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1、WORLDCLASSMANUFACTURINGPLANTAUDIT&EVALUATIONGUIDE1Dr.HajimeYamashinaProfessorEmeritus,KyotoUniversityMemberofRSAMemberofRoyalSwedishAcademyofEngineeringSciencesNewAuditGuideSeptember,20092Thescoreisdeterminedbythislevelasinthecasewherecustomersseeourquality.Step66610TechnicalPillar
2、sStep710ManagerialissuesFinalTargetStepStep444Step3Step2Step13Step5Step2Countermeasures(ListingallandhorizontalexpansionassessmentStep61.Safety(plant-wide)Step7FullyimplementedsafetymanagementManagementinitiatedSelf-initiated4Analysisofaccidents(Analysisofcauses)Step1Step3Settingte
3、ntativestandardsforsafetysafetyproblems)(CountermeasuresRiskatthesimilarareas)Step4Generalinspectionforsafety(Trainandgrowpeopleinsuchawaythattheycareforsafety)Step5Autonomousinspection(Predictivecountermeasuresagainstsafetyproblems)ReactivePreventiveProactiveAutonomoussafetystanda
4、rds(*Overallinspectionofsafetylevels*Reevaluationifsafetycontrol)TeaminitiatedStepCountermeasuresReactive1AccidentanalysisandcountermeasuresIncidentanalysisandcountermeasuresPreventive2-5HorizontalexpansionofcountermeasuresVisualdemonstration(simulation,video,etc.)ofaccidentstoaler
5、tpeopleaboutsafety,CompliancewiththesafetylegalregulationsSafetyriskassessment*ManagementSMAT,SafetyauditRootcauseanalysisofincidentswithspecialemphasisonnearmissesandunsafeactsSelf-initiatedsafetyactivitiesProactive6-7TeaminitiatedsafetyactivitiesSystemtomakepeoplenotabletomakemis
6、takes5Safety(Reactive)1.5G6Heinrichpyramid6.S-Matrix7.Managementinitiatedsafety2.5W+1H,5Why10.Emergencyplan3.7WCMtools9.Basicsafetystandards4.Knowledge8.SafetyStep15.TheprincipleofSafety(Reactive)1.5G2.5W+1H,5Why3.7WCMtools4.Knowledgeofallsafetylegalrequirementsandcompanystandardsa
7、ndcomplianceanalysis5.TheprincipleofHeinrichpyramid6.S–matrix77.Managementinitiatedsafetyactivities8.Safetystep1:Accidentanalysis*,safetyRCAofinjuryincidentsandtheircountermeasures9.Basicsafetystandardsforpedestrianization,controlofvehicles,workatheight,machinerysafetyguarding,etc.
8、10.Emergencyplanandfacilit
