The risk map as a solution to work accidents

SUMMARY

The use of risk maps is of great importance to provide a solution and at the same time prevent workplace accidents in companies. For this reason, our work aims to carry out a detailed study of the production processes of the Las Tunas Fuel Trading Company (CUPET) located on the central highway Km 4½ in San Antonio, using the engineering method. Work constitutes a social contribution, since it contributes to the educational work of its workers, by acquiring knowledge about the possible risks, as well as the awareness of using the means of protection and thus preventing work accidents.

INTRODUCTION

Industrial Engineering is, without a doubt, one of the specialties of great importance and future in the world. It is also called the productivity profession, it positively impacts the efficiency and effectiveness of production and service systems. Indeed, its very definition holds its importance. Industrial Engineering is a set of disciplines oriented towards the design, improvement and installation of systems made up of men, materials, information and equipment in order to improve productivity. (Colombian Association of Engineering Faculties, ACOFI).

His study takes on special importance today due to changes in the scope and magnitude of the markets and their territorial coverage. In particular, it constitutes the specialty that will save the technological backwardness in terms of quality and use of resources of most of our productive industry. It faces the great challenge of generating organizational models that adapt to the needs of our country and in addition to convincing the owners and / or managers of the different companies the importance of its application.

The industrialization process increasingly demands the performance of tasks aimed at reducing costs, increasing the efficiency of labor and increasing equipment, the need for healthy, safe and better remuneration working conditions.

It is relatively frequent to carry out studies aimed at locating, evaluating and giving solutions to the problems of the existing production processes in the work environments, as well as their repercussion on the working population, since work accidents or unsafe working conditions can cause temporary or permanent illness and injury and even cause death. They also cause a reduction in efficiency and a loss in the productivity of each worker.

Since accidents arise from the interaction of workers with the work environment, both elements must be carefully examined to reduce the risk of injury. These can be due to poor working conditions, the use of inadequately designed equipment and tools, fatigue, distraction, inexperience or risky actions.

What has been proposed up to now, allows us to highlight the Risk Map as a study object as a solution to work accidents in the Las Tunas Fuel Trading Company.

The Risk Map is a plan of the labor process that includes the different risks that exist throughout the production process, as well as their magnitude, the health damage that these risks produce and the preventive measures that are adopted. It constitutes an elementary graphic tool for operational personnel, providing basic information in the study of occupational health, allowing the identification, evaluation and control of risks, as well as determining their morbidity.

The project focuses its research activity on the following objectives:

Overall objective:

Carry out a detailed study of the production processes and the risks associated with the work of personnel in the Company.

Specific objectives:

1. Determine the dimension of the problems presented by the different production processes.

2. Propose engineering solutions to these problems.

3. Implement prevention and control mechanisms that minimize the risks associated with the work of personnel in the Company.

DEVELOPING

Theoretical Foundation

For a better understanding of the work, it was necessary to expose several concepts related to the topic.

Engineering: Term applied to the profession in which the knowledge of mathematics and physics, achieved through study, experience and practice, is applied to the effective use of materials and the forces of nature.

Process: Sequence of activities that allow obtaining a final or intermediate result that adds value to the final customer. In the execution of a process, both material, informative and financial activities are carried out.

Production Process: Any process that comes into physical contact. With the hardware or software that will be delivered to an external customer up to that point in which the product is used.

Risks: The possibility of occurrence of unwanted events, as a consequence of potentially dangerous conditions created by people or different agent factors.

Risk Map: It is a plan of the labor process that includes the different risks that exist throughout the production process, as well as the magnitude, the damage to health caused by said risks and the preventive measures adopted.

Work Accidents: Any bodily injury that the worker suffers repeatedly or as a consequence of the work performed by someone else. Among the bodily injuries are, of course, the diseases contracted by the worker due to the performance of their work and even the aggravations of diseases and defects that were previously suffered.

Company Characterization.

