A PROJECT REPORT ON

SAFETY MANAGEMENT
IN ULTRATECH CEMENT COMPANY, DURGAPUR WEST BENGAL By Kumar Pratik Reg. No. EIILMU/SK/RG/0708/025

EXTERNAL GUIDENCE
Mr. P.K.Maity (Head P&A)
1

INTERNAL GUIDENCE
Mr. Kaushal Lohagan

Mr. Sit l Ray (Offic r Safety)

(Lecturer, EIILM University)

CONTENTS 
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ACKNOWLEDGMENT
I feel it¶s my pleasure to extend my profound sense of gratitude to the EIILM University, Sikkim which had made my study a success. I sincerely thanks to the inspirational guidance and Council of my guide Mr. Kaushal Lohagan (Lecturer H.R). I sincerely express our gratitude towards Ultratech cement company (West Bengal Cement Works) which gives me this great opportunity to do my project work in this prestigious company. I also thank Mr. P.K.Maity (Head P&A), Mr. S. Kanungo, Mr.A.K.Chaturvedi, Mr.S.Bhattacharya and all other staffs for their valuable support and their co-operation. I also specially thanks to Mr.Sital Ray (Officer Safety) without whom this project will never be completed he provides all the necessary information and relevant data which I required in my study.

Last but not the least our gratitude to all the Officer and Staff of Personnel Department, Safety Department of Ultratech Cement Company (WBCW) who were instrumental in making this project a grand success.

4

A BRIEF

IN RODUC ION
OF ADITYA BIRLA GROUP

5

Shri. KUMAR MANGALAM BIRLA CHAIRMAN OF ADI YA BIRLA GROUP
 

6 

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:: :: :: :: :: :: :: :: :: :: Mr. Kumar Mangalam Birla, Chairman Mrs. Rajashree Birla Mr. R. C. Bhargava Mr. G. M. Dave Mr. N. J. Jhaveri Mr. S. B. Mathur Mr. V. T. Moorthy Mr. S. Rajgopal Mr. D. D. Rathi Mr. S. Misra, Managing Director 

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::

Mr. K. C. Birla 

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R.K. Shah 

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:: Mr. O. P. Puranmalka 

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:: Mr. S. K. Chatterjee

AD TYA B LA GRO
FACT S EET(1)
A US $30 billion corporation, the Aditya Birla Group is in the league of Fortune 500. With operations in 25 countries, the Group is anchored by an extraordinary force of 130000 employees, belonging to 30 different nationalities. In India, the Group has been adjudged The Best Employees in India and among the top 20 in Asia by the Hewitt-Economic Time and well Street Journal Study 2007. Over 60 percent of its revenues flow from it s over seas operation. The Group operates in 25 countries:- India, UK, Germany, Hungary, Brazil, Italy, France, Luxembourg, Switzerland, USA, Australia, Canada, Egypt, China, Thailand, Laos, Indonesia, Philippines, Dubai, Korea, Singapore, Myanmar, Bangladesh, Vietnam, Malaysia.

FACT S EET (2)
GLOBALLY AD TYA B RLA GRO S:A metals powerhouse, among the world s most cost-efficient aluminum and copper producers. Hindalco-Novelis is the largest aluminum rolling company. It is one of the 3 biggest producers of primary aluminum in Asia with the largest single location copper smelter. 

   

No.1 in viscose staple fiber. The 4th largest producer of insulators. The 4th largest producer of carbon black. The 11th largest cement producer. Among the world s top 15 BPO companies and among India s top 4.
8 

Among the best energy efficient fertilizer plant.

FACT S EET (3)
N ND A AD TYA B RLA GRO 
    

S:-

A premier branded garments player. The 2nd largest player in viscose filament year. The 2nd largest in the Cllor-alkali sector. Among the top 5 mobile telephony companies. A leading player in Life Insurance and Asset Management. Among the top3 super-market chains in the Retail business

Rock solid in fundamentals, the Aditya Birla Group nurtures a culture where success does not come in the way of the need to keep learning afresh, to keep experimenting.

FACT S EET (4) Beyond Business Adtiya Birla Group is: Working in 3700 villages.  Reaching out to 7 million people annually through the Adtiya Birla Centre for Community Initiatives and Rural Development spearheaded by Mrs. Rajashree Birla.  Focusing on: - health care, education, sustainable livelihood, infrastructure and espousing social causes.  Running 41 schools and 18 hospitals. Transcending the conventional barriers of business to send out a message that We Care .

D FFERENT SECTORS OF AD TYA B RLA GRO
9

10

INTRODUTION TO ULTRATECH CEMENT CO PANY

11

9,6,21 

To be a premium global conglomerate with a clear focus on each business.

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To deliver superior value to our customers, shareholders, employees and society at large.

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Integrity Commitment Passion Seamlessness Speed

LANT LOCAT ON OF LTRATEC CEMENT COM ANY N ND A

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De l
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Address of the Plant

Name of the Plant
Ultratech Cement, GCW(Thermal Power Plant)& (CCP)

Gujarat Cement Works, V llage Kovaya, Taluka Rajula City, Dist. Amreli, Gujrat-365541

13

¡

2

Ultratech Cement, GCW-NMCU

Ultratech Cement, GCW,NMCU Plant, Navi Mumbai Ultratech Cement, GCW,MCU Plant, Mangalore Gujarat Cement Works, Village Kovaya, Taluka, Rajula City, Dist. Amreli, Gujarat-365541 Ultratech Cement, ACW, Location: PO Awarpur Cement Project, Taluka, Korpana, Dist. Chandrapur, Maharashtra- 442917 Ultratech Cement, APCW, Village Bhogasamudram, Chukkalur, Tadipatri, Dist:-Ananatpur , Andhra Pradesh-515415 Ultratech Cement, GGU, Ginigera Unit, Ginigera Grinding Unit, Ginigera Village, Koppal Taluk,Karnataka State-832280 Ultartech Cement, HCW, PO: Hirmi, Taluka Singa, Via:Neora, Dist. Raipur, Chatisgarh-493114 Ultatech Cement Limited, JCW, PO: Awarpur Cement Project, Taluka, Korpana, Dist:- Chandrapur, Maharashtra-442917
14

3

Ultratech Cement, GCW-MCU

4

Ultratech Cement, GCW, Jetty

5

Ultratech Cement, ACW

6

Ultartech Cement, APCW

7

Ultratech Cement, GGU

8

Ultratech Cement, HCW

9

Ultartech Cement Limited, JCW

10

Ultratech Cement, JFD

Jafarabad Works(NCCL), Village Babarkot, Taluka, Jafrabad, Dist:Amreli, Gujarat-365540 Magdalla Works(NCCL), Magdalla port, Dumas Road, Surat, Gujarat- 395007 Ultratech Cement, Ratnagiri, MIDC Industrial Estate, Zadgaon Block, Ratnagiri, Maharashtra-415639 Ultatech Cement Limited, Near EPIP Plot, Muchipara, Post:- Rajbandh, Durgapur, West Bengal-713212 Ultratech Cement Limited, Chitteri, PO:- Arakkonam, Dist:- Vellore, Tamilnadu- 631003

11

Ultratech Cement, MGU

12

Ultratech Cement, Ratnagiri

13

Ultratech Cement, WBCW

14

Ultratech Cement, ARCW

LOCAT ON OF LTRATEC CEMENT (WBCW) N WEST BENGAL

COM ANY

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WBCW, DURGAPUR

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WHY DURGAPUR???
West Bengal Cement Works (WBCW) is the 10th cement manufacturing unit of Ultratech Cement Limited, which located at Durgapur.

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Clinker: - Hirmi Cement Works. Fly ash: - Bakreshwar Thermal Power Station, DPL. Gypsum: - Hind Liver Chemicals, Haldia. Slag: - Durgapur Steel Plant and Bokaro Steel Plant.

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DLP, DVC.

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North Eastern Railways.

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Damodar valley

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62.92 areas of good land for construction.

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Huge no of bank for getting easy cash.

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Available number of skilled and unskilled labours from local area.

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Local growth of city development.

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Good demographic structure is found here.

ULTRATEC CEMENT L M TED
WEST BENGAL CEMENT WORKS
Ultra Tech Cement Limited is certified for quality as per the standard ISO 9001:2000 by DNV.

18 

Ultra Tech Cement Limited is certified for environment protection as per the standard ISO 14001:2000 by DNV.  Ultratech is certified for Occupational Health as per the standard OHSAS 18001:2007 by DNV.  TPM (Total production Maintenance)  Status.  Foundation Stone Laying Ceremony: 15th September 20000 by the then honorable Chief Minister, Sri Buddaded Bhattacharya.  WCM(Work Class Manufacturing)  Work started: - November 2000.  Plant trial was: - 20th December 2001.  Plant trial inauguration:- 12th January 2002.

