International HEP Safety Forum
Stanford Linear Accelerator Center
ESTABLISHMENT OF A QUALITY MANAGEMENT SYSTEM IN
THE CERN SAFETY COMMISSION
Matteo Castoldi
12/04/2005
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION

Aim:
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
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
Present a complete model of Quality Management System
Present how it could be applied to the CERN Safety Commission
(SC)
Understand if Quality Management brings added value to SC
Content:
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12/04/2005
Role of SC at CERN
Aim of SC Quality Management System
CERN Integrated Management System
SC Quality Management System
Conclusions
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION
The role of SC at CERN


Perform all the centralized activities of CERN directly related with
health, safety and protection of the environment. Some of the SC
fields of activity are:
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draw up and application of Safety* rules
occupational health
Safety divulgation and training
emergency management
radiation protection
environmental protection
chemical safety
SC organigramme
SC offers a service to the entire CERN
*
Safety, with an initial capital letter, is used to cover health,
safety and protection of the environment
12/04/2005
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION

Aim of a Quality Management System in SC
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Demonstrate SC ability to consistently provide the services it is
deemed for
Demonstrate SC ability to meet regulatory requirements of Host
States (France, Switzerland)
Enhance the satisfaction of the CERN personnel profiting from SC
services
Is there an added value for SC and/or CERN ?
If yes  implement quality management
12/04/2005
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION

CERN Integrated Management System

General model of Integrated Management System
Integrated Management System
Safety
Management
System
12/04/2005
Environment
Management
System
M.Castoldi CERN-SC
Quality
Management
System
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION

CERN Safety Management System

SC Quality Management System + departments Safety related activities
quality systems, constitute the CERN Safety Management System
CERN Safety
Management System
SC
QMS
12/04/2005
Dept’s
Safety
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION

CERN Integrated Management System
SC control
CERN Integrated Management System
CERN Safety
Management System
SC
QMS

12/04/2005
Dept’s
Safety
EMS
CERN
QMS
Added value? …. but without SC Quality Management System it is not
possible to build a CERN Integrated Management System
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION

The Safety Commission Quality Management System
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Based on four pillars(*):

SC organisation quality
 SC personnel quality
 SC units/projects quality
 Continual improvement of the system
SC QMS
Maintenance & Improvement
Organisation
Quality System
Personnel
Quality System
Unit/ project
Quality System
(*) Jean Menthonnex, Lausanne, Switzerland, 2002
12/04/2005
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION

I pillar: Organization Quality System
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Process approach
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Processes to perform activities are the starting point
 Input and output requirements shall be clearly identified
Input
for
Activity
A
12/04/2005
Activity
A
Output
for
Activity
A
Input
for
Activity
B
Activity
B
Output
for
Activity
B
Input
for
Activity
C
M.Castoldi CERN-SC
Activity
C
Output
for
Activity
C
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION

Example of process: Mechanical Safety (approval of new device)
Preliminary
description
of device
focussed
on mechanical
matters
SC
comments
to preliminary
description
Conceptual
Design
Review
SC Safety Study
Report
Engineering
file
preparation
Engineering
file,
test results
Device and
manufacturing
certificates,
SC Safety Study
Report
Fabrication
and
testing
Final
testing at
CERN
Engineering
Design
Review
SC Safety Study
Report
Safety Inspection
Report
Safety Commission
Responsible for the device
12/04/2005
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION

Documentation is prepared, based on processes
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Level A
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Manual
 quality policy, objectives of SC
 implementation, review, approval and revision
of the system
 structure of SC, responsibility, authority and
interrelations
 key processes of SC
 reference to SC procedures for key processes
12/04/2005
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION

Level B
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Procedures
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for SC processes or complex activities
responsibility and authority of SC and other parties
scope, needs of SC and third parties
input and output of processes or complex activities
definition of records
reference to work instructions
Example: procedure for final mechanical testing (commissioning) of an
equipment
12/04/2005
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION

Level C:

Work instructions
 description of important activities
Requirements and scope
Activities description following the operations sequence
 definition of related records
 reference to parent procedure
Example of work instruction: how to perform a pressure test, how to
perform a chemical analysis on a water specimen

Form/record
 record data to demonstrate compliance with procedures or work instructions
 permanently stored into CERN Engineering Data Management System
Examples of form/record: accident declaration, Safety Study Report
12/04/2005
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION

II pillar: Personnel Quality System
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Based on standard CERN tools
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Merit Advancement and Promotion Scheme (MAPS)
 short-term training needs evaluation
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If no training is available to match post requirement: Skills and Talents
Inventory
 inventory of the human skills currently available at CERN
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Personnel certification whenever possible and convenient
Example of SC personnel certification

12/04/2005
the firemen are certified ambulance officers by Swiss authorities
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION

III pillar: Units Quality System
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Whenever necessary, SC units certified by independent body
SC auto-certification when no certifier is available or convenient
Example of SC certified unit
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the Laboratory of Occupational Health Medicine certified QUALAB by
the Quality Control Centre Switzerland
Project Quality System
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Safety Audits Protocol to monitor safety in new projects
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12/04/2005
based on ISO 10006:2003 standard
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION

