Professional Documents
Culture Documents
Education
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Contents
1. Structure of Safety Management
2. OHS Policy
3. Central Safety Organization
4. Mechanism of Accidents and behavioral aspects
5. OHS Hazards
6. Mandatory Rules
7. Kiken Yochi (KY)
8. Behavior Safety in Shopfloor for Suppliers / Vendors
9. PPE Rules
10.Emergency Preparedness and Response
11.List of training modules
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5. KY (Kiken Yochi)
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OHS Policy
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Mechanism of Accidents and behavioral
aspects
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Accident Triangle
1
FATAL
30 MAJORS
(Disabling
Accidents)
300
RECORDABLE ACCIDENTS
(Off Work, limited work and no
lost time)
3,000
NEAR MISSES OR FIRST AID
30,000 HAZARDS
Unsafe acts-Unsafe conditions
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MISTAKES OF PEOPLE
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Analyzing the Key Factors (breakdown of the key factors to achieve the objective)
Man Machine
Fans not properly guarded
Inadequate
safety supervision
New risk introduced
Procedure/Rules Rushing
not followed
Lack of behavioral
intervention
Lack of Skill
Absence of
Lack of
caution
behavioral
Failure to correct intervention
unsafe conditions Unsafe Urgency to cover
actions absenteeism Machine interlock
arrangements not working
Absence of poke yoke
during tip dressing
Material Method
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Hazardous Energy Step Changes
H
a
S z
a a
f r
e d
t Safety Cars, Motorcycles, o
y Skill Snowmobiles, Power u
Gaps Boats, Automated s
S Equipment, etc
k
i E
l Skateboards, Bikes, Climbing Trees, Sports n
l e
Crawling, Walking, Running r
s
g
0 10 20 30 40 y
Age in Years
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Unsafe Conditions
• Unknown
• Failed to correct
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Unsafe Acts
• Unknown
• Unable
• Positive reinforcement of negative
acts
• Unmotivated
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Sources of Unexpected……
Even if people are deliberately willing to increase the risk of a situation, hardly
any of them are deliberately trying to get hurt. Something unexpected or
unplanned always has to enter the equation.
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Conscious - Intentional
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Unintentional
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Habit
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Risk Patterns
States (Cause) Errors (Which cause) Less risk (To become) More risk
Major
Courtesy: SafeStart
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Critical Error Reduction Techniques ©
• Self Trigger on the State to prevent or avoid making the
error
• Analyze Close Calls and small injuries to prevent big
ones – Learn from our OOPS!
• Observers Others for the State to Error Patterns
– To avoid the risk
– To prevent complacency
– To recognize and intervene with co-workers
• Work on our Habits – Personal safety skills
Courtesy: SafeStart
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calling))
Finger pointing and verbal confirmation (Pointing and calling
Courtesy:
Boost the concentration power JICA
Right Ok-Left Ok & Straight OK Sticker
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Occupational health & Safety Hazards
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Types of Hazards
Mechanical Hazards
Fire Hazards
Electrical Hazards
Chemical Hazards
Physical Hazards
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Mechanical Hazards
Situations with potential trapping between rotating
parts
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Cleaning Adjusting / Cleaning during
during cycle on Repairing during cycle on
cycle on
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Fire Hazards
Example
Storing flammable or combustible
materials nearer to open flames, high
temperature zones or sparking zones
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Open containers
with flammable
Cleaner shop materials
Safer shop
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Electrical Hazards
Unearthed machineries
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Preventing Accidental Electrical Contact
Electrocution Prevention
Time GFCI
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Chemical Hazards
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HEALTH HAZARDS
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PHYSICAL HAZARDS
* Flammable
* Explosive
* Reactive
* Radioactive
* Pressurized
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How chemicals enter the Human Body?
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How chemicals enter the Human Body?
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In an emergency,
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Physical Hazards
Ergonomical hazard
Illumination hazard
Noise hazard
Vibration hazard
Radiation hazard
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Corrective Action Sequence
(The three “E”s)
3 Engineering
3 Education
3 Enforcement
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ARRANGEMENT, ORDERLINESS, AND CLEANLINESS
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RISK PREVENTION ON THE MACHINERY
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a. Respect the traffic rules on the site, both internal and external traffic.
b. Slow down when approaching an area with poor visibility or where there is a
presence of pedestrians; mutual respect is required at intersections.
c. Respect the rules of storage and stacking containers.
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PREVENTION OF RISKS IN STORAGE AND HANDLING OF TOOLS,
DIES, COIL PLATE
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USE APPLICABLE ‘PPE’ CORRECTLY
PREVENTION ERGONOMICS
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Behavior Safety in Shopfloor ( Visitor / Supplier / Vendor)
• Enter into shopfloor only if you are accompanied by the supervisor of the area
• Do not carryout any work / Inspection without proper approval of the Shopfloor Manager
• Do not interact with the operator in the line without the presence of line supervisor.
• Understand the safety requirements of the shopfloor before entering the shopfloor
Shop Risks Precautions
Stamping • Exposure to sharp panels • Do not touch any sharp panels without PPE
Shop • Exposure to the suspended loads • Do not walk under / stay beneath a suspended load
• Exposure to the moving objects • Wait for the confirmation of the MHE before crossing the path
Body Shop • Exposure to the sharp panels • Do not touch any sharp panels without PPE
• Exposure to the welding spatter • Do not walk under / stay beneath a suspended load
• Exposure to Electrical lines • Wait for the confirmation of the MHE before crossing the path
• Exposure to the moving objects • Do not touch any electrical cables without authorization.
