You are on page 1of 46

ACC LIMITED, Damodhar Cement Works, Purulia

A Project Report on
Effectiveness of Safety Training
At
Damodhar Cement works of ACC Ltd.
By
Chitritak Mukherjee
From
International Business School,Kolkata

Enrollment No.EIILMU/09/S0069
ACKNOWLEDGEMENT

I am deeply indebted to my esteemed Dean Mr. Sudipta Mitra


(International Business School, Kolkata), for his kind and constant
encouragement.

My gratitude is also due to Mr. Kaushik Chakraborty (Head plant HRM),


Jay Mukherjee (Departmental head) and special thanks to Mr.Shrissendu
Adhikari (Plant Head) for coordinating and providing all assistance of
guidance throughout my work.

I also express my thanks to my teacher Mrs. Mahua Banerjee for boosting


me to complete the project which has a great value addition. .

I would like to extend my thanks to all the respondents who patiently


answered to all my queries and cooperated with us and provided me with
all the valuable information that, I needed for my project study.

Chitritak Mukherjee
DECLARATION

This is to certify that dissertation entitled ‘Effectiveness


of Safety Training’ at ACC Limited, DAMODHAR
CEMENT WORKS , Madhukunda, District - Purulia has been prepared
by Mr. Chitritak Mukherjee in the partial fulfillment of the requirement
of Masters Degree in Human Resources at International Business School,
Kolkata.

I hereby declare that all the information and facts produced here are based
on my own findings and studies at ACC Limited, Damodhar Cement
Works are original in nature. The contents of report are a true expression
of my efforts on the said topic.

Any resemblance to earlier project or research is purely co-incidental.

Chitritak
Mukherjee
MBA – 2009-2010
International Business
School, Kolkata
Page No.
 Introduction 5-6
 History 7
 Plants and their Capacity 8
 Milestones of ACC Ltd. 9-13
 Achievements of ACC Ltd. 14-16
 Awards and Accolades 17-18
 Present Employee status 19
 Corporate Social Responsibility 20
 Social Program and Entertainment Program 21
 Objective of the project 22
 Scope of the Project 23
 Holcim Pyramid 24
 Analysis 25-35
 Cardinal rules of DCW,ACC 36
 Safety Policies 37-39
 Need Assessment 40
 Safety Topics and Suggestions 41
 Made Safety team in plant adjoining township 42
 Vehicle and Training safety 43
 Training on Mental Strength 44
 Training on machine guarding 45
 Fire fighting 46-47
 Conclusion 48
“To be safe is to be human”-but contrary to popular belief, most big accidents or
disasters have in fact taken place due to seemingly human beings to play safe,
whereas it is lack of wisdom that induces a man to adopt calculated risk i.e. unsafe
practices. Though data & information regarding life build up instinct, environmental
situations sometimes predominated over instinct when lack of judgment overrules
wisdom-resulting in danger. In order to react correctly in such situation, both instinct
& wisdom require to appear at surface.

Keeping in mind that safety engineering has become one of the most complexes of
engineering discipline, certain commandment learnt from experience need to be
enforced as far as industrial safety is concerned. It is also true that, strict adherence to
military discipline & commandments may convert human beings to virtual robots
when they fail to rise or act when demanded by extraordinary situation.

If we study the expert’s conclusions on the various factors lead to accidents in


industries, it will be found that among all, the human factor is the most predominated.
The human factor includes lack of knowledge or incomplete understanding of the
hazards involved, error of judgment, negligence, folly, frivolity, bravado, sheer
indifference, absentmindedness, practical jokes and operational fatigue.

The above mentioned factors may be sub-dived into different categories if we intend
to arrive at a solution to our presentation to our present day problems. Some of the
factors like lack of knowledge & error of judgment are outcome of basic ignorance
which includes lack of experience as well as lack of aptitude for the job. It is possible
to overcome these factors only through proper coordination & empathy of all around
besides training & increased scope of acquaintance with the system.

Certain other governing factors like negligence, folly, sheer indifference and
absentmindedness are primarily the results of basic human nature. Social
environmental constraints also add to these factors. In order to overrule these a careful
study of the individual and development of mutual trust along with increased
accountability are of foremost importance.

