Occupational risk analysis method in maintenance

Occupational health and safety is a major issue for businesses. The human and economic impact of workplace accidents and occupational diseases is considerable, and managing these risks is a priority for employers, who are required to take the necessary measures to continuously reduce the likelihood of their occurrence.

Maintenance workers who work on equipment and systems are particularly at risk. They are exposed to multiple hazards, such as the presence of energy sources, harmful substances, harsh environments (noise, heat, cold, humidity, vibrations, etc.), and arduous and dangerous working conditions (uncomfortable positions, confined spaces, working at heights, stress, etc.), and studies conducted by various organizations in France and Europe all show that the incidence of serious, even fatal, accidents in these professions is significantly higher than average. In fact, accident and occupational disease rates in maintenance activities are very comparable to those in the construction and public works sectors, which are unfortunately known for having very high rates.

The analysis of the risks faced by individuals performing maintenance activities—and more specifically, preventive and corrective tasks carried out on assets (industrial, consumer goods, buildings, and infrastructure)—is based on an approach that takes into account:

• human and organizational aspects involved in the structure established to define a strategy, assign responsibilities, coordinate actions, facilitate communication, provide training, manage concurrent activities, etc.; 

• technical aspects related to the maintenance tasks to be performed, the locations where they are carried out, and the equipment and systems to be maintained.

This article focuses on this second aspect, given that best practices regarding work organization—which are essential for risk management—are detailed in numerous documents, particularly those from organizations responsible for occupational health and safety, which can be consulted.

The article proposes a generic method for identifying hazards, assessing risks, and determining defense barriers. It is based on the following actions and developments:

• a classification of hazards into five distinct categories, structured and as comprehensive as possible;

• the introduction of a hazard severity scale that accounts for uncertainties regarding the consequences of hazardous events, thereby facilitating comparisons between hazards of different types;

• risk prioritization based on a combination of the severity, vulnerability, and frequency of the hazardous situation, as well as the uncertainty regarding that frequency;

• the identification of risk control measures based on a classification of defense barriers...