HAZARD IDENTIFICATION AND RISK

ASSESSMENT ON ENGINEERING INDUSTRY

A THESIS

Submitted by

LOGARASU R
(923019423010)

in partial fulfillment for the award of the degree of

MASTER OF ENGINEERING IN

INDUSTRIAL SAFETY ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

ARULMURUGAN COLLEGE OF ENGINEERING

ANNA UNIVERSITY CHENNAI

AUGUST 2021
 ii

ANNA UNIVERSITY, CHENNAI

BONAFIDE CERTIFICATE
Certified that this project work phase-I report titled “HAZARD IDENTIFICATIO
AND RISK ASSESSMENT ON ENGINEERING INDUSTRY” is the bonafide
work of LOGARASU R (923019423010) who carried out the project work phase-I
under my supervision. Certified further that to the best of my knowledge the work
reported herein does not form part of any other thesis or dissertation on the basis of
which a degree or award was conferred on an earlier occasion on this or any other
candidate.

SIGNATURE SIGNATURE

Mr. P.MOHAN BABU., M.E., MBA., (Ph.D)., Mr. P.KARTHIKEYAN., M.E.,

HEAD OF THE DEPARTMENT, SUPERVISOR

Professor, Assistant Professor,

Department of Mechanical Engineering, Department of Mechanical Engineering,

Arulmurugan College of Engineering, Arulmurugan College of Engineering,

Karur – 639206. Karur – 639206.

Submitted for University Viva-Voce Examination held on _________________

INTERNAL EXAMINER EXTERNAL EXAMINER

 iii

ACKNOWLEDGEMENT

The satisfaction and euphoria that accompanies the successful completion of

any task would be incomplete without the mention of the people who made it possible.
I extend my sincere thanks to “my family members” who have been moral support in
all the means to do such wonderful work.

Our most sincere salutation to our honorable correspondent

Dr. P.V.KANDASAMY, M.Tech., M.B.A., M.I.E., for his kind support
throughout the completion of the project in time.

We wish to express our sincere thanks to our respected principal

Dr. P. SHANMUGAM, M .E., Ph. D., for all the blessings and help provided
during the period of project work.

We express our sincere thanks to our project Coordinator and Head of the
Department, Mr. P.MOHAN BABU M.E., M.B.A., (Ph.D)., Assistant Professor
Department of Mechanical Engineering, for his kind encouragement to make our
project a successful one.

We extend our sincere thanks and gratitude to my guide

Mr. A.PRABU B.E, M.E (ISE)., Safety Asst Manager – Bridestone India
Automotive Products Pvt Ltd for his continuous help and creative ideas to make
this project a successful one.

I express my sincere thanks to Mr. S.KARTHIKEYAN M.E., to coordinator

for his valuable time, suggestions and support provided all through the course of my
project.

LOGARASU.R
 iv

ABSTRACT

A safety management system is meant to identify hazards, to control risks and to

measure effectiveness of mitigating actions. Statistical analysis of accidents indicates
that 80% of -related incidents and accident occur in unsafe act & unsafe condition.
Conducted the risk assessment in overall plant & find out the realistic hazards in the
industry and eliminate them at the initial stage. The main objective of this project is to
providing safety guidelines for the safe access in Degreasing machine & Molding
Machine include the safe operation, machine covering, human factor, obstacles,
environment and material used.

Based upon the earlier incidents suggestion to overcome those has been given. And
also, measurements of the existing hazard identification and risk assessment document
had taken to rectify the unsafe conditions. To this project work may reduce the overall
operational injuries and incidents which increases effectiveness of the plant.
 v

