Hidden danger investigation and management system

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The purpose of Article 1 of Chapter 1 General Principles is to standardize the whole-process management of the investigation and control of hidden production safety hazards in the factory, improve the closed-loop management mechanism of "inspection, registration, rectification, acceptance, cancellation, and filing", consolidate the operation foundation of the dual prevention system, prevent and contain various production safety accidents from the source, such as wood dust explosions, thermal oil boiler accidents, mechanical injuries, fires, hazardous chemical leaks, electric shocks, etc., implement the safety production responsibilities of all employees, and formulate this system based on the factory's particleboard production process and on-site actual conditions. Article 2 is formulated in accordance with the "Production Safety Law of the People's Republic of China", "Standards for the Determination of Major Accident Hazards for Industrial and Trade Enterprises", "Safety Regulations on Dust Explosion Prevention for Industrial and Trade Enterprises", "DB37/T 3711-2019 Implementation Guide for the Construction of Safety Production Risk Management and Control and Hidden Hazard Investigation and Governance System for Wood Processing (Particleboard) Enterprises", "Guidance Manual for the Construction of Dual Prevention Mechanism for Guangxi Industrial and Trade Enterprises" and other laws and regulations, industry standards and the requirements of the factory's safety management system. Article 3 Scope of application This system applies to all production operation areas such as the raw material storage yard, chipping section, drying section, hot pressing section, sanding and panel cutting section, dust removal system, thermal energy center (organic heat carrier boiler), glue mixing operation area, finished product warehouse, power distribution room, fire protection system, office auxiliary area, etc. Covering all equipment and facilities, operating activities, operating environment, personnel operations, safety management links and hidden danger investigation and management of all on-the-job employees. The fourth working principle adheres to the principles of "full participation, hierarchical investigation, local responsibility, immediate inspection and correction, closed-loop control, dynamic clearing, and continuous improvement" to ensure that there are no blind spots in the investigation of hidden dangers, no delays in rectification, and no loopholes in management and control, so as to achieve normalized, standardized, and institutionalized management of hidden dangers. Chapter 2 Organizational Structure and Responsibilities Article 5 Responsibilities of the Leading Group 1. General Manager: As the first person responsible for the investigation and management of hidden dangers in the factory, he is responsible for coordinating the management of hidden dangers throughout the factory, ensuring the investment in funds, materials, and personnel for hidden danger rectification, supervising the rectification and cancellation of major hidden dangers, and reviewing and approving major hidden danger management plans. 2. Vice President of Production and Safety Director: Take the lead in organizing the implementation of the hidden danger investigation and management system, formulate investigation plans and clarify the frequency of inspections, supervise the implementation of hidden danger rectification in each department, review the hidden danger ledger, rectification materials and acceptance records, and organize special rectification work of hidden dangers. 3. Heads of various departments: Responsible for the direct management of the investigation and management of hidden dangers in this department and region, organize daily self-examination and self-correction, implement hidden danger rectification measures, and timely report major hidden dangers that cannot be handled by oneself. Article 6 Job Responsibilities 1. Workshop Director: Organize full-coverage inspections of hidden dangers in the workshop every week, track the rectification progress of hidden dangers, review the rectification effects, and prevent equipment malfunctions, on-site hidden dangers, and personnel from operating in violation of regulations. 2. Team leader: Carry out inspections of hidden dangers before, during and after the shift, supervise the standardized operation of the post, promptly discover and stop violations on the job, report various safety hazards on site, and organize the team to complete self-examination and self-correction of hidden dangers. 3. Position employees: Strictly implement the post self-examination system, master the key points of identifying potential hazards on the job, handle or report immediately any abnormalities in equipment, on-site hazards, and violations found, and it is strictly forbidden to ignore hidden hazards or work while sick. Chapter 3 Hidden Hazard Classification Standards Article 7 Major Accident Hazards refer to those that violate production safety laws, regulations, standards and specifications, are extremely risky, and can easily cause fires, explosions, mass deaths and injuries, and major property losses. They meet the standards for determining major accident hazards in the industry and trade industry, and mainly include: 1. Serious dust accumulation in sanding and drying dust removal systems, failure of dust removal, failure of spark detection and extinguishing devices, illegal purge dust accumulation and other major hidden dangers related to dust explosions ； 2. Major risks and hazards such as failure of safety accessories of organic heat carrier