A descriptive study of the Las Tunas Fuel Trading Company belonging to the CUPET (1) union, of the Ministry of Basic Industry; It is located on Carretera Central Km. 4 ½, San Antonio and was created as a Company in 1995. Previously it was categorized as a Basic Unit, belonging to the Holguín Company, called at that time a Petroleum Derivatives Distribution Unit. The Company also had a Terminal in the port of Carúpano in the municipality of Puerto Padre, a sub-warehouse in the municipality of Colombia and another in the municipality of Amancio Rodríguez.

Starting in 2002, the necessary and urgent transformation of emerging and inserting itself into the process of Business Improvement began to be experienced, which forced a redesign of its structure, lowering management levels from 5 to 3, in addition to some modifications to the system. sales and distribution management.

With the introduction of business improvement, the Company has undergone some modifications in its structure, its operation, and its commercial and working relationships with other entities, which forces it to modify or eliminate some of the activities that were initially planned, in order to achieve greater efficiency and effectiveness in the services provided.

The activities carried out by the Company after decreeing the closure of the UEB in Carúpano are the following:

ü Reception, storage, handling, marketing, ground transportation and distribution to the wholesale and retail network of fuels in national currency and freely convertible, based on the prices set by the union for the period in question.

ü Provide installation, repair and maintenance services of retail liquefied gas facilities in both currencies, for the users of their respective territories, applying to the latter the cost principle of more than 10%.

ü Provide laboratory services in specialized analysis of fuel and lubricants and certification of capacities of automotive equipment for loading and transportation of fuel products to entities of the union and third parties in national currency and freely convertible applying to the latter the principle of cost plus 10 %.

ü Rent of specialized equipment for the transportation of fuels when there is available capacity to state entities in national and freely convertible currency, applying to the latter the principle of cost plus 10% and to foreign entities in freely convertible currency.

ü Sale of scrap metal in national currency and freely convertible to the raw materials company of Las Tunas on a wholesale basis.

ü Training and certification services for national and / or foreign entities that carry out fuel operations, in national currency and freely convertible currency.

ü Handling and storage of imported and export fuels in national currency and freely convertible applying to the latter the principle of cost plus 10%.

Mission: We offer marketing, distribution and promotion services for the optimal use of fuels in the territory, to satisfy the needs of economic organizations and people, in an efficient and competitive way, contributing to the country's social economic development.

Vision: It is the leading company in the commercialization of fuels, with motivated, highly qualified and specialized workers, with a high sense of belonging, with advanced technologies, a high level of autonomy and efficiency that allows us to offer a competitive service that makes us a carrier. of the excellence award.

Values of culture:

ü Flexibility: Ability to adapt quickly to changes in the environment. Entrepreneurial spirit to overcome challenges.

ü Innovation: It is a process of changes and transformations in constant disagreement with what has been achieved, seeking new and better ways of being creative, seeking excellence.

ü Honesty: We do not allow or practice deception, we work with simplicity and transparency.

ü Competitiveness: We are guiding the customer as the essential reason for being, therefore, we spare no effort to respond to their demands.

ü Collectivism: All workers together work based on the achievement of the organization's objectives.

ü Patriotism: CUPET workers are highly committed to the Cuban economic social project.

Achievements:

ü After several years operating with economic losses, the organization has been working with profits since 2002.

ü Application of the internal control system, cost system and strengthening of economic control.

ü Implementation of the single salary scale with an increase in the average salary of $ 102.52 average per worker with respect to the improvement scale.

ü A second diagnosis was made from which a total of 67 corrective actions were derived.

ü Increase in labor productivity of more than $ 312.00 per worker.

ü Decrease of fuel losses below the allowable, achieving an efficiency rate of 2%.

ü The coefficient of technical availability of transport increases above 76%.

Projections:

ü Apply participatory management methods and styles based on the introduction of values-based management principles.

ü Certify the quality management system.

ü Introduce technological modifications and take on the tasks derived from the Energy Revolution.

ü Execute the commercialization of the different fuels with high quality, low costs, opportunity, security and managing changes.

ü Develop the Customer Service Program giving continuity to the Energy Contingency Plan, increase the introduction of the mixture to achieve savings of more than 1,114 tons of oil equivalent.