Other situation-based unavoidable factors like operation fatigue and operational


hazards play a vital role as far as safety is concerned. Science these factors vary

widely with the physical and mental capability and limitations of the individual. It
calls for an in-depth study of system as well as human involvement.

A scrutiny of the last two year’s accident cases in a utility organization like ours
reveals that apart factors like absentmindedness, casual approach and irrational
emotive behavior, etc, most, of the incidents were caused due to communication gap
and lack of interdepartmental coordination,

Apprehension of criticism & public communication while on-the-job leads to anxiety


which is likely to be a dominating factor leading to absentmindedness- a factor
beyond the individual’s control.
This however demands a robotic approach towards the job for safety, though not in its
entirety since jobs are mostly varying in nature. In order to ensure greater safety, the
systems with its associates need to act as back-up to disciplines & commandments &
that too as a natural process,

Apart from developing the system as a back-up, endeavor to adhere to traditional


prevailing practices and procedural methods is necessary.

A continuous evaluation of safety systems is also required in order to convert the


disciplines & commandments into a natural process considering the complexities of
our present day problems & challenges of the future.
(DAMODHAR CEMENT WORKS-OVERVIEW)

 DAMODHAR CEMENT WORKS is a ISO 9000 & 14000 unit of ACC. It


was promoted by Ashoka Cement Ltd. and West Bengal Industrial
Development Corporation Ltd in the year of 1978.

 Ashoka Cement Ltd. later disinvested its entire holdings in DCSL to WBIDC
in May 1981 and subsequently WBIDC and Cement Corporation of India Ltd.
(CCI) executed a joint venture agreement in July 1983. From October 1990 it
started its commercial production.

 Bad time for ACC(sick period)


 Suddenly Acc faced lots of problem. Its net worth became negative. Then the
company was referred to Bureau of Industrial & Financial Reconstruction
(BIFR)

 In September 1996 The Associated Cement Cos. Ltd. (ACC) took over the
management of the Company and it became a subsidiary of The ACC Ltd.
with WBIDC as a partner.

 In the year of 1998 after taken up by Acc capacity enhancement from 2.72 to
5.25 LTPA.

 DCSL got fully merged with ACC in Jan-2006


Plants & Their Capacity:
S.
Units State Capacity (MTPA)
No.
Bargarh Cement Works
1 Bargarh 0.96
Chaibasa Cement Works
2 Chaibasa 0.87
Chanda Cement Works
3 Chanda 1.00
Damodar Cement Works
4 Damodhar 0.53
Gagal Cement Works 4.40
5 Gagal
(Gagal I and II)
Jamul Cement Works
6 Jamul 1.58
Kymore Cement Works
7 Kymore 2.20
Lakheri Cement Works
8 Lakheri 1.50
Madukkarai Cement Works
9 Madukkarai 0.96
Sindri Cement Works
10 Sindri 0.91
Wadi Cement Works
11 Wadi 2.59
Wadi Cement Works
12 New Wadi Plant 2.60
Tikaria Cement Grinding and
13 Tikaria Packing Plant 2.31
Milestones of ACC Limited
1936 Incorporation of The Associated Cement Companies Limited on August 1,
1936.

1936 First Board Meeting of The Associated Cement Companies Limited held at
Esplanade House, Mumbai on November 10, 1936.

1937 With the transfer of the 10th company to ACC, viz. Dewarkhand Cement
Company, the formation of ACC is complete on October 23, 1937.

1944 ACC’s first community development venture near Bombay

1947 India’s first entirely indigenous cement plant established at Chaibasa in


Bihar

1952 Village Welfare Scheme launched

1955 Sindri cement works used the waste product calcium carbonate sludge from
fertilizer factory at Sindri.

1956 Bulk Cement Depot established at Okhla, Delhi

1957 Technical training institute established at Kymore, Madhya Pradesh.

1957 Katni Refractories

1961 Blast furnace slag from TISCO used at the Chaibasa Unit to manufacture
Portland Slag Cement for the first time in India.