சுருக்கம்
பாதுகாப்பு மேலாண்மே அமேப்பு என்பது ஆபத்துக்கமை

அமையாைே் காண்பது, அபாயங் கமைக் கை்டுப்படுத்துவது ேற் றுே்

தணிக்குே் செயல் கைின் செயல் திறமன அைவிடுவது. விபத்துகைின்

புை் ைிவிவர பகுப்பாய் வு 80% சதாைர்புமைய ெே் பவங் கை் ேற் றுே்

விபத்து பாதுகாப்பற் ற செயல் ேற் றுே் பாதுகாப்பற் ற நிமலயில்

நிகழ் கிறது என்பமதக் குறிக்கிறது. ஒை்டுசோத்த ஆமலயில் இைர்

ேதிப்பீை்மை நைத்தியது ேற் றுே் சதாழில் துமறயில் உை் ை

யதார்த்தோன ஆபத்துக்கமைக் கண்டுபிடித்து ஆரே் ப கை்ைத்தில்

அவற் மற அகற் றவுே் . டிகிரீசிங் சேஷின் ேற் றுே் மோல் டிங்

சேஷினில் பாதுகாப்பான அணுகலுக்கான பாதுகாப்பு

வழிகாை்டுதல் கமை வழங் குவமத இந்த திை்ைத்தின் முக்கிய மநாக்கே் ,

பாதுகாப்பான செயல் பாடு, இயந்திர ேமறப்பு, ேனித காரணி,

தமைகை் , சுற் றுெ்சூழல் ேற் றுே் பயன்படுத்தப்படுே் சபாருை்

ஆகியமவ அைங் குே் .

முந்மதய ெே் பவங் கைின் அடிப்பமையில் அவற் மறக் கைக்க

பரிந்துமர வழங் கப்பை்டுை் ைது. மேலுே் , பாதுகாப்பற் ற

நிமலமேகமை ெரிசெய் ய தற் மபாதுை் ை ஆபத்து அமையாைே் ேற் றுே்

இைர் ேதிப்பீை்டு ஆவணத்தின் அைவீடுகை் எடுக்கப்பை்டுை் ைன. இந்த

திை்ைப்பணிக்கு ஒை்டுசோத்த செயல் பாை்டு காயங் கை் ேற் றுே்

ெே் பவங் கமை குமறக்கலாே் , இது ஆமலயின் செயல் திறமன

அதிகரிக்குே் .
 vi

S.NO TITTLE PAGE NO

ABSTRACT i.

LIST OF TABLES Vi

LIST OF FIGURES Vii

1 INTRODUCTION 1

1.1 Bridgestone India Automotive Products Pvt. Ltd (BSIA)

1.1.1 Company Profile
1-3
1.1.2 Various Department in Industries

1.1.3 EHS Department

1.2 Safety Policy 7

1.3 Safety Management 9

1.3.1 General principles of effective safety management

10
1.3.2 Safety Organization

1.4 Safety Pyramid 12

13
1.5 Hazard

1.5.1 Definition Of Hazard 13

1.5.2 Types of Hazard 14

1.6 Risk Management 14

1.7 Hazard Identification And Risk Assessment 14

1.7.1 Risk Categories 15

 vii

1.7.2 Monitoring And Review: 16

1.7.3 Responsibilities 17

1.8 Risk Assessment Procedure 18

1.9 Control Measure 21

1.9.1 Implement Additional Risk Controls 21

1.9.2 Hierarchy Of Controls 22

2 LITERATURE REVIEW 23

2.1 summary of the literature review 23

3 PROBLEM IDENTIFICATION 26

3.1 Degreasing Machine 27

28
3.2 Molding Machine

3.3 Degreasing & Molding Machine Hazard & Risk Assessment 29

4 METHODOLOGY 33

4.1 Risk Assessment Procedure 33

4.2 Steps to do RA(Risk Assessment) 34

4.3 Risk Assessment Procedure work sheet 35

4.4 Molding Machine 36
4.5 Degreasing and Phosphating Machine
37
4.5.1 Degreasing Machine Kaizen Theme 37
4.5.2 Why Why analysis
38

4.5.3 Nature of Problem 38

4.5.4 The Noise Pollution

4.5.5 Counter Measure of Noise Pollution 39
 viii

5 IMPLEMENTATION 40
5.1 Degreasing & phosphating Machine
40
5.1.1 WI Monitoring
5.1.2 Noise Level Measurements 43
5.1.3 Noise Level without Rubber Sheet
46
5.1.4 Noise Level with Rubber Sheet
5.1.5 Trail ( After Rubber Sheet Installation) 47

5.1.6 Noise Trend Level 48

5.2 Molding Machine
48
5.2.1 Why Why Analysis
5.2.2 WI Standard Mold alignment Table 49

50
5.2.3 Safety Q Point
5.2.4 Mold Handling Method 52
5.2.5 Abnormal Condition during Mold Operation
5.2.6 Mold Normal Position
5.2.7 Training Record for Mold Handling in Injection 53
Machine
6 CONCLUSION 54

7 REFERENCE 55
 ix

LIST OF TABLES

TABLE CONTENT PAGE.NO

NO.

