Managing Occupational Injury Risks at Various Stages, from Design to Implementation

Evolution of Safety Culture: From Theory to Practice

The development of a safety culture in modern enterprises is not just about complying with regulatory requirements, but a deep transformation of risk management approaches. As production processes become more complex and new technologies are introduced, traditional control methods often prove insufficient. Today, the focus is shifting to proactive hazard identification and the integration of risk assessment at all stages of the project lifecycle — from the initial concept to actual implementation on site.

In his presentation, Andrey Sukhinin, Head of Industrial Safety and Occupational Health at ERG Capital Projects, analyzes the practical aspects of risk management in detail. Drawing on years of experience in major international projects, the speaker demonstrates how a systematic approach to hazard identification not only reduces the level of occupational injuries but also improves the overall efficiency of work processes.

Four Levels of Risk Assessment: A Systematic Approach

Effective risk management requires a multi-level system where each stage complements the previous one, creating reliable protection against potential incidents. The speaker highlights four key levels of risk assessment, each with its specific goals and tools.

Level 1: Baseline Assessment of Significant Risks

This stage lays the safety foundation for the entire project. It is primarily implemented at the design stage, when there is an opportunity to make fundamental changes to technological solutions.

• Identification of energy sources: Identifying all potentially hazardous types of energy (mechanical, electrical, kinetic, etc.) allows for the early development of measures for their isolation or control.
• Designing barriers: Implementing engineering solutions, such as protective guards or automatic shutdown systems, minimizes the likelihood of human contact with the hazard source.
• Assessment of existing measures: A critical analysis of the effectiveness of currently applied control measures helps identify weaknesses and develop additional protective barriers.

Level 2: Risk Assessment of Projects and Changes

Any changes in a project or production process inevitably lead to the emergence of new risks or a change in the level of existing ones. This level is aimed at the timely identification and management of such risks.

• Modification analysis: Equipment replacement, changes in technology or working conditions require a reassessment of risks to ensure the relevance of control measures.
• Change management: A systematic approach to assessing the impact of any innovations on safety helps prevent unforeseen consequences.

Level 3: Risk Assessment of Planned and Unplanned Work Tasks

This level focuses on the direct execution of work and requires the active involvement of line managers and engineering and technical personnel.

• Job Safety Analysis (JSA): A detailed breakdown of the work task into stages, identifying hazards at each of them and developing specific control measures.
• Simultaneous Operations Management (SIMOPS): Using a simultaneous operations matrix to prevent conflicts and ensure safety when performing various operations on the same site at the same time.
• The Socratic Method: Applying critical thinking and asking the question "What happens if something goes wrong?" helps identify hidden risks and develop more reliable solutions.

Level 4: Individual Risk Assessment

The most important and frequently applied level, which should become an integral part of every employee's daily work.

• "Stop, Think, Act" (STA) methodology: Forming the habit of conducting a quick assessment of the situation before starting any work or after a break.
• Conscious safety: Involving every worker in the risk management process, understanding personal responsibility for their own safety and the safety of their colleagues.

The Role of the HSE Specialist in the Modern System

The presentation details the role of the HSE engineer. The speaker emphasizes that the HSE specialist should not be the only one responsible for safety at the enterprise. Their main task is to act as a methodologist, mentor, and facilitator, helping production personnel master risk assessment tools and integrate them into their daily activities. A true safety culture is formed only when every employee, from the worker to top management, understands their role in preventing incidents.

What You Will Learn from This Webinar:

• How to correctly identify hazard sources at various stages of project implementation?
• What is the hierarchy of controls and how to choose the most effective protective measures?
• How to apply the simultaneous operations matrix (SIMOPS) for the safe management of contractors?
• Why the Socratic method is a powerful tool when assessing the risks of non-standard work?
• How to form the habit among employees of conducting an individual risk assessment before starting work?