1961 Manufacture of Accocid Cement, which resists the corrosive action of acids
and chemicals.

1961 Oilwell Cement manufactured at ACC Shahabad Cement Works in


Karnataka for cementation of oilwells up to a depth of 6,000 feet.

1961 Manufacture of Hydrophobic (waterproof) cement at ACC Khalari Cement


Works in Bihar.
Achievement of ACC Limited:

YEAR

1936 The Associated Cement Companies Limited incorporated on August 1

1947 India's first entirely indigenous cement plant installed at Chaibasa.


ACC Sindri uses waste material - calcium carbonate sludge -from fertilizer
1955
factory at Sindri to make cement
1956 Bulk Cement Depot established at Okhla, Delhi
Blast furnace slag, (a waste by-product from steel) from TISCO used at ACC
1961
Chaibasa to manufacture Portland Slag Cement.
Oilwell Cement manufactured at ACC Shahabad for cementation of oil wells
1961
up to adepth of 6,000 feet.
1961 Manufacture of Hydrophobic (waterproof) cement at ACC Khalari.
Manufacture of Portland Pozzolana Cement using naturally available materials.
1965
An Eco-friendly cements using an eco-friendly process.
ACC inducts use of pollution control equipment and high efficiency
1966 sophisticated electrostatic precipitators for its cement plants and captive power
plants decades before it becomes mandatory to do so.
Introduction of the energy efficient pre-calcination technology for the first time
1978
in India.
Commissioning of the first 1 MTPA (million tonne per annum) plant in the
1982
country at Wadi, Karnataka.
ACC achieves a breakthrough in import substitution by developing and
1984
supplying a special G type of oil well cement to ONGC.
ACC develops a new binder, working at sub-zero temperature, which is
1987
successfully used in the Indian expedition to Antarctica.
Incorporation of Bulk Cement Corporation of India, a JV with the Government
1992
of India.
1993 Commercial manufacture of ready-mixed concrete at Mumbai.
Commissioning of the new Wadi plant of 2.6 MTPA capacity in Karnataka, the
2001
largest in India, and among the largest sized kilns in the World.

ACC Cement:

ACC’s brand name is synonymous with cement . its marketing, sales and
distribution processes are industry standards. The brand building
approach to marketing cement which was first adopted by ACC has
proved to be exceptionally successful in respect of blended cements in
terms of providing more effective communication with customers and
has been emulated by other companies in the industry.

Ready- Mix Concrete:


ACC established the country’s first commercial ready-mix concrete
(RMX) in Mumbai. ACC’s pioneering efforts in this respect along with
the introduction of bulk cement handling facilities have been responsible
for redefining the pace and quality of construction activity in metropolitan
cities and in mega infrastructure projects. The JJ flyover in Mumbai was
the first mega construction project in India to use High Performance
Concrete of M-75 grad.

Research & Development:

ACC is the only cement producer in India with its own in-house Research
and Development facility. The sprawling Research and Consultancy
Directorate
(RCD) complex at Thane near Mumbai has a unique track record of
innovative research and specialized technological services.
RCD has helped introduce some unique special projects of immense
value to the concrete and construction sectors. These include repair
products and grouts and Ancones, a non explosive demolition agent. RCD
has developed Acc marg, a revolutionary new product and grouting
composition for the construction and repair of new roads and highways.
The services of concrete group at RCD have been utilized in the striation
of several heritage buildings across the country, such as the CST terminus
at Mumbai, churches and royal palaces in Goa, Mysore and Hyderabad.
Awards & Accolades
• IMC Ramakrishna Bajaj National Quality Award - – Gagal wins Commendation
Certificate and New Wadi Plant wins Special Award for Performance Excellence in
the Manufacturing Sector, 2007.

• National Award for outstanding performance in promoting rural and


agricultural development – by ASSOCHAM

• Sword of Honour - by British Safety Council, United Kingdom for excellence in


safety performance.

• Indira Priyadarshini Vrikshamitra Award --- by The Ministry of Environment and


Forests for "extraordinary work" carried out in the area of afforestation.

• FICCI Award --- for innovative measures for control of pollution, waste
management & conservation of mineral resources in mines and plant.

