Two day national seminar on industrial safety

GITAM university 26-27 March 2014

Safety- A question of mind set

Dr. Y. Manohar Former Director, RINL/ Vizag Steel Plant & Sr Professor, HBS-GITAM University

What is mindset

Fixed mental attitude

General Safety Rules

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Certain facts

An avg. of 200-250 No.s of Accidents / Yr. Includes both Work place and Road Accidents Fatal, Reportable, Nonreportable.

For both Regular and Contractor employees

Many more Near misses
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Hazards in VSP
Fire Explosion Gas poisoning Slips, trips & falls Electrical shock Electrical flash over Fall from heights Hot metal burns Burns due to other hot objects
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Hazards in VSP
Body part caught in moving machinery Material handling hazard Level crossing hazards Cold burns (frostbite) Noise Dust Radiation Confined spaces Working with chemicals Transportation Snake bites
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Hazards Accidents Causes

If hazards are not put under control, Accidents will takes place. Any Accident can only be caused by either/both of the following two reasons.. -

Unsafe acts
Unsafe conditions
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Accident ?
Any event that is
Unplanned Undesired Unexpected which results Or has potential to cause Death Bodily injury Ill health Loss of property Damage to equipment Damage to environment
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Unsafe Acts
X Standing below a hanging load. X Welding / Gas cutting without eye protection. X Jumping over a running conveyor. X Operating crane without permission. X Using compressed air for cleaning body. X Using oxygen for cooling. X Height work without safety belt.
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X Using welding rod holder without proper insulation. X Using damaged sling for X lifting loads. X Entering gas prone areas without permission. X Throwing down material from top without caution. X Running a loco at high speed X Carrying out elect S/D job without caution tag (Men-atwork) at panels.

Causes of Accidents-1 Unsafe Acts

Ignorance Negligence Over confidence Shortcut methods Hurry & worry Horse play No concentration Communication gap Poor co - ordination
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Not trained in the job Unauthorized person Violation of SOP/SMP Using Defective tools No PPEs Poor health conditions No P T - W system Giving wrong / No signals Fatigue

Causes of Accidents-2
Unsafe Conditions
Unguarded m/c Floor openings No hand rails Slippery floor Loose elect. Cables No body earth Working in gas areas Working at heights Obstructions on the path Absence of interlock Poor illumination Jungle growth Water / Oil leakage and stagnation Poor operating condition of the equipment
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Safety ?
State in which the risk of harm to persons or damage to property is limited to a tolerable level.

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Statutory Acts Applicable

Indian Factories Act-1948 AP Factories rules-1950 Indian Electricity Rules-1956 Gas Cylinders Rules-2004 Indian Explosives Act-1884 Indian Boilers Act-1923 Calcium Carbide Rules-1987 Workmens compsn Act - 1923 Indian Motor Vehicle Act-1988 Central MV Rules-1989 Petroleum Act1934, Rules 1976 Noise pollution Act - 2000 Chemical Accident Rules- 1996 The Static and Mobile Pressure Vessels Rules-1981 The Environment( Protn.) Act - 1986

Many More .
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Indian Factories Act 1948

Contains XI chapters and 120 Sections
Chapter III (sec 11-20) Chapter IV (sec 21-41) Chapter IVA (sec 41A-H) Chapter V (sec 42 -50) Chapter VI (sec 51-66) Chapter X (sec 92-106) Health Safety Hazardous processes Welfare Working hours Penalties for Offenses

Section 7A Duties of Occupier Section 101 Exemption of Occupier from liability

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Salient features of Indian Factories Act

Sec 21 Fencing of Machinery 22 - work on/near M/c in motion 23 Employing young persons 28 Hoists / Lifts 29 Lifting M/cs, ropes, chains.. 31 pressure plant 33 pits, sumps, floor openings 35 Eye protection 36 portable elet. Light cautions 37 Explosve/Inflamable gases
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41A Site appraisal Comittee 41B Disclosure of Info must 41C Occupier responsibility in relation to Haz. Processes 41D Power of Central Govt. 41E Emergency Standards 41F permissible Exposure limits of chemical substances 41G Workers participation in safety management 41H Rt of worker to warn about an imminent danger

Complying with the statutory provisions

Appointing Occupier & Manager Accident Reporting and Investigation. Reporting of Electrical accidents to REA, Chennai Safety audits - Internal and External agencies Onsite and Offsite Emergency plans Material Safety Data Sheets (MSDS) SOP / SMPs and HIRA / Control measures Protocols - Hazardous Jobs Fire Fighting facilities Health Checkups Eye, Ear.. Safety Trg. Regular and Contractor Employees 21

COMPLYING WITH THE STATUTORY PROVISIONS

Testing of all Pressure vessels, tools, tackles, Safety Belts . Emergency Management Team. Mock Drills. Permit To Work System. DSC and CSC Meetings. Providing adequate Illumination. Supply of PPEs Interlocks Statutory Records update. Corrective and Preventive actions
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Safety promotional activities

National Safety on 4th of March every year. Fire Safety Day on 14th of April every year. Suggestion scheme on safety. Shop floor safety talks. Safety skits, poster, slogan, Housekeeping competitions. Quality circles for improving safety standards. Weekly review of safety activities of VSP by ED (W). Implementations of OHSAS 18001. Nominating employees to National seminars, Workshops, symposiums, competitions, Trg. programs on safety.
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Accident prevention
Ultimate aim of all these endeavours is to achieve.. The goal

Zero accidents

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Mindset

Correction Techniques
Union leaders Supervisors and managers Total worker population Continuous R&D Experience sharing Quality of PPE Modern Technology (eg:-CCTV)

Counseling

Coaching
Mentoring

Motivation
+ve Reinforcement

Total safety culture

PDCA RTR Walk the talk MWA I-I-I

she is owning it: GM chief steps up to handle safety questions

(Business standard 20-03-14)

Past 10 years Faulty Ignition switch 12 Fatal 1.6 m cars recalled

Mary T Barra ,CEO-GM

Toyota to pay 1.2b $ over safety issues

(Business standard 20-03-14)

Disclosure by Toyota
Since 2009 10m cars recalled US-Toyota settlement

Thank You