Reprinted with permission from Facility
Safety Management
We all know how important a safe and productive workplace
environment is. But did you know that you could increase
productivity, streamline processes and improve safety compliance
through proper facility identification? And, a properly
marked facility has better return on investment, positively
affecting your bottom line.
Having critical information at the point of need, when
you need it most, helps you reduce operating errors and
accidents, minimize unscheduled downtime, eliminate confusion
and increase safety, increase employee knowledge and confidence,
and reduce wasted search time.
Proper facility identification puts
important information about a potential hazard exactly where
it's needed, and all employees have the information
communicated to them through a combination of words, symbols,
diagrams and pictures.
Marking a plant is not just a matter of personal preference.
There are a host of standards developed by the American
National Standards Institute (ANSI) and Occupational Safety
and Health Administration (OSHA). The Visually Instructive
Plant takes these standards and applies them in a coordinated
way to improve safety and productivity.
The
Visually Instructive Plant clearly and simply identifies
resources, processes and potential hazards. The result
is a safer, more efficient, more profitable facility. How
a plant is marked makes a difference. For example, a study
by the Electric Power Research Institute (EPRI) concluded
that 54 percent of errors in the utility industry were the
result of inadequate or missing labeling or signage.
Creating a Visually Instructive Plant means more than just
putting labels on pipes, valves and equipment. It is a way
of documenting and communicating your processes. Processes
such as escape routes, preventative maintenance procedures
and schedules, access restrictions, hazard alerts or general
directions.
The first step toward creating this environment
is to conduct a facility assessment. This requires
a complete evaluation of your plant, assessing what steps
need to be taken to comply with code and safety regulations,
and to increase plant productivity. This step includes
comprehensive data collection along with a strong knowledge
of safety codes and standards.
Once your assessment is complete, the result will be a
complete identification program to be implemented according
to the standards you established at the outset of the
assessment. These standards must also be incorporated into
all company training programs and materials.
For example, you might require that all pipes be marked
at certain intervals with the material they carry and direction
of flow. Perhaps you specify that valves in certain parts
of the plant can only be shut off with supervisor approval.
Tags, labels and signs must be formatted in a consistent
fashion, such as directional arrows and pictograms be listed
below the primary legend on piping labels. Whatever
standards you develop must be universally applied.
We understand that "DANGER" means we need to
take some precautions. But symbols are just as important
as words. We get bombarded with so many printed messages
that they are easy to overlook or misinterpret. The Visually
Instructive Plant also makes use of symbols. It might be
a simple arrow indicating the direction water is flowing
through a pipe, or pictograms detailing the hazard level
for certain materials. Symbols clearly and consistently
employed can be a very effective way to communicate.
Creation of a Visually Instructive
Plant will vary depending upon the needs of your particular
facility. However, there are a number of areas that
require attention in almost every plant:
Safety signs: Whether restricting access, alerting
employees to hazards or providing direction, safety signs
are a critical component in a Visually Instructive Plant.
Electrical equipment: This is a key area because
the potential for injury and death is so great. All electrical
equipment must be clearly marked in accordance with
ANSI and OSHA standards.
Valves and equipment: Unmarked or inadequately marked
valves and equipment are a big problem in many facilities.
A simple tag can include a wealth of information, including
exactly what is being shut down or activated, the PID number,
and bar codes to assist with Asset Management.
Piping: The maze of piping found at many facilities
can be confusing. Proper marking can help employees sort
out pipelines at a glance.
Process control: This could include marking for
preventive maintenance, supervisory approval requirements,
anything related to plant process management.
Tank and vessels: The contents may be harmless,
or may hold hazardous materials. They must be clearly marked
with the required hazardous material information. Confined
Space Warning signs should be placed at the point-of-entry.
Comprehensive sign systems: More complex processes
-- such as a plant evacuation procedure - need to be
clearly communicated through a combination of words,
symbols, diagrams and pictures.
Creating a Visually Instructive Plant
means more than just putting labels on pipes, valves and
equipment. It is a way of documenting and communicating
your processes so that you can reap the benefits of a safer,
more efficient and productive plant.
There are many benefits of the Visually Instructive
Plant. Not only will you realize an increase in safety
compliance, efficiency and productivity, but you should
also see reduced maintenance costs, errors and downtime.
These benefits have a direct impact on overall profitability.
One other important benefit: your facility will look better.
A more orderly plant encourages your employees to be more
organized and productive. Your plant will also look that
much more impressive to customers and other stake holders.
Learn more about Label Printers
for creating a visually instructive plant
