Total Quality Safety Management and Auditing

Total Quality Management (TQM) is a business philosophy that yields customer satisfaction and continuous process improvement. This new reference and workbook embraces the TQM revolution and explains to readers how TQM principles are applied to safety and health programs. The text also focuses on the ISO-9000 Quality Program, Voluntary Protection Program, and Process Safety Management. For each of these topics, the key principles are identified and described, and the quality principles are adapted to safety.

Chapter 1 Total Quality Safety Management

1

(18)

I. Introduction

1

(1)

II. Safety Management

1

(1)

III. Safety Performance

2

(1)

IV. Traditional Safety Programs

3

(1)

V. The Modern Safety Management Solution

4

(1)

VI. The Basic Total Quality Management Concepts, Techniques, and Implementation Requirements

5

(4)

VII. The ISO-9000 Standards

9

(1)

VIII. The OSHA Voluntary Protection Program

10

(2)

IX. Process Safety Management

12

(1)

X. Other Frameworks for Safety Management

13

(1)

XI. Notes on Using This Book

14

(2)

XII. References

16

(3)

Chapter 2 Total Quality Management - Adapted to Occupational Safety

19

(52)

I. Product and Customer Focus

20

(1)

II. Leadership Commitment

21

(2)

III. Company Culture

23

(2)

IV. Effective Communication

25

(1)

V. Organizational and Employee Knowledge

26

(2)

VI. Employee Empowerment

28

(2)

VII. Employee Responsibility and Excellence

30

(1)

VIII. Management by Fact

31

(3)

IX. Long-Range Viewpoint

34

(1)

X. Statistical Process Control

35

(4)

XI. Structural Problem Solving

39

(3)

XII. The Best Techniques

42

(3)

XIII. Continuous Improvement

45

(1)

XIV. Quality Management

46

(1)

XV. Quality Planning

47

(2)

XVI. Assessment and Planning

49

(2)

XVII. Implementation and Organization

51

(2)

XVIII. Cultural Change

53

(1)

XIX. Recognition and Reward

54

(2)

XX. Leadership Development

56

(3)

XXI. Team Building

59

(2)

XXII. Hiring and Promoting

61

(1)

XXIII. Management Readiness

62

(2)

XXIV. Total Quality Training

64

(2)

XXV. Summary - TQM Safety System Evaluation

66

(1)

XXVI. References

67

(4)

Chapter 3 ISO-9000 Requirements

71

(38)

I. Management Responsibility

72

(2)

II. Safety Management System

74

(2)

III. Contract Review

76

(1)

IV. Design Control

77

(3)

V. Document and Data Control

80

(1)

VI. Purchasing

81

(1)

VII. Customer-Supplied Product

82

(1)

VIII. Product Identification and Traceability

83

(2)

IX. Process Control

85

(1)

X. Inspection and Testing

86

(3)

XI. Control of Inspection, Measurement, and Test Equipment

89

(2)

XII. Inspection and Test Status

91

(1)

XIII. Control of Nonconforming Product

92

(2)

XIV. Corrective and Preventive Action

94

(1)

XV. Handling, Storage, Packaging, Preservation, and Delivery

95

(1)

XVI. Control of Quality Records

96

(2)

XVII. Internal Quality Audits

98

(1)

XVIII. Quality Training

99

(3)

XIX. Servicing

102

(1)

XX. Statistical Techniques

103

(2)

XXI. Summary - ISO Evaluation

105

(1)

XXII. References

106

(3)

Chapter 4 Voluntary Protection Program

109

(32)

I. Safety Management Program

111

(1)

II. Safety Policy and Objectives

112

(1)

III. Management Commitment and Involvement

113

(2)

IV. Employee Participation

115

(1)

V. Assigned Responsibilities and Accountabilities

116

(2)

VI. Contract Workers

118

(1)

VII. Program Review

119

(1)

VIII. Work-site Hazards Analysis

120

(2)

IX. Baseline Surveys

122

(1)

X. Site Inspections

123

(1)

XI. Hazard Prevention and Control

124

(1)

XII. Procedures and Protective Equipment

125

(2)

XIII. Facility and Equipment Maintenance

127

(1)

XIV. Hazard and Program Communications

128

(1)

XV. Accident and Injury Analysis

129

(1)

XVI. Emergency Planning

130

(2)

XVII. Medical Program

132

(1)

XVIII. Safety and Health Training

133

(1)

XIX. Safety and Health Training Content

134

(2)

XX. Supervisor and Manager Readiness

136

(2)

XXI. Summary - Voluntary Protection Program Evaluation

138

(1)

XXII. References

139

(2)

Chapter 5 Process Safety Management Guidelines

141

(40)

I. General Process Safety Guidelines

143

(1)

II. Employee Involvement

144

(1)

III. Process Safety Information

145

(3)

IV. Process Hazards Analysis

148

(5)

V. Operating Procedures and Practices

153

(3)

VI. Employee Training

156

(2)

VII. Contractors

158

(3)

VIII. Pre-Startup Safety

161

(1)

IX. Mechanical Integrity

162

(4)

X. Nonroutine Work Authorizations

166

(1)

XI. Managing Change

167

(4)

XII. Incident Investigations

171

(1)

XIII. Emergency Preparedness

172

(4)

XIV. Compliance Audits

176

(3)

XV. Summary - Process Safety Management Evaluation

179

(1)

XVI. References

180

(1)

Appendix A Behavior-Based Safety

181

(10)

I. Discussion

181

(2)

II. TQM Assessment Questions Modified to Include Behavior-Based Safety

183

(7)

III. References

190

(1)

Appendix B Auditing

191

(16)

I. Audit Definition and Purpose

191

(1)

II. Audit Conduct

191

(3)

III. Auditor Qualifications and Characteristics

194

(1)

IV. The Advanced Audit Process

194

(5)

V. Interviewing

199

(2)

VI. Developing Findings and Conclusions

201

(1)

VII. Developing Recommendations

202

(3)

VIII. Exit Interviews

205

(1)

IX. References

206

(1)

Index

207

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Total Quality Safety Management and Auditing

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Table of Contents

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