• Subh Karan Sarawagi Environment Award - by The Federation of Indian Mineral


Industries for environment protection measures.

• Drona Trophy - By Indian Bureau Of Mines for extra ordinary efforts in protection
of Environment and mineral conservation in the large mechanized mines sector.

• Indo German Greentech Environment Excellence Award

• Golden Peacock Environment Management Special Award - for outstanding


efforts in Environment Management in the large manufacturing sector.

• Indira Gandhi Memorial National Award - for excellent performance in


prevention of pollution and ecological development

• Excellence in Management of Health, Safety and Environment : Certificate of


Merit by Indian Chemical Manufacturers Association

• Vishwakarma Rashtriya Puraskar trophy for outstanding performance in safety


and mine working

• Good Corporate Citizen Award - by PHD Chamber of Commerce and Industry

• Jamnalal Bajaj Uchit Vyavahar Puraskar - Certificate of Merit by Council for


Fair Business Practices

• Greentech Safety Gold and Silver Awards - for outstanding performance in Safety
management systems by Greentech Foundation
ACC was the first recipient of ASSOCHAM’s first ever National
Award for outstanding performance in promoting rural and
agricultural development activities in 1976.

Decades later, PHD Chamber of Commerce and Industry selected


ACC as winner of its Good Corporate Citizen Award for the year
2002.

Over the years, there have been many awards and felicitations for
achievements in Rural and community development, Safety, Health, Tree
plantation, A forestation, Clean Mining, Environment Awareness and
Protection.

PRESENT EMPLOYEE STATUS

Permanent employees: 243 (MS: 29, NMS: 214)


Sub contracted FTE: 168 (governed by
cement wage board terms)
Education level – MS (23 Engineers, 6 non engineers)
- NMS (mostly undergraduate)
Alignment of service terms and conditions of NMS: 1st Sept, 2008
Average age: MS: 40
NMS: 45
Training mandays: More than 6 per employee (2008)
A big company never be big with doing something big for that it always be remember
by the society for ever.Acc also doing lots of social activity from last few years.
Some of the social activity are as follows;

o Need assessment done in 2 villages

o Health camps are held: Directly Impacted – 150

o Literacy classes conducted for rural women – 10

o Stitching and knitting classes conducted for rural women – 40

o HIV/AIDs program for truckers


o Up gradation of DAV school

o Providing transport support to school children during exam days

SOCIAL PROGRAM & ENTERTAINMENT PROGRAM


ORGANISED
BY
DCW, ACC

 Durga puja
 Rural football tournament
 Yoga Camp
 Annual Picnic
 Christmas Day celebration
 Republic Day celebration & Annapurna Utsav
 Film Shows
 Shiva Ratri Festival
 Holi Milan
 Construction of new club

The main objective of the project is to measure the effectiveness of


training & development to be one of the major interventions in attaining
not only the safety targets of the unit but to considerably enhance the
safety culture to reach the ultimate organizational goal of ‘zero harm’ to
every body associated with DCW.

Effective training will result in the following:

1. Improvement of operational efficiency of work.


2. Effective time management while maintaining highest standards of
safety.
3. Perceptible behavioral change among employees on matters related
to safety
4. Adequate knowledge in all safety initiatives like work permit, JSA
etc
5. Steady decline in incidents
6. Widespread awareness among the less educated workforce with a
strong focus on contract labor.
7. Vast improvement in the technical knowledge during job
execution.
8. Reduction in cost and wastage.
9. Ability to follow the standard operating procedures (SOPs).

Safety is one of the core values of ACC.ACC aspires to have the best safety records in
the country and unwavering believe in the principals of “NO HARM TO ANYONE”.
Associated with it. To achieve these cherished goal ACC Ltd. has unleashed several
inactive involving all employees including contract employees in the past few years.

Robust training program on both technical and behavioral


safety have been imparted to all by internal external experts.

The scope of this project is strictly limited to examine the


effectiveness of the training programs and their consequent contribution to achieve the
safety goal.

