Development of an Electronic Risk Register through the Improvement of HSE Tools

Evolution of Digital Tools: From Disconnected Apps to a Unified Database

The drive of large industrial enterprises towards zero injuries requires the most accurate recording and processing of hazardous conditions in the workplace. However, large-scale digitalization brings a new problem: an overabundance of unsynchronized IT solutions. In his presentation, Dmitry Chetvertkov, Leading Specialist of the HSE Department at PJSC MMK, analyzes a practical case of transforming disconnected mobile and desktop applications into a unified electronic risk register.

Historically, the enterprise implemented various tools for different categories of employees: "Safety Navigator" for shop managers, "Shift Handover" workstation for workers and foremen, and "Shop Assessment" workstation for monitoring specialists. Despite the convenience of mobile access and photo recording, the autonomous operation of these systems led to massive data duplication. The same violation (e.g., an oil spill) could be recorded by a worker in the morning, a site manager in the afternoon, and an auditor during an inspection. This distorted statistics and overloaded line managers with unnecessary bureaucracy.

Unified Module and Root Cause Analysis

To solve the duplication problem, an integrated module was developed that combined data flows from all systems. The speaker details how consolidating information not only cleared the database of duplicates but also freed up a significant amount of working time. Eliminating nearly 400 duplicate records per month saves foremen up to 19 hours, which they can direct towards actual safety control on the production floor.

However, simply recording and eliminating the consequences does not reduce the risk level in the long term. If workers just wipe up spilled oil, the incident will recur. Therefore, a key stage in the system's development was the implementation of the "Root Causes" functionality. Now the system requires assigning and monitoring measures aimed at the source of the problem (e.g., replacing a worn bearing), with strict deadline tracking and a multi-level push notification system for managers.

Integration with Uniform Standard Norms: Automatic PPE Selection Based on Risks

Special attention in the report is given to a pilot project integrating the electronic risk register with the personal protective equipment (PPE) provision system. In accordance with the requirements of the Ministry of Labor Order No. 766n, the issuance of PPE must be based on the results of occupational risk assessments.

The speaker describes the algorithm of the new module: after workers note hazards at their workplaces via a mobile app and the responsible manager verifies them, the data goes to a PPE specialist. The system automatically analyzes the confirmed risks and, in addition to the basic set according to the Uniform Standard Norms, suggests additional protective equipment. For example, if a risk of chemical corneal burn is identified, the algorithm automatically adds closed-type safety goggles to the requirements.

Data Moderation and Personnel Engagement

An open system for reporting hazards often faces the problem of information noise, where workers massively record minor everyday flaws. To maintain data quality in the register, a two-level moderation system has been implemented. The immediate supervisor (foreman) checks the accuracy of the description and photographic materials before sending them to the general database, and the person responsible for the unit has the right to combine similar minor violations into one comprehensive measure. This allows maintaining focus on truly critical occupational risks.

What you will learn from this webinar:

• How to combine data from different HSE applications into a single database and eliminate duplication of violations?
• How does the "Root Causes" functionality help combat recurring hazardous conditions?
• How much of a line manager's working time is saved by automatic duplicate filtering in the IT system?
• How to set up automatic selection of additional PPE according to Uniform Standard Norms based on identified occupational risks?
• Who should moderate the flow of hazard reports from line personnel and by what criteria?