UTCL started its business in Durgapur in the year 2002.It is professionally managed conglomerate and enhancing stakeholder s value is critical to all their business. Our stakeholder s universe goes customers, shareholders and employees to include communities as well. Our belief that business is not an end in itself but the means to an end. Our people and our processes are at the core of our professionalism. It is their passion, their emotional and intellectual equity that has helped to build and grow our highly successful business. Aditya Birla Group is one building stared teams rather then individual, stars. We believe in people s power. Aditya Birla Group is in fact first multinational company. It has its major investment in 9 countries across 4 continents. Its mission is to build a major position for the group in India, while developing beachheads over seas through profitable export business.

19

EM LOYEE OTENT AL N ULTRATEC CEMENT COM ANY DURGAPUR
Ultratech Cement Limited, cement division of Durgapur has its permanent company staff including Officers, Supervisors, Labourer, etc. counts to 41 in number. They are all salary paid and are
20

responsible for each and every performance of the industry. They will have to look after every safety measures of the workmen not only during the production of quantity and quality of goods, but also after production. The permanent staff also called the Direct Employee. In the above 41 staffs 20 staffs are form Management Cadre i.e., Officers and above category and rest 21 are Support Staff to Assistant Officer Category. The company has its contract workmen, who work under the contracted supervisors as a daily/weekly basis. They are not the company s permanent labourers but are hired from outside by those contractors and they counts to 300 in numbers. They are not responsible so much to any type of wrong performances within the industry during production. So special type of training and safety measures are being taken against them. These are also called Indirect Employees. These employees are hired by different contractors. Below these contractors and there hired employee are shown:Nature Of Work Packing Plant Operation Mechanical Maintenance Electrical and Instrumental Maintenance Hoticulture,Material Handeling,Pentry,Wagon Tippler, Bag Branding and Civil & Office Boy Supply Name Of Contractor M/s Sen. Brothers M/s Raj Engineering Megha Marketing Overall Strength 68 Actual Engagement 58

57

53

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Prgati Cooperative and Labour Contract Construction
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73

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Society Ltd Railway Track Maintenance Project Work Of Silo Ganguly Associate M/s Singh Construction Company M/s Orange Securitas 12 12

22

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Security Deployment

46

46

INDUSTRIAL LAW FOLLOWED IN ULTRATEC CEMENT LIMITED WEST BENGAL CEMENT WORKS
1. Factories Act 1948 & West Bengal Rules 1957
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2. Industrial Dispute Act 1947 & West Bengal Rules 1957 3. Payment of Wages Act 1936 4. Minimum Wages Act 1948 5. Payment of Bonus Act 1965 6. ESI Act 1948 and Regulation 1950 7. Employees P.F & Miscellaneous Provision Act 1952 8. Payment of Gratuity Act 1972 9. Contract Labour Act 1970 10. Industrial Employment(standing order) Act 1946 11. Workmen Compensation Act 1923 12. West Bengal Labour Welfare Fund Act 1974

WEST BENGAL CEMENT WORK MILESTONE EVENT
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First Land Registry  First Excaration in Plant
23

October,2001 October,2000 

        

6.6 KV EHT Line Commissioned Railway Track Laid Down Wagon Tippler Commissioned First Clinker Rake Received Cement Mill Commissioned Cement Production Started Packers Commissioned Cement Dispatch by Road Cement Dispatch by Rail Wagon Loading System Commissioned

September,2001 March,2002 March,2002 March,2001 December,2001 January,2002 January,2002 January,2002 January,2002 July, 2004 

COMPANY PROFILE
Company Name Ultratech Cement Company (An ADITYA BIRLA GROUP of companies)

Industry

Cement Manufacturing

Type of Company Company

Public Limited

24

Unit Name and Address

West Bengal Cement Works Near EPIP, Muchipara, G.T Road Post:-Raj andh, Durgapur 713212 Dist:- Burdwan, West Bengal

Registered Office

Ultratech Cement Limited B-Wing, Ahura Center, 2nd Floor, Mahakali Caves Road, Andheri(east), Mumbai-400093 

Stud of Production System Includ ng Transportation, Handl ng,
25

Loadin , Unloadin , Stora e et . o Ra Materials, Intermediate Goods and Finished Goods.

In this plant they do not have any intermediate products. The details of production system and handling of raw materials and finished products are as under:Ultratech Cement Company, unit of WBCW is a dry process plant fully equipped with modern equipments including ESP and JPF for pollution control. Basic raw materials for cement grinding units are CLINKER, SLAG, GYPSUM and FLY ASH. Clinker is being procured from Hirmi Cement Works (HCW) which is Ultratech Cement Company s own integrated cement plant situated at Raipur in the province of Chhattisgarh. The clinker is being transported from HCW through rail and unloaded at WBCW through wagon tippler and transported to clinker storage Silo if 15000MT through conveyor belt. The other raw materials gypsum, slag and fly ash are being procured from near by area through trucks/browsers/wagons and stored in a covered shed of about 3000Mts. for slag and gypsum and fly ash bin of 500Mts. for fly ash Fly ash is stored in fly-ash closed bin inside the plant to prevent environment pollution. Fly ash is transported from Bakreshwar Thermal Power Plant in a closed container called Bowser in a fly ash bin with the help of pneumatic transport system.

26

Dedicated Separate jet pulse filter has been installed for dedusting of 500MT capacities fly ash bins to keep environment dust free. Raw materials are being filled in their respective hoppers through conveyor belt and fed to the cement mill of closed circuit with high efficiency separator, through electronic weigh feeder in the pre set ratio. The output of the cement mill is transported through screw conveyor and bucket elevator to a Sepax Separator where finer particles are separated from coarser particles. The finer particles are separated from coarser particles. The finer particles are transported to the cement silos through bucket elevator and air slides. Coarser particles are returned to the cement mill for further grinding. This way very consistent fineness of product is maintained. An ESP ensures collection of fine cement dust and discharge into the stream of final product, and thus ensures a dust free environment. Beside ESP, JPF have been provided at every material transfer points and for slag drier to ensure dust free atmosphere. The cement is dispatched through the two Rotary Packer of 90MX capacities each in 50Kg bags.

3(5621$/
Routine Safety check is being carried out by the respective department employee s as well daily safety round by safety officer.

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A full-fledge Occupational Health Centre established and functioning with a qualified doctor. All the eligible employees (both regular and contract employee) are covered under ESI.
27

The company have tie-up with a local Nursing Home, which is situated just 3kms away from the plant for emergency purpose.

25*$1,6$7,21$/(19,5210(17
West Bengal Cement Works has rail and road connectivity to meet inward and outward logistics requirement. The private railway siding is connected to main line of Eastern railway at Durgapur, which is 8.72 kms from plant. The cement is packed in bags with the help of three packers operating round the clock. The packed cement is dispatched to various destinations by road and rail.

25*$1,6$7,21$/&8/785(
385326(  To produce the cement as per marketing requirement with minimum lost. 2%-(&7,9(  Zero Breakdown, Good Housekeeping, Building Trust and Support West Bengal Cement Works is having following facilities:y Clinker unloading by wagon tippler(capacities 15 trips/hrs) y Fly ash browsers unloading system
28

y Cement will 1.0 million ton per annum capacity y Cement dispatch facility by road and rail y Clinker, Gypsum and Fly ash receipt by rail and road respectively

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Factory 16 Flat Residential Complex Assisted Sidings Private Assisted Siding 61.67acres 10,202.4 sq. feet 2830M 2210M

PROCESS FLOW IN ULTRATEC CEMENT COMPANY (WEST BENGAL CEMENT WORKS), DURGAPUR

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Ultratech Cement Company West Bengal cement works
M/s Larsen and Toubro Ltd with effect from 14th May, 2004 demerged its business and a new company named Ultratech Cemco Ltd paving the way for the cement business to be ac uired by Aditya Birla Group s Grasim Industries. It is a wholly owned subsidiary of L&T. According to deal, the L&T will hold 20% of the e uity shares of the new cement company and the balance 80% will be allotted
30

to the e isting L&T shareholders in proportion to their shareholding in the company. Grasim Industry Ltd. agreed to ac uire 8.50% of e uity shares of the new cement company from L&T at Rs.99.30/share and therefore to make an open offer for ac uiring 30% of e uity shares at the same price to the shareholders of the new company with a view to take management control. The pioneer of L&T Ltd. presently known as Ultratech Cemco Ltd. which was setup on 1968 are:y Henning Holck Larsen y SOREN Toubro Ultratech Cemco Ltd. is being lots of specified sectors and few of them can be said as business tycoon:y y y y y y Engineering and Construction Project Construction Heavy Engineering Electrical Business Group Information Technology Cement- formally known as L&T Ltd.