1.7.1 Risk categories 15

1.7.2 Monitoring & Review 16

1.7.3 Action Required 17

4.1 Risk Assessment Methodology 33

5.1.1 WI Monitoring 40

5.1.2 Noise Level Measurements 43

 x

LIST OF FIGURES

FIG. NO CONTENT PAGE.NO

1.2 Safety Policy 7

1.3 Safety Management 9

1.3.1 General Principles of Effective Safety Management 10

1.4 Safety Pyramid 12

1.5 Hazard & Risk Assessment 13

1.8 Risk Assessment Procedure 18

1.9.1 Implement Additional Risk Controls 21

3.1 Degreasing machine 27

3.2 Injection Molding operation 28

4.3 Risk Assessment Procedure Worksheet 35

4.4 Molding Machine 36

4.5 Degreasing Machine 37

4.5.1 Degreasing Machine Kaizen Theme 38

4.5.2 Why Why…. Analysis 38

4.5.3 Nature of Problem 39

4.5.4 The Noise Pollution 39

4.5.5 Counter Measure of Noise Pollution 39

40
 xi

5.1Degreasing & phosphating Machine 40

5.1.1 WI Monitoring
43
5.1.2 Noise Level Measurements
5.1.3 Noise Level without Rubber Sheet 46
5.1.4 Noise Level with Rubber Sheet
47
5.1.5 Trail ( After Rubber Sheet Installation)
5.1.6 Noise Trend Level 48

5.2 Molding Machine 48

5.2.1 Why Why Analysis
49
5.2.2 WI Standard Mold alignment Table
5.2.3 Safety Q Point 50
5.2.4 Mold Handling Method
52
5.2.5 Abnormal Condition during Mold Operation
5.2.6 Mold Normal Position
5.2.7 Training Record for Mold Handling in Injection
53
Machine
 1

CHAPTER 1

INTRODUCTION

1.1 Bridgestone India Automotive Products Pvt. Ltd (BSIA)

1.1.1 Company Profile

Bridgestone India Automotive is a 100% subsidiary of Bridgestone Corporation, Japan with its
head office in Chennai. It has the state of art plants, manufacturing Anti-Vibration product at
Oragadam (Chennai) and Manesar (near Delhi).
Bridgestone India Automotive mission is "Serving society with Superior Quality" with strong
emphasis on quality and customer service, the company has grown rapidly becoming one of the
major suppliers to reputed car manufacturing companies in India. Backed by a strong R & D
team, the company is in the forefront of new technologies providing end to end solutions. The
Company is backed by the strong support of technical center at Bridgestone, Japan.
The company is managed by a competent team of Japanese and Indian professionals.
History
 1996 -Technical Alliance signed between Bridgestone, Japan ( BS ) & Sundaram Industries
Limited, India ( SIL ) – TVS Group
 2000-Gurgaon plant Started Operation
 2008-Shifted to Manesar Plant ( Current Location )
 Mar-2009 Joint venture between Bridgestone Corporation, Japan and Sundaram Industries Ltd
(TVS Group), Madurai was formed and named as NS Antivibration Products Pvt. Ltd.
 Jul-2009 The company’s name was changed to Bridgestone TVS India Pvt. Ltd.
 Sep-2010 The Chennai plant started operation.
 Aug-2012 the Company became a 100% subsidiary of Bridgestone Corporation, Japan. The
name of the company was changed to Bridgestone India Automotive Products Pvt. Ltd (BSIA).

VISION

 To sustain Zero Accident.