ü Transform the management of human resources, reinforcing its strategic role in the improvement of the organization, increasing productivity to more than 500 thousand liters per worker, reaching an average salary of 540 pesos per worker per month.

ü Materialize a training policy and cadres that allow greater professionalism and competitiveness of human resources.

Approved template and covered template:

There is an approved workforce of 226 workers, of which 221 are covered, structured as follows:

Occupational category Quantity

Leaders 15

Technicians 91

Administrative 2

Services 13

Workers 100

Total 221

Function performed by engineers in the Company:

Engineer	Function performed in the Company	Quantity
Industrial	ATM specialist	one
Mechanics	Saving and Rational Use of Energy	one
Mechanics	Esp. Exploitation of Automotive Transport	two
Mechanics	Transportation Director	one
Mechanics	Energy Specialist	one
Mechanics	Logistics Group Head	one
Mechanics	Esp. Quality Management	one
Mechanics	Tec. Fuel and Lubricant Distribution Base	one
Mechanics	Industrial Maintenance Tech.	one
Mechanics	Technical director	one
Mechanics	Esp. Saving and Rational Use of Energy	two
Chemical	Commercial Director	one
Chemical	Chemical Process Technologist	3
Chemical	Esp. Saving and Rational Use of Energy	two
Chemical	Tech Training	one

Diagnosis of the current situation

We must emphasize that this Company since its creation in 1995, operated with planned losses, which were absorbed by the CUPET system; Currently, although the fuel is owned by the CUPET Union, it has foreign currency income and expense accounts and operates under the principle of self-financing, based on a transfer price for the total liters distributed.

To carry out the study, we rely on the experience of the personnel who have been working in the Company for the longest time, as well as the highest qualifications, obtaining historical, operational documentation of the plants, number of personnel working, the inputs required for the process, products generated and prevention plans.

We obtained that the main problems of the different productive areas of the Company (See Annexes 4, 5, 6, 7,8) are the following:

ü The maintenance of the tanks is insufficient.

ü Hearing protection equipment does not exist in the company.

ü Warning signs do not exist in all areas.

ü The risk of fire and falling to another level.

ü There is insufficient lighting.

ü The Company requires centralizing the information on the risks inherent in its operational processes, in order to keep them updated and quantified, as well as to locate them geographically. All this in order to minimize the effects that they could have on the personnel who work there.

Projection of solutions.

Taking into account the aforementioned problems, the number of workers and the risks that affect their health, we determined to propose as a solution to prevent accidents and occupational diseases, as well as to improve working and stay conditions in the Company, the implementation of prevention and control mechanisms that minimize risks and therefore the occurrence of accidents and occupational diseases and the graphical representation, through the methodology of Risk Maps in critical areas of the Company.

Methodology for preparing the risk map:

1. Identification of the Risks: It is carried out by means of the inspection of the different areas, as well as interviews with holders of a vast knowledge of the installation. The type of process, substances, product and by-products, possibility of formation of dangerous substances, real conditions of each job are obtained. Once the risk is identified, it is controlled, it is suggested which ones to evaluate in depth and which ones to correct immediately, saving costs in the general risk study.

2. Assessment of Risks: Once these are obtained, their characteristics are defined and the magnitude of the exposures are determined, they are determined qualitatively and / or quantitatively, by means of various techniques: measurement of noise, with a sound level meter, danger of falls, fires, exposure to dangerous substances, explosion, poor lighting with a digital light meter, contact with high temperatures, as well as psychological risks.

3. Control: It is carried out by medical and administrative personnel, providing support for the measures adopted, according to the risks.

When we identify the risks we evaluate and control them, we take the plan of the Company and there it is located, in a representative way, that is, by means of symbols, signs and figures, the risks in each area.

We would carry out the Risk Map:

1. Obtaining a plan of the labor process, where we can locate machinery and the development of the production process from the beginning to the finished product, indicating:

§ Raw material.

§ Intermediate products.

§ Final product.

§ Type of machinery.

§ Number of workers, officials and organization.

2. We locate occupational hazards using figures and / or colors to indicate:

§ Most exposed workers.

§ Interaction of different risks.

3. Legend:

§ Risks.

§ Damage to health.