WEST BENGAL CEMENT WORKS PROFILE
WBCW is HCW s second cement grinding unit after Jharsuguda Cement Works with a production capacity of 1.0 MPTA. It is located in the industrial town of west Bengal at Durgapur with 61.67 acres of land. Durgapur is known as Ruhr of Bengal. WBCW is 173 km from Kolkata-New Delhi National Highway (NH-2) i.e., G.T Road. The

31

factory is situated 4 km away from Durgapur railway station on HowrahNew Delhi Rail route. It is well connected by both road and rail. The construction started in October 2000 and completed on November 2001. The factory is producing two types of blended cement namely Portland Pozzolona Cement (PPC) and Portland Slag Cement (PSC). But presently they are only producing Portland Pozzolona Cement (PPC). They are getting Clinker from their mother plant at Hirmi (HCW). Fly-ash is sourced from Bakreshwar Thermal Power Plant and Durgapur Project Limited. Slag is procured from Durgapur Steel Plant and Gypsum (Mineral) from Jodhpur, Rajasthan. The WBCW is playing a vital role in respect of Corporate Social Responsibility toward the society.

KEY TO DEVELOPMENT
The development of a company depends upon its performance in the market. In Ultratech the management follows various methods for initializing the development process. Some of the main processes that Ultratech follows are:-

1) :RUOG&ODVV0DQXIDFWXULQJ  WCM is primarily organized
for bringing the employees closer. In this process various seminars are arranged to discuss the different problems occurs during work and try to find out there possible solution through positive interaction, brainstorming, and discussions on the topics concerned. In many instances, the solutions are achieved thus developing the decision making power of the employees. Sometimes WCM s seminars are held with the aid of video conferencing, which further enable the
32

employees to with a wider cross section of people. The WCM process gives results through

QUALITY

COST

PRODUTIVITY

DELIVERY

INNOVATION 

7RWDO XDOLW 0DQDJHPHQW 7 0 The TQM stands
for Total Quality Management. The philosophy of TQM says that quality is a holistic word and can only be achieved through the participation of each and every employee of an organization whether she/he is a worker or a top officer. It also says that quality is the responsibility of all the employees in an organization. 

6L 6LJPDSix Sigma is a quality standard setup for operation
so as to check the quality standards of a process or the degree of variation of the planned standards or universally accepted standards. Numerically Six Sigma standards for any process are 3.4 defects per million opportunities.
33 

7RWDO3URFH 0DQDJHPHQW 730 TPM stands for
Total Process Management. It means that the processes should be such managed that they produces the optimum output within the operating constraints in a cost effective manner. 

/HDQ0DQDJHPHQWIn Lean Management the firm
produces only that much which is demanded or which maximizes the value of the firm.

34

IN ULTRATEC CEMENT COMPANY (WEST BENGAL CEMENT WORKS)

SAFETY MANAGEMENT
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Documented process for managing risk that integrates operations and technical system with the management of financial and human resource to ensure safety of employee.

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The main purpose of effective safety programme in an organization is to prevent work-related injuries and accidents. A well managed factory will see to it that there are no physical hazards such as
35

(i) Slipping and Falling Hazards, (ii) Collision and Obstruction Hazards, (iii) Equipment Hazards, (iv) Fire Hazards, (v) Hazards from Falling objects, etc. 1. Slipping, tripping, or falling on the floor hazards: People fall when they slip. Highly polished surface, accumulation of water, soap, or oil, etc., on the floor, torn or loose coverings cause the floor to be slippery. 2. Obstruction and Falling hazards: When the factory layout and space management are poor, it results in improper placement of furniture and equipment causing collision of employees with equipment and machinery, tables, chairs, etc. Further, overcrowding and a narrow space for movement also result in accidental collision between employees. 3. Equipment hazards: Quit often, unguarded moving parts, wiring, switches and cards, edges of metal equipment, etc., can cause injuries to employees working in these surroundings. Further, waste paper baskets, lobbies, plumbing fixtures and small snail carts also cause problems for employees. All these should be guarded against 4. Hazards from Falling objects: When file cabinets, lockers and shelves are not properly placed, they could fall on employees and injure them. Also, the stocked materials, paper stands, when placed on the working tables might fall on employees. 5. Fire hzards: The places where paperwork is heavy and precautionary measures taken are nil; the possibilities of accidents are high. Improper disposal facilities for smokers, lack of provision of safety cans for inflammable materials, non-existence of fire escapes and exits are the factors that contribute to fire accidents. It is necessary for the manager to see that fire protection equipment and extinguishers are available at all times in the factory.

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LEGAL PROVISIONS REGARDING SAFETY T E FACTORIES ACT 1948 
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21. Fencing of Machinery.
37

22. Work on near machinery in motion. 23. Employement of young person on dangerous machines. 24. Striking gear and device for cutting off power. 25. Self-acting machines. 26. Casing of new machinery. 27. Prohibition of employment of women and children near cottonopeners. 28. Hoists and Lifts. 29. Lifting machines, chains, ropes and lifting tackles. 30. Revolving machinery 31. Pressure plant. 32. Floors, stairs and means of excess. 33. Pits, sumps, openings in flors etc. 34. Excessive weights. 35. Protection of eyes. 36. Precautions against dangerous fumes, gases etc. 36 (A). Precautions regarding the use of portable electric light. 37. Explosive or inflammable dust, gas etc. 38. Precaution in case of fire. 39. Power to require specifications of defective parts or test of stability.
38

40. Safety of building and machinery. 40 (A). Maintenance of building. 40 (B). Safety Officers. 41. Power to make rules. 41 (A).Constitution of Site Appraisal Committees. 41 (B).Compulsory disclosuser of information by the occupier. 41 (C). Specific responsibility of the occupier in relation to hazardous process. 41 (D). Power of Central Government to appoint Inquiry Committee. 41 (E). Emergency standards 41 (F). Permissible limits of exposure of chemical and toxic substance. 41 (H). Right of workers to about imminent danger.

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In every factory the

following namely-i) every moving part of a prime mover and every flywheel connected to a prime mover, whether the prime mover or flywheel is in the engine house or not. II) The headrace and tailrace of every water-wheel and water turbine. III) Any stock-bar which projects beyond the head stock of a lathe and IV) unless they are in such position or of such construction as to be safe to every person employed in the factory as they could be if they were securely fenced.
39

This provision is strictly followed by UTCL & the details are as follows: All rotating parts of machines are guided by proper mechanical fencing in such a way to achieve zero access machine guard. :RUNRQRUQHDUPDFKLQHU\LQPRWLRQ 

1) Where in any factory it becomes necessary to examine any part of machinery referred in Section 21, while the machinery is in motion , or, as a result of such examination, to carry out- a) in a case referred to in clause i) of the provisions to sub-section(1) of Section 21, lubrication or other adjusting operation; or b) in case referred to in clause (ii) of the provisions aforesaid, any mounting or shipping of belts or other adjusting operations, while the machinery is in motion such examination shall be made.  (PSOR\PHQWRI\RXQJSHUVRQVRQ

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1) No young person at any machine to

which this section applies, unless he has been fully instructed as to the dangers arising in connection with the machine and the precautions to be observed and (a) has received sufficient training in work at the machine, or (b) is under adequate supervision by a person who has a thorough knowledge and experience of the machine. 21 sub-section(1) shall apply to such machines as may be prescribed by the State Government, being machines which in its opinion are of such dangerous character that young person ought not to work at them unless the foregoing requirements are complied with.

