06 Jun Close Calls

Close Calls

Take a Close Look at Close Calls

A close call, also known as a near miss, is an unplanned event that did not result in injury, illness, property damage, or other loss—but easily could have. Close calls should never be ignored simply because no one was hurt.

A close call is a warning that a hazard, unsafe condition, or breakdown in a work process exists. If the cause is not identified and corrected, the same event may happen again with much more serious consequences.

Why Close Calls Matter

Close calls provide an opportunity to identify and correct hazards before someone is injured. Employees should report close calls promptly so they can be evaluated and appropriate corrective action can be taken.

Examples include:

• A worker nearly being struck by moving equipment or a falling object.
• A load shifting or falling without striking anyone.
• A worker slipping or tripping but avoiding a fall.
• Equipment unexpectedly starting, moving, or malfunctioning.
• A tool or piece of equipment failing without causing an injury.
• A vehicle nearly striking another vehicle, worker, or structure.
• An object falling from an elevated location and narrowly missing someone.
• A worker discovering an uncontrolled energy source before beginning maintenance.

The absence of an injury does not mean the situation was safe.

Report Close Calls

Employees should promptly report close calls to their supervisor. Reporting is not about assigning blame—it is about identifying hazards and preventing future incidents.

When reporting a close call, provide as much useful information as possible, including:

• What happened;
• Where and when it occurred;
• The task being performed;
• Equipment or materials involved;
• Conditions that may have contributed to the event; and
• What could have happened if circumstances had been slightly different.

Employees should also immediately report hazardous conditions that could result in a close call or injury.

Investigate the Cause

Close calls should be reviewed to determine why the event occurred, not simply who was involved. Avoid jumping to conclusions or assuming that employee behavior was the only cause.

Contributing factors may include:

• Equipment: damaged tools, defective equipment, missing guards, or equipment failure.
• Work Environment: poor lighting, excessive noise, congestion, uneven surfaces, or inadequate access.
• Work Procedures: procedures that are missing, unclear, inadequate, or not followed.
• Training: employees not adequately trained or unfamiliar with the task or hazard.
• Planning: hazards not identified before work began or changing conditions not addressed.
• Communication: employees, contractors, supervisors, or equipment operators not coordinating their activities.
• Management Systems: inadequate inspections, maintenance, supervision, staffing, or enforcement of established procedures.

The goal is to identify both the immediate cause and the underlying or root causes that allowed the event to occur.

Corrective Actions

Once the causes have been identified, corrective actions should be implemented as soon as practical. Depending on the hazard, corrective measures may include:

• Eliminating the hazard entirely;
• Installing guards, barriers, or other engineering controls;
• Repairing or replacing defective equipment;
• Improving housekeeping or workplace layout;
• Revising work procedures or Job Safety Analyses (JSAs);
• Providing additional training;
• Improving communication or supervision;
• Increasing inspection or preventive-maintenance activities; or
• Providing appropriate personal protective equipment when other controls cannot adequately eliminate the hazard.

Corrective actions should be communicated to affected employees and reviewed to ensure they are effective.

Look for Warning Signs

Employees should remain alert for unsafe conditions and changing hazards throughout the workday. Before beginning a task and whenever conditions change:

• Inspect the work area.
• Identify potential hazards and pinch points.
• Check tools and equipment before use.
• Correct hazards when authorized and safe to do so.
• Report hazards that cannot be immediately corrected.
• Stop work when conditions present an immediate danger.
• Never ignore a close call because “nothing happened.”

Remember

A close call is an opportunity to prevent the next incident. Report it, determine what happened, correct the hazard, and share what was learned. The difference between a close call and a serious injury can be only a matter of inches or seconds.