Here is an hopefully almost complete explanation of the Safety Plan on Jobplan/Workorder in Maximo. This sub-module was designed for a steel-maker by 1999 (for Maximo 4, yes it hurts).

Vocabulary

• Work Order: intervention of Technician on Asset.
• Safety: Safety of Technicians when they intervene on Assets.
• Hazards: Hazards endanger the safety of workers when they intervene. There are three categories of hazards:
  •          Non-eliminable hazards
  •          Eliminable hazards
  •         Hazardous material
• Precautions. Used to reduce non-eliminable hazards.
• Tagout Procedures. Used to eliminate eliminable hazards.
• Work Asset: Asset on which technicians will intervene.
• Related Asset: Asset that are functionally related to the Work Asset. They induce hazards.
• Assets to be Locked Out: very optional, Asset to be locked/unlocked during Tagout procedure.

Limitations

Managing eliminable hazards largely involves identifying Asset that is either in proximity to or functionally related to a given piece of Asset (e.g., electrical supply) and therefore induces Hazards on the given Asset. Since these pieces of Asset pose hazards when intervening on a given piece of Asset, they need to be locked/unlocked. These pieces of Asset are called "Related Assets" (related in terms of induced safety hazards).

This implies that all these assets are static and do not move relative to each other. For components that are subject to removal/installation, it is not possible to dynamically determine the hazards induced by the related assets (unless the related assets are manually redefined after each removal/installation that requires cumbersome manual keying in).

However, for “movable” Assets this data are still relevant:

• Non-eliminable hazards and their generic precautions (e.g., wearing gloves, helmets, etc.).
• Eliminable hazards where the Tagout procedure concerns the Asset itself only (work asset = hazard-generating asset).

Ad-hoc Hazards Management

The first mode of Hazard Management in "IBM Maximo Manage" is to enter hazards only at the level of Asset where technicians will work, also known as “Work Asset”. These data are entered in the “Safety” tab.

• Non-eliminable hazards (with precautions): enter here all possible non-eliminable hazards (all potential non-eliminable hazards induced by all possible ways to intervene on the Asset) and enter the precaution to follow.

• Eliminable hazards with their relevant Tagouts procedures :

-       First:

§  Enter known Tagout procedures on the Work Asset itself for eliminating hazards induced by the work asset itself. Make sure you have at least one Tagout procedure for each future Hazard to eliminate.

§  Enter known Tagout procedures on Related Assets for eliminating hazard induced by those related asset (individually). Make sure you have at least one Tagout procedure for each future Hazard to eliminate.

-       Second:

§  On the Work Asset, enter all possible eliminable hazards (all potential hazards induced by all possible ways to intervene on this asset) and enter all possible Tagout procedures to apply for each of them. 

• Related Assets and Locations (induced hazards by others Asset): 

o   If a Work Asset might be a risk for others Work Assets, enter it in the “Safety Related Asset” sub tab on those others Work Assets.

o   Hint: always note the Work Asset as Related Asset (self relation)

• Once this is done, from any Work Order, it becomes possible to view all Hazards associated with these Related Asset and potentially copy them to the Work Order (action "Select Safety Hazard", button "Apply to Work Order"):

Limitation: This mode of management is not functional for Tagout procedures. To overcome this limitation, switch to the second mode: the "Safety Plan" (see the next chapter).

Management Hazards through Safety Plan

The second mode of Hazard Management in "IBM Maximo Manage" involves using a "Safety Plan". Note that this second mode is not independent of the first mode; it is complementary: the hazards in the safety plan must first be fully and exhaustively identified on the Asset where technicians will work (the “Work Asset”). This second mode is therefore an improvement of the first mode for the following reasons:

• It allows selection of some associated Hazards to the Work Asset.
• It allows selection of some associated Tagout procedures associated to the Hazards of the Work Asset.
• It will copy the Tagout procedures to the future Work Orders.

The idea behind the “Safety plan” concept is that’s a contextual “Response plan” relevant for a specific context: an Asset plus a type of Work.

List of Work Assets for which this Safety plan is applicable:

Non eliminable Hazards: select any important non-eliminable Hazards to consider

Eliminable Hazards:

o   Enter all the combinations of “Related Asset + one of its Hazard” to be eliminated.

o   Existing Tagout Procedures are copied.

o   You may delete some useless Tagout procedures.

That’s it. After you may select a Safety plan on Work Orders. Maximo enables three ways of searching:

o   Among all Safety plans

o   Among Safety plans applicable on the Work Asset

o   Among Safety plans applicable on the Work Asset AND on the selected Job-plan (this topic is explained in the next chapter). 

Management Hazards through Job Plan

The third mode of Hazard Management in "IBM Maximo Manage" complements the second mode (and still the first mode): it involves specifying for each Job-Plan which “Safety Plan” to apply (automatically) on a new work order. It completely automates the application of Hazards on a new work order.

The screen to be filled out is as follows:

In this case, any work order targeting one of the pairs identified here will automatically get the given Safety Plan. It is also possible to define the pairs at the levels of a Location or a Rotating Item, but lockout/tagout procedures are rarely relevant at these levels (they are rarely generic, most often they are specific to each asset). These definition levels are, however, very relevant for Safety Plans that would only include non-eliminable hazards (with precaution).

Use case (example)

Let's say that working on pump X12 involves two hazards:

·       Hazard of injury caused by the pump X12 itself

·       Hazard of projection caused by its supply circuit A45.

Identification of objects

In this case, we have:

·       A Work Asset: Pump X12

·       Two pairs "Related Asset + Hazard":

·       Pump X12 + Hazard of injury

·       Supply circuit A45 + Hazard of projection

·       Two « Tagout » procedures:

·       One to address the pair Pump X12 + Hazard of injury

·       One to address the pair Supply circuit A45 + Hazard of projection.

Data to key-in

·       Create two “Tagout” procedures (Tag Out application):

·       One that will eliminate the hazard of injury from asset X12, let's call it TagX12.

·       One that will eliminate the hazard of projection from asset A45, let's call it TagA45.

Note: In the 'Lockouts' table, the asset is optional, you can leave the TAGLOCK.ASSETNUM attribute blank.

·       For each “related” asset, specify its individual hazards and the relevant “Tagout” procedure previously mentioned:

·       Asset Pump X12 :

·       Hazard of injury.

§  Tagout procedure TagX12

·       Asset Supply circuit A45 :

·       Hazard of projection

§  Tagout procedure TagA45

·       Create a Safety Plan :

·       Work Asset : Pump X12

·       Related Assets and their Hazards:

·       Pair Hazard of injury + Related Asset X12.

·       Pair Hazard of projection + Related Asset A45.

That's all good !

When applying the Safety Plan to a Work Order associated to Pump X12, the system will:

·       Apply the 2 pairs "Hazard + Related Asset" from the Safety Plan

·       And for each pair, apply the “Tagout” procedure (of that pair).

End.