40 

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SRZHU 

(1) In every factory (a) suitable striking gear or other efficient

mechanical appliance shall be provided and maintained and used to move driving belts to and from fast and loose pulleys which from part of the transmission machinery, and such gear or appliances shall be so constructed, placed and maintained as to prevent the belt from creeping back to the fast pulleys; (b) driving belts when not in use shall not be allowed to rest or ride upon shafting in motion. (2) In every factory suitable devices for cutting off power in emergencies from running machinery shall be provided and maintained in every workroom: Provided that in respect of factories in operation before the commencement of this Act, the provisions of this sub-section shall apply only to workrooms in which electricity is used as power. (3) When a device, which can advertently shift off to on position, is provided in a factory to cut off power, arrangements shall be provided for looking the device in safe position to prevent accidental starting of the transmission machinery or other machines to which the device is fitted. 6HOI²DFWLQJPDFKLQHV 

No traversing part of a self-

acting machine in any factory & material carried thereon shall, if the space over which it runs is a space over which any person is liable to pass, whether in the course of his employment or otherwise, be allowed to run on its outward or inward traverse within a distance of forty five centimeters form any fixed structure which is not part of the machine. Provided that the Chief Inspector may permit the continued use of a machine installed before the commencement of this Act which does not comply with the requirements of this section on such conditions for ensuring safety as he may think fit to impose.
41 

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(1) In all machinery

driven by power and installed in any factory after the commencement of this Act (a) Every set screw, bolt or key revolving shaft, spindle, wheel or pinion shall be so sunk, uncased or otherwise effectively guarded as to prevent danger. (b) All spur, worm and other toothed or friction gearing which does not require frequent adjustment while in motion, shall be completely encased unless it is so situated as to be as safe it would be if it were completely encased. (2) Whoever sells or lets on hire or, as agent of a seller or hirer, causes or procures to be sold let on hire, for use in factory any machinery driven by power which does not comply with the provisions of sub-section [1] or any rules made under sub-section [3], shall be punishable with imprisonment for a term which may extend to three months or with fine which may extend to five hundred rupees or with both. (3) The State Government may make rules specifying further safeguards to be provided in respect of any other dangerous part of particular machine or class or description of machines. 3URKLELWLRQRIHPSOR\PHQWRIZRPHQ 

FKLOGUHQQHDUFRWWRQ  No women or child shall be employed in
any part of factory for pressing cotton in which in a cotton-opener at work: Provided that if the feed-end of a cotton-opener is in a room separated from the delivery end by a partition extending to the roof or to such height as the Inspector may particular case specify in writing, women and children may be employed on the side of the partition where the feed-end is situated.
42 

+RLVWVDQG/LIWV 

(1) In every factory - a) every hoist

and lift shall be  Of good mechanical construction, sound material and adequate strength;  Properly maintained, and shall be thoroughly examined by a competent person at least once in every period of six months, and a register shall be containing the prescribed particulars of every such examination. b) every hoist way and lift way shall be sufficiently protected by an enclosure fitted with gates, and the hoist or lift and every such enclosure shall be constructed as to prevent any person or thing from being trapped between any part of the hoist or lift any fixed structure or moving part. c) The maximum safe working load shall be plainly marked on every hoist or lift, and no load shall be carried thereon. d) The cage of every hoist or lift used for carrying persons shall be fitted with a gate on each side from which access is afforded to a landing. e) Every gate referred to in clause [b] or clause [d] shall be fitted with interlocking or other efficient device to secure that the gate cannot be opened except when the cage is at landing and that the cage cannot be moved unless the gate is closed. (2) The following additional requirements shall apply to hoists and lifts used for carrying persons & installed or reconstructed in a factory after the commencement of this Act, namelya) Where the cage is supported by rope or chain, there shall be at least two ropes or chains separately connected with the cage & balance weight & each rope or chain with its attachments shall be capable of carrying the whole weight of the cage together with its maximum load, b) efficient devices shall be provided & maintained capable of supporting the cage together with its maximum load in the event of breakage of

43

ropes, chains or attachments. c) An efficient automatic device shall be provided & maintained to prevent the cage from over running. This provision is strictly followed by UL

RA EC

CEMEN LIMITED and the details are as follows: - They have 2
electrical operators overhead hoists/crane which are using for lifting of machinery during maintenance work. Details of these cranes are as follows A) One is located at cement mill area. The capacity of this crane SWL is 20 tones. B) Another EOT is located at wagon tippler at wagon tippler area. The safe working load of this crane is 5 tones. They are having a hoist which is used in production department & located at packing plant (back go down for lifting empty bags from ground level to back godown). The safe working load of this hoist is 20 tones. All these cranes of the hoists are maintained by mechanical department & recorded. These lifting cranes/hoists along with the sling. Deshakles are tested by the competent persons authorized by the Chief Inspector of Factories as per Factories Acts. /LIWLQJPDFKLQHVFKDLQVURSHVOLIWLQJ

WDFNOHV 

(1) In any factory the following provision shall be complied

with respect of every lifting machine & every chain, rope & lifting tackle for the purpose of raising or lowering persons, good or materialsa) All parts including the working gear, whether fixed or movable of every lifting machine. 5HYROYLQJPDFKLQHU\ 

In every factory in which the

process of grinding is carried on there shall be permanently affixed to or placed near each machine in use a notice indicating the maximum safe working peripherals speed of every grindstone, the speed of the shaft or spindle upon which the wheel is mounted & the diameter of the pulley
44

upon such shaft or spindle necessary to secure such safe working peripheral speed. 3UHVVXUH3ODQW 

(1) If in any factory, any plant or

machinery or any part thereof is operated at a pressure above atmospheric pressure, effective measures shall be taken to ensure that the safe working pressure of such plant or machinery or part is exceeded. (2) The State Government may make rules providing for the examination and testing of any plant or machinery. This provision is strictly followed by UTCL & the details are as follows: For operating of their manufacturing processes, they use air which is more than atmospheric pressure & used for correct operation of pneumatically controlled device/machinery. The pneumatic pressure which is more than atmospheric pressure is generated by Air Compressor machine, driven by electric energy. The pressurize air is stored in a closed vessel & carried through enclosed pipelines to the device. This complete setup of pressure valve is used in operation is 7kg/cm². These pressure plants are tested by the competent person authorized by Chief Inspector of Factories. The test certificates are available at safety department. )ORRUV6WDLUV PHDQVRIDFFHVV 

In every

factory- A) All floors, steps, stairs, passages & gangways shall be of sound construction & properly maintained & where it is necessary to ensure safety, stairs, passages and gangways shall be provided with substantial handrails. B) There shall, so far reasonably practicable, be provided and maintained safe means of access to every place at which any person is any time required to work.

45 

3LWV6XPSV2SHQLQJVLQIORRUHWF 

(1) In every

factory every fixed vessel, sumps, tank, pit or opening in the ground or in the floor, which by reason if its depth, situation, construction or contents is or may be a source of danger, shall be either securely covered or fenced. These two provisions (Section 32 & 33) are strictly followed by UTCL and the details are as follows: A) Proper housekeeping is followed & strictly controlled by the management in this unit. (2) To achieve good housekeeping 5S technique is followed and maintained. 5S technique is basically a Japanese technique to achieve good housekeeping. These 5S are: Seiri Identification and separation of necessary and unnecessary items at the work place.  Seiton Arrangement of necessary items in a good order.  Sieso Cleaning of work place to remove dust.  Sriketsu Maintain and record of high standard of housekeeping.  Shitsuke Training of people to follow the housekeeping. ([FHVVLYH:HLJKWV 

(1) No person shall be employed in

any factory to lift, carry or move any load so heavy as to be likely to cause him injury. (2) The State Government may make rules prescribing the maximum weights which may be carried or moved by adult men, adult women, adolescents & chidren. This provision is strictly followed in

UTCL and the details are as follows: - The excessive weight carried by
men is 55kg. No women or children are employed in this unit. 3URWHFWLRQRI(\HV 

In respect of any such manufacturing
46

process carried on in any factory as may be prescribed, being a process

which evolves - A) Risk of injury to the eyes from particles or fragments thrown off in the course of the process, or B) Risk to the eyes by reason of exposure to excessive light, the government may by rules require that effective screens or suitable goggles shall be provided for the protection of persons employed on, or in the immediate vicinity of the process. 3UHFDXWLRQVDJDLQVWGDQJHURXV)XPHV*DVHV

HWF (1) No person shall be required or allowed to enter any
chamber, tank, vat, pit, pipe flue or other confined place in any factory in which gas, fume vapor or dust is likely to be present to such an extent as to involve risk to persons being overcome thereby, unless it is provided with a manhole of adequate size or other effective means of aggress. (2) No person shall be required or allowed to enter any confined space as is referred to in sub-section[1] until all applicable measures have been to remove any gas, fume, vapour or dust, which may be present so as to bring its level within the permissible limits and to prevent any ingress of such gas, fumes, vapour or dust and unless (a) a certificate in writing has been given by a competent person, based on a test carried out by himself that the space is reasonably free from dangerous gas, fumes, vapour or dust; or (b) such person is wearing suitable breathing apparatus and a belt securely attached to a rope the free end of which is held by a person outside the confined space.  $ 3UHFDXWLRQVUHJDUGLQJWKHXVHRISRWDEOH