Health &
Wealth Issues

90%
Occupational Procurement Management
Rehabilitationn of Changes
88% 68% 73%

Safe Working Inspection Design Audit and


Procedure and Testing safety System
Improvement

90% 75% 74% 53%

Induction and Incident Industrial Employee Information


Training Investigation and Hygiene and communicatio and
corrective Action Monitering n and Reporting
involvement

90% 89% 53% 88% 82%

Roles, Hazerdous Hazard Planned Legal Management


Responsibilitie work identifation Inspections Obligations commitment
s and Activities and risk and Planning
Accountibilitie Assessment

88% 87% 86% 80% 91% 92%

HOURS SPENT FOR TRAINING


As we see here every yearACC has increased the time for giving trining
to their employees sothay could be well trained and chances of any
accident will be minimum.

THE FATALITY AND NON-FATALITY RATIO


Here Fatality means death of any worker or employee during working
hours at ACC plant and Non-Fatality means chances of any injury of an
employee during working hours at ACC plant where no chance to die.

In this analysis we see that in the last 5 years fatality is only 1 which is
less than 1% and No. of non fatality is 275 which covers the remaining
area of the above pie chart.

NON-FATALITY AREAS
Here in the pie chart, each areas of non-fatality has been shown with their
percentage of happening.

From this chat e see that out of these incidents maximum no, are near
miss incidents which is 63%,then minor injury 27%,then medical
treatment like first aid come only 6%.

MEDICAL TREATMENT GIVEN TO EMPLOYEES


From the above table we see in the last 5 years the No. of employees
taken medical treatment from the plant for any reason.

NO. OF TOTAL INCIDENT REPORTS


Here No. of total incident reports in the last 5 years if we see the table
then see that it is fluctuating, But in the last 2 years it decreased.

NO. OF NEAR MISS INCIDENTS


In this chart we see that the No. of near miss incidents are decreasing in
the last 2 years.

WORKING HOURS OF EMPLOYEES


The chart shows that every year the working hours of employees has
increased .Only at 2007 it was very long suddenly.
WORK DAYS LOST

Here the No. of work days lost is maximum at 2007 and after that it
decreased every year. On the year 2010 till the month of May, not a single
work day lost.
NAME OF TRAINNG PROGRAM AND HOURS SPENT
FOR TRAINING-1

ACC LTD gives training employees. Some of them here shown above,
Out of these we may see that the No. of participants and hours of training
are maximum for work permit with new format and emergency
preparedness.
NAME OF TRAINNG PROGRAM AND HOURS SPENT
FOR TRAINING-2

From the above chart we see that No. of employees are more or less same
for all training programs but trining hours spent for Computer Ergonimics
is maximum.

NAME OF TRAINNG PROGRAM AND HOURS SPENT


FOR TRAINING-3
Here For every training program No. of trainees are more or less same but
hours spent maximum for workshop on JSA training.

From all the training programs we have seen that For most of the
programs average 2 hours used for an employee. But there are also
exceptions. As for Computer Ergonomics and Workshop on JSA
trainings. For Those trainings 8 hours have been spent for each employee.
From that we can understand that ACC has given more importance in
these trainings than other training programs.

As a part of PaSSion for safety(a new inactive),a set o Cardinal Rules


have been developed to use in ACC in their journey towards zero harm.

Those rules are as follows;


1. Do not override or interfere with any safety provision nor allow anyone else to
override or interfere with them.

2. Personal Protective Equipment (PPE) rules applicable to a given task must be


adhered to at all times.

3. Isolation & Lockout procedure must always be followed.

4. No person may work if under the influence of alcohol or drugs.

5. All injuries and incidents must be reported.

Safety is a back bone of a company. If the safety procedure is well, then no accident
will be happened in a plant or a company ,so that the company run safely.

Making this safety policy strong or rigid


lots safety policies have been taken by a company. Various safety training, lots of
safety awareness program & lots of different things are included in this safety policy.

Before giving any type of safety training, the 1st step of this policy is to
find in which area, what type of safety training is needed. This process is called need
assessment process. After that a training schedule is made. This training schedule is
containing of these following things,
1) which area or department training is needed.
2) What type of training is needed.
3) Who will be conducting the training program(external or internal faculty)
4) What will be the time period of deferent training program.
After observing all the elements training program is conducted.

