Original Date: 06/05/2006
Revision Date: / /
Best Practice : Pre-Purchase Analysis and Pre-Startup Review
The Pre-Purchase Analysis is a series of safety-related questions regarding the item to be purchased or the layout of a facility and is used before any action is taken. The Pre-Startup Review is the same series of safety-related questions used in the Pre-Purchase Analysis and is used before the start-up of new machinery, the usage of new chemicals, or before facility modification/new construction. This process has enabled Rockwell Collins to save money on safety modifications by taking a proactive approach to ensure the safety of its employees before problems arise.
Prior to 2002, new machinery and equipment were installed without the knowledge of the Environmental, Safety and Health (ES&H) Department at Rockwell Collins at a time when it was not mandatory for the user/purchaser of the equipment to take safety issues into consideration before procuring the item. It was not until the ES&H Department conducted area inspections that they became aware of new equipment and its associated hazards, which prompted corrective actions to reduce and/or eliminate safety concerns. This caused unnecessary rework from a safety standpoint, and equipment owners had to incur the additional costs associated with the corrective actions that were implemented. The ES&H Department was also not given the opportunity for input when new tools and chemicals were purchased or when the company planned for new construction or remodeling of the facilities. This resulted in the need to do safety modifications after the start-up process, which was costly and inefficient.
To become more proactive and efficient and to establish safety as a priority, Rockwell Collins’ ES&H Department developed the Pre-Purchase Analysis and Pre-Startup Review process. This process mandates a safety evaluation of new machinery and equipment, new tools, new chemicals, and new construction and remodeling before any action is taken. Reviews are completed prior to purchase and startup, release for use, and modification or new construction. No procurement groups at Rockwell Collins will purchase an item unless the Pre-Purchase Analysis has been approved by the ES&H Department.
The Pre-Purchase Analysis is performed by the person responsible for the equipment/asset in conjunction with the employee who is going to be using the asset. The analysis is a series of checklists that are completed by answering yes, no, or not applicable to a series of safety-related questions regarding the item to be purchased or the layout of a facility. The checklist for new machinery asks questions about mechanical hazards, electrical system safety, heat and temperature concerns, vibration and noise, and lasers and radiation. The checklist for hand tools asks a series of questions concentrating on the ergonomic properties of the tools. The new chemical checklist calls for such things as storage considerations, material safety data sheet obtainment, and ventilation issues. The checklist for facility layout is comprised of questions about access to the area, maneuverability in the area, and material storage.
Once the Pre-Purchase Analysis is completed, it is submitted to the ES&H Department for review and approval. Any checklist with a no answer indicates a potential hazard. The hazard must then be documented and corrected prior to purchase. Other hazards that exist that are not on the checklists must also be documented and corrected prior to purchase. After the Prepurchase Analysis is approved, the procurement group may proceed with the purchase and the Pre-Startup Review. This step consists of completing the same checklists used for the Pre- Purchase Analysis after the purchase is made and the equipment is set up prior to startup. The Pre-Startup Review has been implemented to determine the existence of potential hazards before the asset is released for startup.
The Pre-Purchase Analysis and Pre-Startup Review process ensures that the ES&H Department is aware of and approves an asset prior to purchase by establishing safeguards before the asset is put into use. It also prevents potential hazards and risks from entering the workplace, reducing the chance of occupational injuries and illnesses. The process further enables Rockwell Collins to save on safety modification costs by taking a proactive approach to ensure employee safety before a problem arises.
For more information see the
Point of Contact for this survey.