HOHFWULFOLJKW  In any factory

(a) no portable electric light or any

other electric appliances of voltage exceeding twenty-four volt shall be permitted for use inside any chamber, tank, vat, pipe, flue or other confined space; (b) if any inflammable gas, fume or dust is likely to be present in such chamber, tank, vat, pipe or other confined space, no
47

lamp other than that of flame proof construction shall be permitted to be used therein. ([SORVLYHRU,QIODPPDEOHGXVWJDVHWF 

(1)

Where in any factory any manufacturing process produces dust, gas, fumes or vapour of such character and to such extent as to be likely to explode to ignition, all practicable measures shall be taken to prevent any such explosion by a) effective enclosure of the plant or machinery used in the process; b) removal of the accumulation of such gases, dust, fumes or vapour; c) exclusive enclosure of all possible sources of ignition. (2) Where in any factory any manufacturing used in a process such as is referred to be in sub-section [1] is not so constructed as to withstand the probable pressure which such an explosion as to aforesaid would produce, all practicable measures shall be taken to restrict the spreads and effects of the explosion by the provision in the plant or machinery of chokes, baffles, vents or other effective appliances. (3) Where any part of a machinery in a factory contains any explosive or inflammable gas or vapour under pressure greater then atmospheric pressure; a) before the fastening of any joint of any pipe connected with the part, any flow of the gas or vapour into the part shall be effectively stopped by a stopvalve or other means; b) before any such fastening as aforesaid is removed, all practicable measures shall be taken to reduce the pressure of the gas in the part to atmospheric pressure. (4) No plant, tank or vessel which contains or has contained any explosive or inflammable substance shall be subjected in any factory to any welding, brazing, soldering or cutting operation which involves the application of heat unless adequate measures have first been taken to remove such substance and any fumes arising therefrom. 3UHFDXWLRQLQFDVHRI)LUH
48 

(1) In every factory, all

practicable measures shall be taken to prevent outbreak of fire and its

spread, both internally and externally and to provide and maintain a) safe means of escape for all persons in the event of fire; b) the necessary equipment and facilities for extinguishing fire. (2) Effective measures shall be taken to ensure that in every factory all the workers are familiar with the means of escape. (3) The State Government may make rules in respect of any factory or class. 3RZHUWRUHTXLUHVSHFLILFDWLRQRIGHIHFWLYH

SDUWVRUWHVWRIVWDELOLW\  If it appears to the Inspector that any
building or part of building or any parts of the ways, machinery or plant in a factory is in such a condition that it may be dangerous to human life or safety, he may serve on the factory of an order in writing requiring him before a specific date a) to furnish such drawings, specifications and other particulars as may be necessary to determine whether such building, ways, machinery or plant can be used with safety, or b)n to carry out such tests in such manner as may be specified in the order, and to inform the Inspector of the result thereof. 6DIHW\RI%XLOGLQJ 0DFKLQHU\ 

(1) If it appears

to the Inspector that any building or any part of the ways, machinery or plant in a factory is in such a condition that it is dangerous to human life or safety, he may serve on the an order in writing specifying the measures which in his opinion should be adopted, and requiring them to be carried out before a specified date. (2) If it appears to the Inspector that the use of any building or part of a building or any part of the ways, machinery or plant in a factory involves imminent danger to human life or safety, he may serve on the factory an order in writing prohibiting its use until it has been properly repaired or altered.
49 

$ 0DLQWHQDQFHRI%XLOGLQJ 

If it appears as to the

Inspector that any building or any part of the building in a factory is in such a state of disrepair as is likely to lead to conditions detrimental to the health and welfare of the workers, he may serve on the occupier or manager or both of the factory an order in writing specifying the measures which in his opinion should be taken and requiring the same to be carried as is specified in the order.   % 6DIHW\2IILFHUV 

(1) In every factory wherein one

thousand or more workers are ordinarily employed. (2) The duties, qualifications and conditions of service of Safety Officer shall be such as may prescribed by the State Government. 3RZHUWRPDNH5XOHVWRVXSSOHPHQWWKLVFKDSWHU  

The State Government may make rules requiring to the provisions in any
factory or in any class or description of factories of such further for securing the safety of persons employed therein as it may deem necessary.  $ &RQVWLWXWLRQRI6LWH$SSUDLVDO&RPPLWWHHV 

(1) The State Government may, for purpose of advising it to consider application for grant of permission for the expansion of any such factory, appoint a Site Appraisal Committee consisting of A) The Chief Inspector of the State, B) A representative of Central Board for the Prevention and Control of Water Pollution, C) A representative of Central Board for the Prevention and Control of Air Pollution, D) Representative of State Board, E) A representative of State Board for the Prevention and Control of Air Pollution, F) Representative of Department of Environment in the
50

State, G) Representative of Meteorological Department, H) An expert in the field of Occupation Health & I) Representative of Town Planning Department. (2) The Site Appraisal Committee shall examine an application for the establishment of a factory involving hazardous process.  % &RPSXOVRU\GLVFORVXUHRI,QIRUPDWLRQE\WKH

2FFXSLHU  (1) The occupier of every factory involving a hazardous
process shall disclose in the manner prescribed in all information regarding dangers, including health hazards. (2) The occupier shall act the time of registering the factory involving a hazardous policy with respect to health and safety. (3) Every occupier of a factory shall A) If such factory engages in a hazardous process on the commencement of Act 1987, within a period of 30 days of such commencement & B) If such factory purposes to engage in a hazardous process inn any time after such commencement within a period of 30 days before the commencement of that process.  & 6SHFLILF5HVSRQVLELOLW\RIWKH2FFXSLHULQ

UHODWLRQWR+D]DUGRXVSURFHVV  Every occupier of the factory
involving any hazardous process shall A) Maintain accurate and up to date health record. B) Appoint person who posses qualification and experience in handling hazardous substance. C) Provide medical examination of every worker.  ' 3RZHURI&HQWUDO*RYHUQPHQWWRDSSRLQW

,QTXLU\&RPPLWWHH  (1) Central Government may, in the event of
the occurrence of an extraordinary situation involving a factory engaged
51

in a hazardous process, appoint an enquiry committee into the standards of health and safety observed in the factory. (2) The committee appointed consists of Chairman and two other members and the tenure of office of its member shall be determined by Central Government.  ( (PHUJHQF\6WDQGDUGV 

Where the Central

Government is satisfied that no standards of safety have been prescribed in respect of a hazardous process. The emergency standard shall be incorporated in the rules made under this Act.   ) 3HUPLVVLEOHOLPLWVRI([SRVXUHRI&KHPLFDO 

7R[LFVXEVWDQFH  (1) The maximum permissible threshold limits
of exposure of chemical & toxic substance in manufacturing process in any factory shall be of the value. (2) The Central Government may, at any time, for the purpose of giving effect to any specific proof obtained from specialized institutions or expert in the field.  * :RUNHU·V3DUWLFLSDWLRQLQ6DIHW\

0DQDJHPHQW  (1) The occupier in every factory where an
hazardous process takes place or where hazardous substance are used or handled, set up a Safety Committee of equal member of representative of workers and management and promote cooperation between them. (2) The composition of Safety Committee, the tenure of office of its members and their rights and duties shall be such as may be prescribed.   + 5LJKWRIZRUNHUVWRZDUQDERXW,PPLQHQW

'DQJHU  (1) Where the workers employed in any factory engaged in
52

a hazardous process have reasonable apprehension that there is likelihood of imminent danger to their lives or health due to any accident. (2) It shall be the duty of such agent or manager or person in charge of the factory or process to take remedial action if he is satisfied about the existence of such imminent danger. (3) If the occupier is not satisfied about the existence of any imminent danger as apprehended by the workers, he shall refer the mate forth with to the nearest Inspector. 