But sometimes it’s seen that after giving training though same type of
mistake is happening again & again.

Then it have to find it out that what type of lack or misunderstanding is


happening in this training program. Main motto of a training program is to make a
habit for the persons that they do not again do the same mistake which they did before
taking those training.

Last stage is to observe or do a research that really training process is able to


solve the mistakes for which those training have given. If the mistakes have
decreased, then the training process is successful.

ACC safety follows some well accepted transparent rules. As per the rules ACC
follows some steps & they also try to keep document in written form also.

For keeping this document in written form ACC use some forms. One of the form is
SAFETY OBSERVATION TOUR. This observation form have lots of heads or
column by filling up those heads the observer’s easily keep in records which he have
seen in the time of observation, Except that there is another form which called SOT
OBSERVATION TABLE. Where observer easily record the feedback about safe 7
unsafe work. There is another type of form where have space for different work(like
hot work excavation & digging, electrical work, work at a hight etc) It is compulsory
to fill-up this form. By filling-up this form it’s became clear that what types of risk
related with what types of risk is related with what types of work, How the work will
be performed.

There are lots of training program in ACC which provides for making people aware of
different types of safety, trained them against different types of unsafe work will not
happened by those people. Those training are given all the person in the category of
the contractor & the employee both.

There are different types of training program provided for different types of safety.
The training have given by internal & external faculties. Every training program
contains lots of thing that help to make people understand clearly about the training.
Training program contains presentation on training, practical exercise etc. After the
finishing of this training program a feedback process must be there to know how it
have helped the participants. By this feedback we can understand that it’s effective or
not.

Mother concern of ACC is Holsim. Holsim is followed their own competency module
to drive the business.

COMPETENCY;

It’s defined as a behavior or set of behaviors that excellent performance


in a particular work context

Holsim competency has four buckets.

1. Think the business..


2. Act as role model.
3. Deliver result.
4. Energize result.

The four bucket help to understand the business, make the people energetic for
doing their job carefully.

Each block have different part. By applying those part or process work become
easy & transparent to perform. One of the main think is to assume about the result.
If we can measure the out comes then it will good for the company.

Holsim is followed a triangle about safety. In this triangle the lower base is
minimal injury & top place is fatality.
1
Fata
lity

30
Loss time injury

300
Medical treatment injury

3000
Near Miss

30000
UN Safe act

Those training have been provided for solving those problem.

Beside the objective one of the vital things before starting the project is is need
assessment. By this we can understand the particular reason behind doing this
project.
The things which observed at need assessment are as follows;
- 1) the organizational goals and its effectiveness in
Reaching the goals.

2) Gaps or discrepancies between current and future performance.

3) Types of programs needed



4) Target audience

5) Content based on facts

6) Parameters for cost effectiveness

The levels of need assessment are as follows;

• Organizational assessment- Identifies the knowledge, skills and abilities


employees need in the future

• Task assessment- Compares job requirements with employee knowledge and


skills to identify areas needing improvement

• Individual assessment- Focuses on individual employees and how they


perform their jobs usually determined thorough performance reviews

I have chosen some of the field in safety department & on those things I want 2 give
safety suggestions.

RISK ASSESSMENT
My first chosen topic is risk assessment. Why I have chosen risk assessment as my
first topic for safety I want to clarify it.

We need safety because we want to save ourselves from risk or any danger’s. First I
have to identify which type of risk is waiting for us. The process of identify is called
risk assessment. So how we identify the risk, which type of training is given for the
risk assessment, which type of more training we can able to give them those are my
discussing thing.

For that RISK ASSESSMENT ACC provides lots of internal training. Those help to
improve employees ability in risk assessment. We think those type is very much
needed for the employees.

But we know after getting those type of training though lots of accident are on in the
factory. After assuming the risk lots of accident is happening in the factories. So I
want 2 give some suggestion.

