Maintenance operations play a critical role in ensuring the reliability and functionality of industrial equipment and facilities. However, these tasks have inherent risks that can pose significant safety hazards to personnel. Prioritising safety is paramount to protecting workers and preventing accidents in maintenance operations. In this article, we explore lessons learned and best practices for enhancing safety, drawing from real-world experiences and industry expertise.
Lesson 1:
A comprehensive risk assessment is essential to identify potential hazards and develop appropriate mitigation strategies. Experience and lessons learned provide control strategies from past incidents that underscore the importance of considering a range of factors. Factors include equipment complexity, environmental conditions, and the presence of hazardous materials. By systematically evaluating risks and implementing controls, maintenance teams can minimise the likelihood of accidents and ensure the safety of personnel.
Best Practice: Implement a formal risk assessment process that is inclusive of all stakeholders, including operations and maintenance personnel, supervisors, and safety professionals. Use tools such as Job Safety Analysis (JSA) or SWMSs (Safe Work Method Statements) to systematically identify, assess, control and review risks.
Lesson 2:
Investing in effective training and competency development is essential. It equips maintenance personnel with the knowledge, skills, and competencies needed to perform tasks safely. Incidents often highlight gaps in training or inadequate understanding of procedures. This underscores the importance of ongoing education and skill development.
Best Practice: Develop tailored training programs that address specific hazards and risks associated with maintenance tasks. This includes working at heights, electrical safety, confined space entry, and hazardous materials handling. Provide hands-on training, simulations, and refresher courses to reinforce learning and ensure competency among maintenance personnel.
Lesson 3:
Clear Communication and Coordination are critical. Learnings from incidents emphasise the importance of clear communication channels, role clarity, and coordination between maintenance teams and stakeholders.
Best Practice: Establish clear communication protocols and procedures for coordinating maintenance activities, including pre-task briefings, work permits, and shift handovers. Foster a culture of open communication where each worker feels empowered to raise safety concerns, report near misses, and collaborate on problem-solving. Use digital communication tools and job tracking systems to streamline communication and ensure real-time updates.
Lesson 4:
Regular equipment inspections are essential for minimising equipment failures and safety risks in maintenance. Lessons learned from incidents often highlight the consequences of neglected equipment, underscoring the importance of proactive maintenance.
Best Practice: Implement a robust equipment inspection program that includes routine inspections and preventive maintenance, including calibration checks. Conduct regular audits to ensure compliance with maintenance schedules.
Lesson 5:
Continuous Learning and Improvement from incidents provide valuable insights. This delivers opportunities for review, identifying areas for improvement and implementing corrective actions.
Best Practice: Establish a culture of continuous learning and improvement by conducting post-incident reviews, safety audits, and performance evaluations. Encourage participation in safety committees, toolbox talks, and safety observation programs to promote active engagement and knowledge sharing. Implement a feedback loop to capture lessons learned from incidents and near misses and incorporate them into training programs and safety protocols.
Enhancing safety practices requires a proactive and multifaceted approach that encompasses various tasks. This includes risk assessment, training and competency development, communication and coordination, equipment inspection and maintenance, resulting in continuous learning and improvement. By applying learnings from past incidents and adopting best practices, organisations can create a culture of safety that prioritises the well-being of personnel and fosters a safe and productive work environment.
To learn more about services and support at Triple i, or to speak to someone today, visit our website at www.triplei.com.au/service-support/.
About Triple i
Triple i delivers outcomes for all your control, data, electrical, instrument, and mechanical needs with over thirty-five years of experience. We supply a range of technology-based projects, consultancy, maintenance, and support services in the industrial sector. With over eighty skilled employees, Triple i provides the best product and services, with integrated solutions designed for client needs.