ULTRATEC CEMENT LIMITED
ealth and Sa ety Poli y (Rule 63 B o W.B Fa tories Rules, 1958) $ 2%-(&7,9( 
Management of Ultra Tech Cement Ltd. West Bengal Cement Works is engaged in manufacturing of Portland Slog Cement (PSC) & Pozzollon Portland cement (PPC). Management is committed to provide safe and healthy environment to all its employees and associates engaged in the activity of production directly or indirectly.
53

To achieve this object HEALTH AND SAFETY POLICY is being formulated as follow:-

% 7+(32/,&<   

Health and safety procedure of all employees is a major part of the establishment.  The health and safety procedure of the organization is to serve as safety consciousness amongst the employees at all levels.  Promote and maintain safe & healthy working atmosphere with an objective to achieve a zero accident.  The management shall conduct and implement awareness programmers for all levels of employees based on safe working methods and relevant statutory requirements.  Every employee of the factory is responsible in the light of his knowledge & experience with regard to his own personal safety & that of his coworkers as well as of any material/property entrusted to his care.  It should be his duty to . (a) Observe the safety (b) Make use of safety appliances supplied to him. (c) Ensure usage of safety appliances supplied to employers under him by such employers. (d) Follow instruction of the appropriate authority. (e) It shall be the responsibility of every employees and every person undertaking work or every person working in the premises of the factory to act in such a way so that :(i) They do not endanger themselves, other people plant or machineries or materials. (ii) They follow safe working practice, and
54  

 

(iii) They do not damage any equipment or facility provided by the company for ensuring safety measures. The management will have the final authority to take action for violation of the statutory provision for safety and health as well as the rules and procedures. All employees at the time of their joining the company would be given mduction training in safety. Regular safety training for all employees would be arranged on a continuous basis. The health and safety policy of the factory would be adopted without prejudice to the statutory provision.

& 0(',&$/(;$0,1$7,21  
Periodical medical examination will be carried out of all employees in accordance with the rules framed as per West Bengal Factory Rule, 1958.  Occupational health center will be set up with part time medical officer, if required. However, ambulance and first-aid facility with be available in the health center.  During emergencies patients are referred to specialists, nursing home or hospital directly through ESI medical benefit scheme. Such nursing homes are at a stone throw distance from the factory.  We take personal care, by visiting patients who are admitted in nursing home or hospital.

' -2,17&2168/7$7,21 
55 

To effectively implement the safety policy of the factory and to elicit full co-operation of the employees though their representative in the safety committee.

( )81'6$1')$&,/,7,(6  
The company will make separate annual budget for the safety and health of the employees and provision of the funds & facilities in order to effective implementation of the policy of the company.

) 58/(6$1'352&('85(  
The rule & procedure would be same as laid in the statutory provision in the sphere of safety & health & also may be supplemented as agreed by management.

* 67$7,67&6$8',76$1'5(9,(:  
The management shall undertake periodical audit of safety & health by a constituted audit committee with a view to finding out the status of implementation of and compliance of the safety & health recommendation.

56

+ 67$1',1'25'(56  
Every employee would be personally responsible to abide by the provision of low & rules on safety & health. Safety committee would oversee & monitor implementation of the provision of the safety & health.

, 6$)(7<$8',7  
An audit team will be formed under the leadership of a senior officer. This team would be conducting safety audit in the whole factory on regular basis to bring out deficiencies in safety application/procedures with an objective to have continuous improvement in the safety standards.  Another safety audit is conducted by well known safety auditor M/s DNV in every six months.

- (9(5<(03/2<((6+$//81'(57$.( 6$)(7<  
Education of the co-workers voluntarily, thus contributing effectively to the implementation of the safety & health policy of the factory. He should :(a) Observe the safety rules. (b) Make use of safety appliances supplied to employees under him. (c) Ensure usages of safety appliances supplied to employees under him. (d) Follow instruction of the appropriate authority high order of safety discipline has to be maintained by all employees.
57

High order of safety discipline has to maintain by all employees.

. 6$ (7<2 *$1 6$7 21 
Safety committee shall have the following broad functions :(a) Accidents prevent & control including maintenance & upkeep of safety appliance. (b) Publicity, propaganda, education, training & liaison.

UNIT HEAD

Management V ew towards Safety
58

¢

£

£

£

SECTION HEAD SAFETY

E ECTRICA HEAD

MECHANICA HEAD

PROCESS HEAD

CIVI HEAD

¤

¢

¢

TECHNICA HEAD

COMMERCIA HEAD

HEAD P A DEPARTMENT

This organization is having separate Quality, safety; Health & Environment Policy Management implemented all possible steps to achieve total safety towards zero accident work place in this unit. They are having a separate safety department which is looking after exclusively for safety and health of the employees at work place and this department is equipped with all possible modern techniques and control. The department is headed by the general manager technical with one qualified safety officer and other supervisors who are engaged with monitoring and implementing safety measures for continuous improvement to achieve zero accident and health hazard.

4XDOLW\6DIHW\+HDOWK (QYLURQPHQW3ROLF\ 
They are committed to produce and deliver cement of consistent quality to our customers. It shall be our commitment to maintain production improvement and cost effectiveness. We shall continually upgrade employee s knowledge, skills & attitude through systematic training & development by utilizing informational technology. They are committed to develop and implement quality management system as per ISO 9001, environment management system as per ISO 14001 & OHSAS as per OHSAS 18001 and to bring continual improvement in quality, safety and health & environmental performances. They are committed to conserve the environment and treat natural resources with cave and respect. Not only they shall abide by all statutory rules and regulation of environment and safety but to reduce it to an
59

absolute minimum by setting and reviewing environmental and safety objectives and targets. They apply all realistic efforts to prevent injuries, fire explosions, pollution & conditions that may harm the health to the employees or damage the equipments or environment.

6$)(7<&200,77((,18/75$7(&+ &(0(17/,0,7(' 
0HPEHUV 
1. Chairman/technical head. 2. Secretary- safety officer of the plant. 3. Body members- senior persons from each department (technical/mechanical/P&A). 4. 50 of the workers participation is compulsory.

)XQFWLRQ 
1. 2. 3. 4. 5. Monitoring of unsafe condition and activities. Providing suggestion to management to improve health and safety. Providing guidelines to improve safety measures. We follow 50 of participation of workers. We follow the meeting of members monthly.

60

Types of acc dent n Ultratech cement l m ted:

Accidents

Reportable

Non reportable

first aid

nearmiss

61

5HSRUWDEOH if a worker is not able to work for 48 hours, due to an
accident.

1RUHSRUWDEOH if somebody meets an accident and getting injury but
again join his work before 48 hours then it is not reportable accident and it will be called non reportable.

)LUVWDLG if a worker meets an accident, and after getting first aid
continue his normal work.

1HDUPLVV  if an incident happens which may cause for an accident
but not made an accident and nearer to that, that is called nearness. In Ultratech cement limited (WBCW) award is given to the SHUVRQ ZKRUHSRUWVQHDUPLVVZLWKSRVVLEOHUHODWHGFDXVHV  

Causes o a idents:1. 2. 3. 4. 5. 6. 7. Fall of height. Electrocution (electric shock). Impact with rotating machineries. Accident during railway operation. Accident during material handling. Accident during lifting of equipment. Eye injury due to contact of cement dust.

Di erent causes o accidents in this unit for the year 200708:62

1. Lack of concentration. 2. Because of the excavation of soil staked near the power control circuit. 3. Violation of safety rules. 4. Malfunctioning of machinery. 5. Bad condition of road. 6. Unsafe act /unsafe practice. 7. Unknown about the hazard.  

ACCIDENT REPORT FROM 2007- July 09
YEA 2007 Type of Accident Non-Reportable Reportable Fatality No. of Cases 1 1 0

YEAR 2008 Type of Accident
63

No. of Cases

Non-Reportable Reportable Fatality

0 0 0

YEAR 2009(till July) Type of Accident Non-Reportable Reportable Fatality No. of Cases 0 1 0

SAFETY STATITICS OF T E YEAR 2007 and 2008

Safety Statistics Year Sl. No Description 2007 1 2 No. of Fatal accidents to Our employee No. of Fatal accidents to Contractor¶s employee.
64

2008 Nil Nil

Nil Nil

3 4 5 6 7 8

No. of reportable accidents Man days lost Man-hours worked Frequency rate (Reportable) Severity rate (Reportable) Major fire incidences

Nil Nil 707610 0 0 Nil

Nil Nil 662684 0 0 Nil

PROCESS OF SAFETY MEASURES
H-Hazard I-Identification R- Risk A-Assessment
Incident is defined as the combination of accident and near miss.

65

67(3672:$5'6$&&,'(17)5((:25. 3/$&( 
If there is a hazardous source, then it may hit the target and accident happens. Hazard Source Target

In UTCL they can make their workplace accident free by the following steps. y y y y y Elimination towards hazards. Substitution towards hazards. Management control towards hazards. Engineering means towards hazards. Personal protective equipments towards hazards.

Elimination, substitution and engineering means are given the first priority. Management control and personal protective equipment (PPE) are given the second priority.

(OLPLQDWLRQ 
66

If the source that causes accident is permanently eliminated, then accident can be presented. This process is called elimination.

6XEVWLWXWLRQ
If the source is substituted by another are then accident can be prevented.

(QJLQHHULQJPHDQV
If barriers are made between target and source, thus accident can be prevented.