Suggestions are as follows;

• If some type of accident have happened in any where then collect the picture
of that accident place from all location,& show the people who are involving
in risk assessment. By that they can get an idea that what type of accident had
happened & they have 2 take what type of precaution is needed there.
• They have to give lots of case studies on those accident & want lots of
innovative idea from them to prevent those types of accident.
• We can also arrange a competition on the innovative idea of the employees for
prevention of accident. We must give the person a lucrative prize who gives
best innovative idea. It will encourage them.
• Proper checking of work permit form which help them to know that all the
possible risk have been written on the form or not. By checking it properly
they can assess the risk .
• Must keep the records of previous mistakes which stop them to repeat it once
again.
• Regular meeting with efficient person & try to work in a team help them in
risk assessment.

If our home is not safe then we are most unsafe animal on this earth. So make our
home safe is our first & foremost duty. At the same time Plant adjoining town-ship or
colony is the home for plant employee.
If they do not safely live at their or do not keep their family in a safe place then they
will not able to concentrate in their work & can’t give their 100% in it.

So make the colony safe we can find some suggestion:

 Colony is vast place. N So it’s not possible for one person to manage the
whole safety of the colony. So we need to make a organized team out of
efficient people from the colony for the safety of the colony.
 First we have to choose suitable person from the colony. We can choose a old
& retired person as a leader. Because he have the experience, knowledge & the
main thing is all obey & respect him or her.
 We have to try to involve the house wives also in the safety team.
 Then we have to make a plan through meeting that what type of safety is
needed for the colony like safety for children, safety for their home, proper
maintenance of the surroundings area of their quarter which can safe them
from snake & insects, uncovered water resources will be covered properly etc.
 Must talk with the colony gate keeper or guard for stop trespassing. When
anybody want to meet with colony person, then gate keeper must talk with him
or her over phone before allowing the unknown person.
 Must make a program of a entire colony checking my distributing duties on
many people,
 Must make every colony people aware about one or more number which help
them in risky situation. Like make people aware about number for fire
prevention, health center, ambulance etc.
 In every month try 2 arrange a cultural program to make people aware about
safety.
 Arrange monthly medical check-up camp for every people of the colony for
health safety.
 Must be aware about the unlikely incident that happened in that colony or
other colony before n stop the repetition of the same incident.

Transport n traveling is one of the main part of a plant n it’s adjoining colony.
Inside. The colony or town ship & just out side of both the place lots of
vehicles are moving from here & there. So we have to be safe from that too.

In the factory lots of outsiders & in the colony too lots of outsider moving here
& there everyday. Some are good driver some are not, so know the inside
road properly & some are not. Some factory driver also need more training
with the outsider driver & guard who help them to move vehicles insides.

Lots of internal trainings have given on that but I want to more suggestion;

 Have to keep proper gate keeper or guard in the gate from where the vehicles
are come in & out in the plant & colony. One thing have to remember that the
person who is at vehicle gate he/she must have little knowledge about
vehicles.
 Must check the driving license of the driver regularly.
 Before entering the gate have to check the tire & the break properly.
 Must give proper road direction board in every turn or suitable places. That
helps the driver in guiding.
 Made foot road for waking & road for vehicles.
 In front of the colony school or play ground or other places we should keep a
guard to manage the vehicles.
 Have to post proper guard in proper places for give instruction to the driver in
moving vehicle.
 We can use lighted signal & lock gate too for more safety from the vehicle.
 If any accident happened then should contact with police & hospital. do not
take any risk.
 Taking feedback everyday that any person or driver, insider or outsider is
doing any type of reckless driving or something like that. Then must take
possible action.
Head & mind is our main part of our body. We drive by our mind & brain. Mind
makes them decide that which path is proper for us & by taking which path we can
easily able 2 reach our goal.

After getting some type of shock or some unforgettable or terrible incident made our
mind weak. For that we lost our confidence to do any type of work.

To rebuild the confidence & made our minds strong we can apply some process.
Those are as follows;

o First have to find out that why one person became weak. What is the cause
behind his weakness,
o Arrange a psychiatrist for the person.
o Keep a look on the person that he/she is listening the or following the
psychiatrist or not.
o Make him understand what had happened, that had happened that will not
happen again.
o Show him/her some motivational movie.
o Arrange some yoga n meditation program for them.
o Do not behave badly with him/her.
o Make him/her feel that they can able to do lots of work still now.