§ Protection measures.

§ Proposed preventive measures.

CONCLUSIONS

1. This work constitutes a social and economic contribution, as it contributes significantly to the educational work of both workers, technicians and administrators, and operations personnel.

2. It has allowed the knowledge by all the Company's workers of the possible risks to which they are exposed in the different jobs.

3. It has been gained in consciousness by the workers, in the use of the means of prevention and control of accidents and occupational diseases.

4. With the intervention of this work, the aim is to reduce economic expenses caused by work accidents.

RECOMMENDATIONS

1. Generalize the preparation of Risk Maps in all workplaces, due to their importance in the prevention and control of accidents and occupational diseases.

BIBLIOGRAPHY

1. Benítez G., Gustavo. Manual on risk analysis and evaluation. Puerto de la Cruz, 1995.

2. Chávez María Gómez Juan. Contingency plan in case of massive leak of hydrofluoric acid in the Alkylation Plant of Amuay, Lagoven SA Mérida, July 1995. University of Los Andes, Venezuela.

3. www.google.com.cu

4. Biaggio A. Palacios E. Sajaroffp. National Radiological Safety Course. Faculty of Engineering. UCV October 1990.

5. Petróleos de Venezuela, SAPDVSA Safety Guide for jobs and ionizing radiation. Corporate management of comprehensive protection, January 1994.

6. Palomo Gutiérrez, Miguel A. Mapfre Security. Mapfre Foundation magazine. pp. 3-23. 1997.

7. Stebart Wolf, Albert J. Finestone, Occupational, Stress, Health and Performance ut Work.

8. Sell Valery, F. Ergodynamics: Theory and Applications. Ergonomics, 1995.

9. www.wikipedia.org

ANNEXES

Annex # 1: Distribution of risk prevention systems. Las Tunas Fuel Marketing Unit.

Not.	Prevention and Control System	Tank Area	Laboratory	Loading bays	Mtto	Warehouse Lubric.	Plant LPG	Workshop Car- motor	Warehouse ATM
one	Inspection and Maintenance	X	X	X	X	X	X	X	X
two	Personal protective equipment.	X	0	X	X	X	X	X	X
3	Standard use of stairs and scaffolding.	X		X	X
4	Training.	X	X	X	X	X	X	X	X
5	Emergency plan.	X	X	X	X	X	X	X	X
6	Volunteer firemen.	X		X	X
7	Pre-employment and periodic medical exams.	X	X	X	X	X	X	X	X
8	Warning signs.	X	0	X	0	0	X	0	0
9	Work procedure.	X	X	X	X	X	X	X	X
10	Hearing protection equipment.				0		0	0

Source: survey.

Annex # 2: Distribution of risks in the different areas. Las Tunas Fuel Marketing Unit.

Not.	Risks	Tank Area	Laboratory	Loading bays	Mtto	Warehouse Lubric.	Palnta LPG	Workshop Car- motor	Warehouse ATM
one	Fire.	X		X		X	X		X
two	Explosion.	X		X		X	X
3	Contact with pathogens.				X
4	Poor lighting.		X				X
5	Drop to another level.	X		X			X	X
6	Drop to the same level.						X	X
7	Environmental impact.		X
8	On effort.				X	X	X	X	X
9	Vibrations							X
10	Solar radiation.	X			X

Source: survey.

Annex # 3: Distribution of risks according to the prevention and control system. Las Tunas Fuel Marketing Unit.

Not.	Risks	Inspection and Mtto.	Personal protective equipment	Standard use of stairs and scaffolding.	Training- I lie.	Emergency plan Inc.	Volunteer firemen.	Pre-employment and periodic medical exams.	Warning signs.	Procedure. of work.	Protective equipment auditory.
one	Fire.	X			X	X	X	X	X
two	Explosion.	X			X	X	X		X
3	Contact with pathogens.		X		X			X
4	Poor lighting.	X						X	0
5	Drop to another level.			X	X
6	Drop to the same level.
7	Environmental impact.							X	0	0
8	On effort.				X
9	Vibrations	0	0	0				X	0		0
10	Solar radiation.		0