boilers, circulation system failure, over-temperature and over-pressure operation, massive leakage of thermal oil, etc. ； 3. High-risk equipment safety interlocks and protective devices are missing and ineffective, causing long-term operation with illness. ； 4. Hot work and limited space work without approval, supervision, and illegal operations without measures ； 5. Serious problems such as paralysis of the fire protection system, long-term blockage of safety passages, and large-scale failure of explosion-proof electrical appliances. Once a major hidden danger is discovered, production must be stopped immediately, machines must be shut down, and personnel must be evacuated. Alert control must be set up, a special rectification plan must be formulated, and reported to the company and the local regulatory authorities. Production can only be resumed after passing the rectification acceptance. Article 8 General accident hazards refer to minor violations of regulations on site, minor equipment defects, missing signs, non-standard environmental sanitation, slight aging of lines, partial protection defects and other hidden dangers that are low risk and can be quickly rectified and eliminated. They will not directly cause major accidents. Closed-loop management of rectification within a time limit and on-the-spot rectification is implemented. Chapter 4 Types and Frequency of Hidden Hazard Investigations Article 9 Daily self-examination of posts Employees at each position should conduct self-examination before, during and after each shift, focusing on checking the operating status of post equipment, safety protection facilities, working environment, tools and equipment, personal protective wear, and post violations, so that small hidden dangers can be rectified on the spot and abnormal problems can be reported immediately. Article 10 Daily Inspection of the Team The team leader shall conduct comprehensive inspections of the team's working areas, equipment and facilities, operating behaviors, fire-fighting equipment, and passage environment every day, establish team inspection records, promptly correct violations, and rectify on-site hidden dangers. Article 11 Weekly Inspection of Workshops The workshop director shall organize a weekly inspection of all hidden dangers in the workshop, focusing on special inspections of dust removal systems, mechanical equipment, high temperature and high pressure equipment, electrical explosion protection, fire protection facilities, use of hazardous chemicals, and operating specifications, forming inspection records, and implementing a closed loop of rectification. Article 12 The company’s monthly comprehensive inspection. The company’s safety department will take the lead, and jointly with the production, equipment, and warehousing departments, conduct a comprehensive hidden danger inspection of the entire factory every month. Simultaneously, special inspections of dust explosion prevention, boiler safety, electrical safety, fire management, and operation permits will be carried out to comprehensively sort out various hidden danger issues. Article 13 Special and seasonal inspections Before and after holidays, resumption of work and production, flood season, high temperature, winter fire prevention, and equipment overhaul and technical renovation, special hidden danger inspections must be carried out to focus on weak links and high-risk points to strictly prevent periodic safety accidents. Chapter 5 Hidden Hazard Closed Loop Management Process Article 14 Closed Loop Management Process All hidden dangers in the factory are strictly implemented through investigation and discovery→registration and filing→graded judgment→issue rectification→implementation of three determinations→implementation of rectification→review and acceptance→closed loop account cancellation→data archiving and full-process closed-loop management. Article 15 Hidden Hazard Registration and Assignment All hidden dangers discovered during the investigation must be truthfully registered in the "Hidden Hazard Investigation and Management Ledger", clarifying the location of the hidden danger, the description of the hidden danger, the level of the hidden danger, the time of discovery and the person who discovered it, and attaching photos of the on-site hidden dangers. General hidden dangers will be rectified on the spot by the workshop, while major hidden dangers will be supervised by the company and assigned on a special basis. Article 16 Three: Determine the rectification and implementation of all hidden dangers. Strictly implement the responsible person, rectification measures, and time limit for rectification. At the same time, implement rectification funds and on-site control measures to prevent hidden dangers from being left unchecked and unresolved after the deadline. General hazards will be rectified within 24 hours, complex hazards will be rectified within 3-7 days, and major hazards will be suspended for special rectification. Article 17 Review, Acceptance and Cancellation After the rectification of hidden dangers is completed, the safety department and the workshop will jointly conduct an on-site review and acceptance to check the rectification effect and compare photos on site. After the acceptance is passed, the signature will be signed and the account will be cancelled. ； Those who fail to make rectifications will be ordered to rework and make rectifications within a time limit until the hidden dangers are completely eliminated. All hidden dangers must be 100% rectified, 100% closed-loop, and 100% traceable. Chapter 6 Hidden Hazard Control Requirements in Key Areas Article 18 Dust Explosion Hidden Hazard Management and Control Strictly implement the dust