(A)

Ma hine guards

Belt guard

oupling guard

fen ing of e hineries

e hani al guard with interlo ed ele tri ity

(B)
67

protetion against dust
ESP (ele trostati pre ipitator)

Bag filter 

7KHVHDUHWKHPHDVXUHVWDNH E\ 8OWUDWHFKWRSURWHFWWKHH SDUWLF ODWHPDWWH  30     L RQPH WIURPVXVSH H 

Management control and education
Safety training is provided to the employees both internally and externally. Internal training is provided by safety officer and other departmental senior engineers and external training is arranged by P&A through the external institution like Stale Productivity Council, Kolkata, West Bengal, Occupational Health Monitoring Task Force, City Center, Durgapur, & Det Norkse Veritas as India, Park Street, Kolkata. Every workman or supervisor, who are entering our premises are provided with safety induction training before common68

center of work we issue a green card to the workman or supervisor, after completion of training. The duration of training of workers is 45 minutes and for supervisors is 1 and1\2 hours.

&  3HUPLW WR :RUN 37: 
taken while permit to work are:

Following safety measures are

(1) Switches/fazes/breakers switched off/taken out. (2) Is there any possibility of feedback of power? (3) Temporary earth connection details. (4) Caution plates placed on switch/breaker.

'   &RQILQHG 6SDFH$UHD    Following
taken while entering the confined space in Ultra Tech:

safety measures are 

Equipment isolated from main production line.  Minimum Oxygen level of 19.5%. Power ventilation arrangement ensured.  Work area is free from toxic gas/high temperature.  Sufficient light & use of 24 V lamps ensured.  Stairs ladders, platform provided to approach work.  Process clearance for hold up obtained & ensures to be maintained.  Fire fighting arrangement made, if required.  Rescue arrangement made, First Aid Box updated.  To check abd ensure.  Personal protective equipment provided.
69 

Associated job hazards explained to workers.  Person engagement is experienced for the job.

(    :RUN DW +HLJKW   
    

Following safety measures are taken

while working at height in Ultratech: Persons engaged are experienced and suitable for the job. Necessary instructions for safe job execution given. Stairs/ladders provided approach work at height. Ladder tied and supported properly at ends. Work Platform/scaffold of sound construction provided. Safe walk ladder or crawling board provided for working on fragile/false roof.

) +RW:RUN  
*DV&XWWL  3UHFDXWLRQV 

y It should be always kept in a trolley. y Both cylinders (Diluted Acetylene and Oxygen) should be kept separately with proper clamping on the trolley. y There must not be any leakage in the rubber host pipe. y Fuel host pipe (Diluted Acetylene) is red coloured and Oxygen host pipe is sky blue colour. y The gas cutting torch should be fitted i.e., equipped with flash back arrester. y Gas cutter must be provided with gas cutting goggles and apron. y The area should be clean before starting the gas cutting mark. There should not be any combustible material near by the job. y A fire aid extinguisher of DCP type should be kept there for extinguishing any fire incident. 

:HOGL 

6DIHW 0HDVXUHV
70

y Check the proper insulation of welding cables. y Fitness certificates of welding machines. y Welding should be done by trained welder. y Cleaning of the area. There should not be any combustible material. y Welder must be equipped with the following PPE- welding screen, leather, hand gloves, welding apron and welding gloves. y A fire extinguisher is required.

PERSONAL PROTECTIVE EQUIPMENTS

71

1 Safety helmets 2. Safety shoes 3. Safety belts 4. Safety goggles 5. Safety gloves 6. Welding screen 7. Welding apron 8. Ear plug 9. Ear muff

FIRE AND FIRE PREVENTION
72

7KHWKUHHFRPSRQH WVUH +HDW

LUH IRUILUHDUH XHO2[\JH DQ 

OXY EN

FUEL

HEAT

FIRE

&/$66(62 

( 

Combustible Solid like COAL, WOOD, PAPER, GRASS, etc.  Combustible Liquid like PETROL, DISEL, KEROSEN, GREASE, etc.  Combustible Gases like HYDROGEN, ACETYLENE, LPG, etc.  Combustible Metal like POTASSIUM, SODIUM, CALCIUM, etc.

(;7 1*8 6+( (86('
73

The extinguishers which are used for the prevention of large and dangerous fire in a plant area, must have to a effective and strong enough for quick prevention and some of these type used are as follows: 1) Water CO Type 2) Fome Type 3) Dry Chemical Type 4) Carbon Dioxide

&2/285&2$',1*2)3,3(6
The most complex piping requirements may be found in the chemical and allied industries, where, in addition to general industrial applications, pipe systems are used for distribution of raw materials, compounds in process and final products. &2/28586(',17+(3,3(6 RED: - Red is used exclusively in connection with fire prevention and fire fighting equipments. ORANGE: - It indicates dangerous points of machineries that can cut, shock or otherwise, injures. YELLOW: - The universal signal for caution. It is used most often to make areas when there are tripping, falling, storing against, or being caught-inbetween hazards. GREEN: - The basic Safety colour. It should be used to indicate the location of first aid equipments, gas masks, and safety bulletin boards.

74

BLUE: - A cautionary colour. It is a specific warning against starting equipment that being required. It may be used as a general cautionary aid around such equipment as elevator, boilers, scaffolding, ladders, etc. PURPLE: - It indicates the presence of radiations hazards. Tags, Labels, Signs, and floor markers are made with a purple and yellow colour combination. BLAC , WHITE or BLAC & WHITE Combination: - It indicates traffic and housekeeping locations such as stairs ways, dead ends of aisles, etc.

MOCK DRILLING PRACTICES
75

Mock drill fighting is a rehearsal of fire fighting training. It is both indoor & outdoor. There is a participation of response element teams. The mock drill fighting helps to know the drawbacks of the emergency plan. This helps to test the response skill & simultaneous operations. Real life conditions are tested & decision taken.

76

OTHER SAFETY BANNERS IN COMPANY PREMISES

77

78

FIRST AID

For first aid the management of UTCl is very conscious they do the following practices for workers so that they will know about the first aid.

1) Register should be documented. (2) The training for first aid is provided to every department. (3) The first aid box is provided to every department. (4) External guidance is given.

The main constituents in the first aid are:(1) Small size roller bandages (2). (2) Medium size roller bandages (2). (3) Large size roller bandages (1). (4) Cotton wool (2).

By the following practices the workers of UTCL gets the basic training of first aid and how to use the first aid box in any emergency.

79 

80

On Safety Management

3HUVRQDO3URILOH 
Name : Designation : Department: - Technical/Non Technical: No. of years in the company :

&DQGLGDWH·V3URILOH 
Sir, I am Kumar Pratik, pursuing M.B.A form EIILM University, Sikkim and at present undergoing Summer Training Programme which is mandatory for the partial fulfillment of the course curriculum. Here are some questions, which I would like to ask you as a part of my Summer Trainin survey, you are kindly requested to put against your view/response.

1) Does Ultratech provide any special training on safety?
a) Strongly agreed b) Agreed c) Disagree

81

2) Is worker s participation is compulsory for safety committee

in UTCL?
a) Strongly agreed b) Agree c) Disagree

3) Is the management provides special Fire fighting training to

the worker s in UTCL?
a) Strongly agree b) Agree c) Disagree

4) Does the management take care at the maintenance of all

machinery to prevent accident in UTCL?
a) Strongly agree b) Agree c) Disagree

5) Is the management provides any special training on First

Aid?
a) Strongly agree b) Agree c) Disagree

6) Do the workers use safety belts while working at height?
a) Strongly agree b) Agree c) Disagree

7) Is there any engineering device implemented to minimize the

dust in the work place in UTCL?
a) Strongly agree b) Agree c) Disagree

8) Does the awareness of safety help the employees efficiently

in performing their work in UTCL?
a) Strongly agree b) Agree c) Disagree

9) Is there are periodical health checkup system in UTCL?
a) Strongly agree b) Agree c) Disagree

10) Is the factory noise under control?
a) Strongly agree b) Agree c) Disagree

11) Is there any Safety committee formed in UTCL?
a) Strongly agree b) Agree c) Disagree