• Wear proper eye protection before entering the shop
Paint Shop • Exposure to the paint fumes • Do not get exposed to the paint / chemical / radiation without the
• Exposure to the chemicals respiratory protection
• Exposure to radiation • Wait for the confirmation of the MHE before crossing the path
• Exposure to the moving objects • Do not carryout any heat / fire causing material into the shopfloor.
Trim and • Exposure to sharp objects • Do not touch any sharp / protruded without PPE
Chassis • Exposure to suspended loads • Do not walk under / stay beneath a suspended load
• Exposure to the moving objects • Wait for the confirmation of the MHE before crossing the path
• Exposure to paint fumes • Do not get exposed to the paint / chemical / radiation without the
respiratory protection
Power Train • Exposure to sharp objects • Do not touch any sharp / protruded parts without PPE
• Exposure to rotating objects • Do not work/ stay near the rotating objects
• Exposure to moving objects • Wait for the confirmation of the MHE before crossing the path
• Exposure to suspended loads • Do not walk under / stay beneath a suspended load | 55
G / H / AS /
5 Hit by flying spatter HG
12 Exposure to Noise EP EP EP
Legend : *G -Goggles *H - Helmet *SS -Safety Shoes *HG-Hand Gloves * EP - Ear Plugs *A -Apron *AS - Arm Sleeve *M - Mask *FS -Foot sleeve *C- Cap
Helmet
Goggles
Earplug
Arm sleeve
Gloves
Safety Shoes
Note: All applicable functional Protection must be used as per the Standard Operation Sheet (SOS) in case of working in / visiting a specific station
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SAFETY MANAGEMENT
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Safety Management
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•Sampling/Audits/inspections/Feedb
Sampling/Audits/inspections/Feedb
ack
–Audits (Process)
–Inspections (Hazardous Conditions)
–Observations (OBS/BBS Employee
Behavior)
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Safety Evaluation System (SES)
The driver got out of the tow 1.5.4 A Awareness Given to SCM Iyappan/
truck without applying the People Rajesh
parking brake
Tow Truck -
11 1/27/2011
SCM -2
Aware SCM.tif
Check of the Superior once/ 1.1.8 C Awareness Given to SCM Iyappan/
week is not performed for People Rajesh
the daily inspection of tow
Tow Truck -
13 truck 1/27/2011
SCM -2
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The entire company is evaluated with equal standard to clarify the difference
of the safety level between plants or between processes. Thus, the entire
safety level is improved.
It is used as the benchmark to check whether the safety level is maintained
or not.
Official warning is issued for failure of control status.
Observation of the “specified rule” is followed up. (Rules based on accidents
in the past as well as rules, regulations, NES, NEM, and NMS based on
repeated failures.)
The target is a centrally controlled standard.
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SES - Safety Evaluation System- Check List
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Fire Prevention Evaluation System (F-
(F-PES)
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For the risk of afire, improve level of overall fire control by evaluating
objectively and quantitatively all the sections from the same view point
and clarify differences in the level of fire control among sites, offices and
processes.
Establish a bench mark to see if the level of fire control is maintained.
Give an official alarm against a defect in fire control.
Monitor status of compliance with ‘the established rules” on fire
prevention.
“The established rules” are:(Regulations, company standards such as
NES, NEM, NMS, etc, the rules based on the past fire accidents, and
the rules based on repeated defects.)
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F-PES – Fire Prevention Evaluation System-Check list
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Machine Safety Inspection- Purpose & Procedure
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Work Permit System- Types
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Accident Investigation system - Category of Accident
Category Level of Injury
Frequency Rate = (No. of Major & Minor Injury Accidents) * 1,000,000 man-hours
(Total Man Hours Worked)
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Licensing System for Specialised Operation
Company Internal License has to be obtained for the following specialised operation
Car
Fork Lift
Tow Truck
Crane
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<Kiken Yochi>
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Hiyari-
Hiyari-hatto,
hatto, KY & Risk assessment:
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Models of a “KY before starting work”
Date Description of Classification Foreman
Work instruc- acceptance Electricity, machine
Name of line
tion and KY
sheet Equipment no. Instructor’s
Station comment
Manufacturing Manufacturing completion Maintenance (confirm rules after a
Request Items confirmation Production
pause.)
(1) Pre-starting confirmation
(Signature)
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KY Training Exercises
Drilling work with bench drilling machine
A worker is drilling a hole on work with a bench drilling machine.
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KY Training
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KY Training
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KY Training
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KY Training
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KY Training
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KY Training
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KY Training
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KY Training
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KY Training
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KY Training
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KY Training
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KY Training
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KY Training
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EMERGENCY PREPARATION
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8. Emergency Preparedness and Response Plan
How will you recognize an Emergency Situation?
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Do not panic
Immediately switch off any machinery in use, close the valves in the gas
lines, fuel lines and gas cylinders, etc,.
Leave the area by the shortest safe route using the nearest Emergency
Exit
044-37197777
91766 34415
Tackle the fire only if you know and it is safe to do so
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Trim
Medical and
Communicate by phone call Center
Chss
sis
Paint
Just Dial 99990 (From intercom) Admin
Building
Shop
Body
Shop
Stam
Main ping
044-37199990 Gate
Shop
8939933446
Do not get panic and Please give way to the Medical Emergency Team
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Emergency Preparedness and Response Plan
ALWAYS REMEMBER!
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Safety Training
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Stop any unsafe activities inside company
premises and inform concerned supervisor.
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Making Common Sense
Common Practice
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RNAIPL