cleaning system, and it is strictly prohibited to use compressed air to directly blow away accumulated dust ； Daily inspection of dust removal pipes, filter bags, and fans to promptly clear blockages and dust accumulation problems ； If the dust concentration exceeds the standard, the anti-static grounding fails, the explosion-proof device is damaged, or the explosion-proof electrical is damaged, stop the machine immediately for rectification. Operation with hidden dangers is strictly prohibited. Article 19 Hidden Hazards of Thermal Energy Boilers: Abnormal temperature, pressure, and flow of organic heat carrier boilers, failure of safety accessories, failure of circulation pumps, leakage of thermal oil, aging pipelines and other hidden dangers must be immediately implemented. Overtemperature, overpressure, and non-cyclic operation are strictly prohibited. It is strictly forbidden to start furnace production until the hidden dangers of the equipment are eliminated. Article 20 Hidden hazards in mechanical operations shall be controlled to control the safety protection of mechanical equipment such as chipping, sanding, hot pressing, and transportation. Safety gratings, interlocking devices, emergency stop switches are missing or damaged, and hidden dangers such as abnormal noise, jamming, and looseness of equipment must be immediately shut down for maintenance. It is strictly prohibited to operate equipment without protection and personnel to operate in violation of regulations. Article 21 Management of Hazardous Chemicals and Hot Work Hidden Hazards: Irregular storage, leakage, and poor ventilation of hazardous chemicals such as MDI glue and thermal oil ； If there is no approval, supervision, fire prevention measures, or flammable gas detection for hot work, the work will be stopped immediately and rectifications will be put in place within a time limit. Article 22 Fire Electrical Hazard Management and Control Fire equipment is missing, expired, or ineffective, safety passages are blocked, and fire prevention distances are insufficient. ； Problems such as unauthorized connection of electrical lines, explosion-proof damage, and irregular grounding should be rectified immediately and cleared within a time limit to ensure the intrinsic safety of fire protection and electrical systems. Chapter 7 Hidden Hazard Files and Dynamic Management Article 23 File management requires the Safety Department to uniformly establish a complete set of hidden hazard investigation and management files, including hidden hazard investigation ledgers, rectification notices, acceptance forms, before and after comparison photos, special rectification plans, major hazard report records, and various investigation record forms. All information is classified and archived, filled out in a standardized manner, and the retention period is no less than 3 years. The entire process is traceable and verifiable. Article 24 Dynamic update management combines process and technical modifications, equipment updates, on-site changes, and hidden danger rectification situations to dynamically update the hidden danger checklist and key management and control points ； Every six months, combined with the dual control system review, we sort out high-frequency hidden dangers and repetitive hidden dangers, formulate special rectification measures, and eradicate hidden dangers from the system, equipment, and management levels. Chapter 8 Hazard Reporting and Emergency Response Article 25 Hidden Hazard Reporting Mechanism Posts and teams should immediately report general hazards to the workshop if they discover them ； When major hidden dangers are discovered, operations must be stopped as soon as possible, personnel on site must be evacuated, and reports must be reported immediately to the company's safety management department and the person in charge. It is strictly prohibited to conceal, omit, report late, or fail to report. Article 26 Management and Control of Major Hidden Hazards During the rectification of major hidden dangers, warning signs and warning fences must be set up, special personnel be assigned to monitor on-site, and temporary control measures must be formulated to prevent accidents caused by out-of-control hidden dangers. Operations can be resumed only after passing the rectification and acceptance inspection. Chapter 9 Assessment, Rewards and Punishments Article 27 Reward Provisions 1. Departments and individuals that have properly checked for regular hidden dangers, timely closed the rectification loop, and have no repetitive hidden dangers will be included in the monthly and annual safety evaluations ； 2. Employees who proactively investigate and report major hidden dangers and effectively avoid safety accidents will be rewarded with notifications and special cash rewards. Article 28 Punishment Regulations 1. If hidden dangers are concealed or omitted, rectifications are not made within the time limit, rectifications are not in place, or false rectifications are made, the responsible team and responsible person will be notified, criticized and financially punished ； 2. If there are repeated hidden dangers for a long time and the management and control performance is not in place, the department heads and team leaders will be seriously evaluated. ； 3. If safety accidents occur due to neglect of hidden dangers or illegal operations, management personnel at all levels and personnel in positions shall be strictly held accountable. Chapter 10 Supplementary Provisions Article 29 System Interpretation The safety management department of the factory is responsible for the interpretation of this system. Article 30 Implementation Date This system will be officially implemented from the date of promulgation.