Guard means something which use for protection. Machine guarding means
cover the unsafe portion of the machine. Like covering the sharp edge of the
machine, covering the blades of the machine, properly keeping the relate
electrical wars in proper way, installing the machine in proper place, after
using the machine covered the machine properly.
So machine guarding is a vital thing to prevent the accident in the plant. But
after happening lots of accident again & again though this issue is neglected.

So our duty is to make the labourer, contractor, HOD, employees aware about
the matter. I also want to add some suggestion on this issue.

Suggestions are as follows;

a. First we have to made a survey team. The team will conducting a


survey which are those machines that need proper guarding, any
problem in previously guarded machine or not, where the machine is
running without following rules.
b. They will made a report after conducting the survey & they will submit
that to the manage management.
c. After that management will organized a meeting on machine guarding.
In this meeting all the departmental head will be there & survey team
also be there, Every one’s suggestion will be taken there.
d. After that some effective training program will be organized to solve
this problem,
e. For made this training program effective we can appoint external
faculty or external consultancy with internal guide.
f. Feedback of the participants should be recorded after the training.
That will help to improve the training.
g. Survey will be appointed again that to observe that everyone one is
properly following the rules or not.
h. We have to observe that after finishing work everyone is turn off the
machine properly .
i. Isolation & lockout procedure is followed properly or not.

Fire made every one so much scared. So when fire broke out inside the
industry or at township then a massive lose have happened. Peoples are
running helplessly from here to there.
Fire can be occurred for lots of causes inside the factory or town ship.

Some of the causes behind the fire broke out is are follows;

• Fire can be broke out from short-circuit. It can be happened inside the
plant as well as inside the colony.
• Fire can be broke out for some type of fuel that are using for run a
machinery. Except that lots of vehicles are moving & also parked
inside the factory, So the fire can be broke out from the fuel of the
vehicle.
• Lots of fire work is going on inside the factor .So fire can be broke out
from those types of elements.
• In town-ship fire can be broke out from the kitchen of the quarter.
• If some inflammable material is stored in warehouse then if short-
circuit happened then fire can be broke-out.
• If small fire is ignored then it will transformed into a massive fire.
• Lack of security arrangement can cause behind a fire that have set by
some cruel people means external source.

Suggestion for prevention of this fire;-

1. First identify which place is very much fire prone by the help of
efficient person.
2. Have to make a fire fighting training schedule.
3. As per the training schedule we need faculty. For that we need
external faculty or external organization.
4. We can contact some of the x-fire men for conducting this training.
5. We must show some videos on fire fighting, some still pictures etc., to
the people.
6. We must give participants some cases on fire fighting & want
suggestion about prevent the fire, Those innovative ideas help them in
real scenario.
7. Give the person a mental training to remove the fear from their mind
about fire. Psychiatrist can be appointed for that.
8. Made a fire fighting team for the plant & township also. Team is
containing with x-fire person,& brave, trained & efficient person.

9. Have to bought a fire engine made a office for fire fighter. The office
should have one or two phone numbers. The phone numbers have to
inform to everyone properly by add or leaflets etc. There will be a
telephone attender every time to attend the call. He inform these to
fire fighting team for quick action.
10. Fire fighting office is a proper place from where the fire fighting engine
can move very fast to the any place inside town-ship or plant.
11. Eire fighting team a engine must be for 24 hrs service.
12. Inside the plant or township there must be the proper recourse of
water.
13. Fire Extinguisher will be in sufficient places inside the factory &
township. Guide line for using extinguisher is given beside the
extinguisher where it is kept.
It is concluded from the survey on “Effectiveness of Safety Training”
that training program conducted in ACC Ltd, Damodhar Cement Works
is very effective in improving the skill and knowledge of the employee to
meet the present and future requirement of the organization. It’s found
that training place a crucial role in not only the development of
employees but also in achieving the overall organizational goals.

Through the research work it was found that employees were very
satisfied by the training provided to them and strongly agreed that after
training their confidence have increased and their skill and knowledge has
also been increased and hence, their was remarkable improvement in their
performance.