The Safety Audits Protocol (1/6 - definitions)
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Audited project
 selected by the Safety Commission
 based on the advancement of the activities and risk involved
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Safety responsible
 the GLIMOS[1] of the experiment, or
 the Project Safety Responsible
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Audit coordinator
 a member of SC appointed by the Head of SC
 technical competences, leadership skills
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Safety Commission team of experts
 chosen by the Audit coordinator
 individually competent, motivated, and supportive
[1] For Safety matters, an experiment is represented by a Group Leader in Matters of Safety (GLIMOS), who is responsible for Safety, with
the necessary authority, from the design stage and subsequently throughout the development, construction, and operational stages
of the equipment until it is dismantled and correctly disposed of. The GLIMOS is appointed by the parent Department Head with the
consensus of SC.
12/04/2005
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION
The

Safety Audits Protocol (2/6 - procedure)
Audit procedure
 initiated by SC
 systematic meetings
 four steps (see picture)
 terminated at the end of the
project
 final audit report
 registered in the Risk
Management Plan
12/04/2005
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION

The Safety Audits Protocol (3/6 - steps)
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Hazard identification
 at the initiation of the project
 the Safety responsible presents information and documents
 hazards with significant impact noted in the Risk Management Plan
 a responsible for the risk assigned for each hazard

Risk assessment
 criteria and techniques decided by SC experts
 the responsible for the risk presents analyses
 assessment performed by SC following CERN Safety rules
 non acceptable risks noted in the Risk Management Plan
12/04/2005
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION
The Safety Audits Protocol (4/6 - steps)
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Risk treatment
 non-acceptable risks treated
 the responsible for the risk presents solutions
 SC decides whether to retain a solution
 Retained solutions noted in the Risk Management Plan and implemented
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Risk control
 SC experts monitor the implementation of solutions
 SC experts and the Safety responsible watch on new risks
 Personnel anticipate and identify risks and report to the Safety responsible
12/04/2005
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION

The Safety Audits Protocol (5/6 - example)

Roles
 Audited project: LHCb gantry structure
 Safety Responsible: LHCb deputy-GLIMOS
 Audit Coordinator: SC-GS/MS section leader
 Team of expert: SC mechanical engineer, SC safety inspector

Hazard identification
 the LHCb deputy-GLIMOS presents the envisaged structure and information
relevant to the gantry hazard
 mechanical safety is identified as unique hazard
 an LHCb engineer is assigned as responsible for the risk

Risk assessment
 the SC mechanical engineer gives details on the calculations and documents
to be submitted to SC. Safety requirements are recalled
 the LHCb engineer prepares and presents the calculations and documents
 the SC engineer assesses the submitted design and other documentation
 the SC engineer and the SC-GS/MS section leader prepare a Safety Study
Report
12/04/2005
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION
The Safety Audits Protocol (6/6 - example)

Risk treatment
 in case of negative Safety Study Report the LHCb engineer presents options
 the SC engineer and SC-GS/MS section leader may issue a positive Safety
Study Report
 Retained solutions are implemented and the gantry manufactured

Risk control
 the SC safety inspector monitors the correct construction of the gantry and
on new hazards arising
 in case of new hazards during the gantry construction a new hazard
identification step is undergone
12/04/2005
M.Castoldi CERN-SC
V HEP Safety Forum

ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION
IV pillar: Maintenance & Improvement
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Based on the PDCA approach
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Actions to improve quality are planned (Plan)
 Actions are implemented (Do)
 Result of actions is monitored (Check)
 Corrective actions are undergone if necessary (Act)

Both at managerial level and at process/activity level
From: D.Hortensius, et all., Towards a generic model for integrating management systems, ISO Management Systems Special Report, Jan. – Feb. 2004.
12/04/2005
M.Castoldi CERN-SC
V HEP Safety Forum
ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION

It applies to organisation, personnel and units/projects quality systems
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Example: PDCA (environmental protection - EMS)
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Managerial level
1 SC management wants more efficient environmental protection
2 SC-IE group receives resources
7 results of environmental protection is reviewed by the SC management
8 environmental policy and resources review by the SC management

Process level
3 SC-IE establishes the EMS (manual, procedures, etc.)
4 SC-IE implements the EMS at CERN (other Departments involved)
5 SC-IE audits EMS performance and reports to SC management
6 SC-IE modifies EMS, when necessary
12/04/2005
M.Castoldi CERN-SC
V HEP Safety Forum

ESTABLISHMENT OF A QUALITY
MANAGEMENT SYSTEM IN THE CERN
SAFETY COMMISSION
Conclusions

The presented Quality Management System model

can be extended to an Integrated Management System for the entire
CERN
 improves SC organisation, personnel, units/projects quality
 allows to enhance the satisfaction of CERN Director General,
Personnel, Host States
Is there an added value for SC and/or CERN ?
In our opinion yes !

12/04/2005
The strategic decision of implementing quality management and
allocate necessary resources is under evaluation by the Safety
Commission top management
M.Castoldi CERN-SC
V HEP Safety Forum