82

12) Does the management take care at fencing of machinery

in UTCL?
a) Strongly agree b) Agree c) Disagree

13) Is there any safety guards provided to rotating machine

parts in UTCL?
a) Strongly agree b) Agree c) Disagree

14) Do the employees in Ultratech use P.P.E during their

work?
a) Strongly agree b) Agree c) Disagree

15) Is there any rewarding system established for the

employee?
a) Strongly agree b) Agree c) Disagree

16) Are the injuries recorded and discussed in safety

committee meeting from time to time?
a) Strongly agree b) Agree c) Disagree

17) Do you agree that safety awareness can add value to the

organizational effectiveness?
a) Strongly Agree b) Agree c) Disagree

18) Do you think that safety awareness is a tool for achieving

ZERO level of accident?
a) Strongly agree b) Agree c) Disagree

19) Are the safety induction training is given to the new

workman in the plant?
a) Strongly agree b) Agree c) Disagree

83

20) Are the equipments being tested by the competent person

under Factory Act in UTCL?
a) Strongly agree b) Agree c) D isagree

21) Does the company have any Published Health and Safety

manual?
a) Strongly agree b) Agree c) Disagree

22) Does the management take care of the maintenance of

the extinguishers time to time in UTCL?
a) Strongly agree b) Agree c) Disagree

23) Does the management provide First Aid Box to the entire

department?
a) Strongly agree b) Agree c) Disagree

24) Does the management take care of Floors, Stairs and

means of access in UTCL?
a) Strongly agree b) Agree c) Disagree

25) Do you know about the PTW (Permit to Work) System?
a) Strongly agree b) Agree c) Disagree

26) Do you know that UTCL got OHSAS 18001:2007 Certificate

for Health and Safety?
a) Strongly agree b) Agree c) Disagree

84

4XHVWLRQV5HODWHGWR0DQDJHPHQW
27) Do you feel the employees are well known regarding the

new techniques and way of performing their Job or Operation?
a) Strongly agree b) Agree c) Can t Say d) Disagree

28) Do you think that the employees are maintaining good

Interpersonal Relationship?
a) Strongly agree b) Agree c) Can t Say d) Disagree

29) Do you feel the employees are successful in maintaining

the industrial environment healthy and hazard free?
a) Strongly agree b) Agree c) Can t Say d) Disagree

30) Do you feel that employees are well aware of

Organization s Rule and Regulations?
a) Strongly agree b) Agree c) Can t Say d) Disagree

31) In UTCL does Safety awareness among employees helps to

work efficiently in performing his/her task?
a) Strongly agree b) Agree c) Can t Say d) Disagree

32) What do you think that On the Job Training is always

effective for the organization?
a) Strongly agree b) Agree c) Can t Say d) Disagree

33) Does the company have any appraisal system for the

excellent performance of staff of UTCL?
a) Strongly agree b) Agree c) Can t Say d) Disagree

85 

DATA ANALYSIS
1) Does Ultrate h pro ide any spe ial training on safety?
a) Strongly agreed b) Agreed c) Disagree

WORKERS
5

20 Str ngly Agree
Agree Disagree 75

75% of Workers are strongly agreed that UTCL provides them special training on Safety, 20% Workers only agreed that it provides training but to some extent, 5% Workers says that it do not provide any special training.

2) Is the anage ent pro ides spe ial Fire fighting training to the wor er s in UTCL?
b) Strongly agree b) Agree c) Disagree

86

¥

WORKERS

10

20

Strongly Agree Agree
Disagree

70

From the above question we get to know that 70% of the Workers syas that UTCL provide them special training on Fire fighting where, 20% says it provides but not good enough. 10% says that they do not provide any special training on fire fighting.

3) Is there are periodi al health he up syste
b) Strongly agree b) Agree c) Disagree

in UTCL?

87

WORKERS
0

Strongly Agree
Agree Disagree

00

From the above question we get to know that 100% of the Workers says that UTCL Provide their periodical Health Checkup.

4) Do the e ployees in Ultrate h use P.P.E (Personal Prote ti e Equip ent) during their wor ?
b) Strongly agree b) Agree c) Disagree

5 10

¦

WORKERS

Strongly Agree Agree Disagree

85

88

85% of the Workers are Strongly Agreed that they use PPE during their work where, 10% only Agree with this question and 5% are Disagree with this.

5) Do you now about the PTW (Per it to Wor ) Syste ?
b) Strongly agree b) Agree c) Disagree

WORKERS
0

Strongly Agree Agree Disagree

00

100% of the Workers of UTCL are Strongly Agree that they know about the PTW (Permit to Work) system and they use this system when it required.

6) Is there any Safety o
b) Strongly agree b) Agree

§

ittee for ed in UTCL?
c) Disagree

89

WORKERS
0

Strongly Agree
Agree Disagree

00

100% of the Workers of UTCL are Strongly Agree that there is a Safety Committee in UTCL no worker says that there is not any Safety Committee in UTCL.

7) Do you thin that safety awareness is a tool for a hie ing ZERO le el of a ident?
b) Strongly agree b) Agree c) Disagree

¨

90

WORKERS
0

10

Strongly Agree
Agree Disagree

90

90% of the Workers Strongly Agree that Safety Awareness is a tool for achieveing ZERO level of accident while 10% of workers only Agree with that point.

8) Is there any engineering de i e i ple ented to the dust in the wor pla e in UTCL?
b) Strongly agree b) Agree c) Disagree

ini i e

WORKERS

0

0

© 



Strongly Agree Agree
Disagree

0

91

80% of Workers Strongly Agree that yes the Dust of the Plant is minimized through engineering device while 10% only Agree that it is not good enough to minimize the dust and rest 10% are Disagree with this question they says that the dust is not minimized.

9) Is there any rewarding syste e ployee?
b) Strongly agree b) Agree

established for the
c) Disagree

WORKERS
0

Str ngly Agree Agree

Disagree

100

100% of the Workers of UTCL Strongly Agreed that yes there is a Rewarding system in UTCL they got reward when they report any near miss case in the plant for every near miss report they got Rs.20

10) Does the anage ent ta e are at the aintenan e of all a hinery to pre ent a ident in UTCL?
b) Strongly agree b) Agree c) Disagree

92 

WORKERS
0

10

Strongly Agree
Agree Disagree

90

In UTCL 90% of the workers Strongly Agreed that yes the management takes care of the maintenance of machineries to prevent accident while 10% only agree with this.

FINDINGS 
After survey it is found that majority is agreed that UTCL provides Special Safety Training to them for Safety Awareness.  Though majority agreed that management does provide special training on First Aid but few suggest that there should be more improvement in this.

93 

Some of the workers agreed that UTCL does provide special training on Fire Fighting but few are disagree with this view.  Though maximum are agreed that they use PPE during their work while are not agree with this.  Though maximum of the employees agreed that the awareness of safety help them to work efficiently in UTCL, but few disagree with this view.  Majority agreed with the view that they use safety belts while working at height.  Maximum agreed that the management take care of machineries.  Majority agreed that workers participation is compulsory in safety committee.  Maximum employees strongly agreed that there is a engineering device that minimize the dust.  Maximum employees are strongly agreed that the machineries are well fenced.  Majority of workers are agreed that their periodical medical check up is done under UTCL.  Maximum workers are strongly that yes UTCL have a rewarding system  Majority of workers are agreed that they take special permit for working in confined space.  Maximum employees are known about the PTW system.  Most of the workers strongly agreed that safety awareness is a tool for achieving ZERO level of accident in plant but few are disagree with that point.

94

RECOMMENDATIONS 
The duration of Safety Training should be increased.  Little importance s required in the training of First Aid.  More emphasis should be given on the training of Fire Fighting.  There should be availability of PPE in UTCL.
95 

There should be more programmed schedules to enhance
awareness of Safety among employees in UTCL. 

There should be sufficient availability of Safety Belts in UTCL.  The machines should be maintained properly.  The participation of both the workers and management in Safety
Committee in UTCL is necessary. 

More modernized device should be implemented to minimize dust  All are satisfied with First Aid Box.  Approaching road to the factory area outside the main entrance is
very hazardous.

CONCLUSION

The management of Ultratech Cement Company (West Bengal Cement Works) Durgapur, implemented all possible steps to achieve total Safety towards ZERO accident workplace.
96

Any visitor before entering the premises of the factory has to show the gate pass. It is the rule in UTCl to wear Safety Helmets while entering on the premises. UTCL provides regular health checkup for workers and for staffs also. It also provides all needed safety training to the workers for the safety awareness so that there is no accident. For better and good safety environment the management do the safety audit weekly to identify and rectify the near miss cases also there is a monthly safety review meeting is held. UTCL also got the ISO certificate OHSAS 18001:2007 for occupational health and safety system. UTCL is doing the entire possible thing to maintain the safety in the plant also by keeping the worker happy.

BIBLOGRAPHY
The following web site and books I have used for collecting more information 

web site of Aditya Birla Group www.adityabirlagroup.com www.ultratech.com 

Book which I have used for the project V.S.P.Rao of Human Resource Management
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