workers know their job better than anyone. They know the hazards and risks and the safe way to work and what is useful to train others. Why not get their perspective?