Hazard Identification, Signs and Markings: UC RUSAL Experience

From Control to Prevention: A Systematic Approach to Hazard Visualization

Creating safe working conditions begins with what an employee sees upon arriving at the workplace. If hazards are not marked and rules exist only on paper, a culture is formed where safety is perceived as a mere formality. Ilya Pakhaluev, Head of the HSE Department at Ural Foil JSC (UC RUSAL), shares his experience in developing and implementing a comprehensive hazard visualization program, which has become an important step towards proactive risk management.

The presentation details the process of transitioning from a reactive model to systematic injury prevention. Using his enterprise as an example, the speaker demonstrates how a unified visualization standard helps not only to reduce risks but also to change personnel's attitude towards their own safety.

Unified Visualization Standard: Signs, Markings, and Alarms

The foundation of the program is a corporate standard that defines uniform rules for hazard identification. The speaker breaks down the key elements of this system:

• Group safety signs: Placed at the entrances to workshops and hazardous areas. A strict top-to-bottom layout rule applies: prohibition (red), warning (yellow), and mandatory (blue) signs. Mandatory PPE signs are arranged logically: from head protection down to foot protection. This simplifies the perception and memorization of requirements.
• Signal markings: A unified color code has been implemented. Yellow-and-black markings indicate permanent hazards, red-and-white indicate temporary ones, and green lines highlight safe walking paths. This approach eliminates misinterpretation and builds strong habits among personnel.
• Light and sound alarms: Used where signs alone are insufficient. The speaker provides an example of using flashing beacons (light markers) on presses and transfer carts. In noisy workshops, the emphasis is on light alarms; in dusty ones, on sound alarms; and in particularly hazardous areas, they are combined.
• Fencing system: The standard classifies fences into permanent, sliding, removable, and portable. All of them are painted yellow, which visually links them to permanent hazards and makes the system intuitive.

From Audit to Implementation: The Rollout Algorithm

The program is implemented in three stages: hazard identification, solution preparation, and practical execution. A permanent working group plays a key role in this process.

The group must include the head of the department, as they know the specifics of their area best. The team conducts targeted inspections with mandatory photo and video recording of hazardous zones both outdoors and indoors. Based on these data, specific solutions are developed: which signs to install, where to apply markings, and what PPE to use. The project becomes a flexible document that is adjusted during implementation to achieve maximum efficiency.

Overcoming Resistance and the Role of the Leader

Implementing any changes comes with challenges. The speaker notes that the main problem is not technical execution, but the engagement of managers and personnel.

If a manager does not demonstrate leadership in safety matters and fails to comply with marking and PPE requirements, workers will also ignore the new rules. To change behavior, behavioral audits and a progressive motivation system are used, starting with explanatory conversations. The goal is not to punish, but to achieve conscious compliance with the rules, elevating safety to the level of each employee's personal values.

What you will learn from this webinar:

• How to develop and implement a unified hazard visualization standard at an enterprise?
• What types of alarms are effective in high noise and dust conditions?
• How to properly arrange group safety signs for better perception?
• How to engage department heads in the process of identifying and eliminating risks?
• What tools help change personnel's attitude towards compliance with safety rules?