The Visually Instructive Plant Signs and Labels for a Safe Workplace
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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.
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