 Maintain Clean and Green Environment.
 Create Awareness of Health, Safety and Environment.
 To Protect Employee who is a valuable Asset.
 2

MISSION

 To achieve Zero Accident by creating and maintaining safe workplace and safe
equipment.

 Insist on safe work methods & practices by all employees in their day-to-day
operations.

 Consistently maintain Safety, Health & Environmental Standards inside the

Plant.

 Create Safety Awareness amongst Employees through Education and Training.

1.1.2 Various departments in the industry

Bridgestone India Automotive Products Pvt. Ltd (BSIA) the following are the main
departments

 Admin department
 Human resources department
 EHS department
 Production department
 Design department
 Quality control department
 finance department
 planning department
 R&D department
 IT department
 3

1.1.3 EHS DEPARTMENT

Safety Training

EHS department shall conduct safety education & Training of all employees in Safety and
Accident prevention as per the training schedule. Safety training programme on various
activities like Work permit system, Material handling, Personal Protective Equipment, Fire –
classification, types of extinguisher & operation, Fire hydrant system, Fire fighting and
Emergency preparedness – identified hazards and action in the event of emergency & etc.HR
departments shall co-ordinate and maintain the record of the trainings. Written test and feedback
after training shall be conducted to assess the effectiveness of the training. If necessary
retraining shall be conducted. The contract personals training shall conduct with respect to plant
procedures, New employee training, Emergency reports, Specific job safety training which
needed & etc.,

Accident / Incident Investigation

EHS department along with Shift In-Charge & Department heads shall investigate the all
Incidents / Accidents. Incident / Accident investigate should be sure that the following ways -
Collect all the facts, Determine the causes of the Incident / Accident, recommend ways to
prevent the similar occurrences, Record (The result of the
investigation & the recommendation to prevent recurrence of the Incident / Accident) and
follow-up on the implementation of all recommendations. Safety executive shall communicate
the result of investigate to all employees know the facts as the recommendation to paint
recurrence. The safety performance record (The mandays worked without lost time) shall
display.

Safety Committee Meeting

EHS department shall conduct the safety committee meeting once in a month along with Safety
Committee Members [Equal representation form management and workers along with AGM-
Manufacturing – acts as the Chairman and the EHS as Secretary]. During Safety Committee
Meeting discuss all the safety matters relating to the Plant safety, Environment, Safety
performance, statutory activities & Incident / Injury report etc., In every meeting, previous
 4

meeting minutes shall be reviewed. Minutes of Meeting shall be circulated to all members and
recorded (As per rule No.61M of Tamil Nadu Factrories Rules 1950)

ON-Site Emergency Mock drill

The important aspects of emergency planning is to familiarize all concerned with the role
they should play and actions expected from them in the event of an emergency. This could be
achieved by conducting periodic mock drills. Mock drill also helps to evaluate the effectiveness
of the formulated plan and suggest improvements in the plan. AGM- EHS along with AGM-
Manufacturing shall conduct the Emergency Onsite Mock drill. The AGM- Manufacturing shall
asses the performance of the various action and the recommendation shall be implemented for
effectiveness and improvements in the plan / performance (As per Section 41B (4) of Factories
Act 1948 Amendments 1987, Environment (Protection) Act 1986 and Rules, MSIHC Rules
1989 (Rule 13,14 & 15)). Senior Officer - Safety shall prepare the Minutes of Mock drill and
circulate to all employees and recorded.

Safety Inspections

EHS Department shall conduct the plant safety inspection daily. Safety executive shall
observe the unsafe condition / unsafe acts during the routine inspection in the plant. Senior
Officer – Safety shall highlight the unsafe aspects during the above inspection in the daily
meeting and all concerned department heads shall take corrective action. Senior Officer – Safety
shall record the observation of inspections.

Fire fighting equipments Maintenance:-

EHS Department shall carryout the fire fighting equipments maintenance as per the
maintenance schedule along with external agencies after getting work permit duly signed by
Shift Engineer. Fire fighting equipments maintenance like, Fire Hydrant system, Water Monitor
(Fixed & Mobile), Sprinkler system, Fire extinguishers & etc. Safety executive shall record the
maintenance observation.

Work Permit Systems

EHS department shall duly signed the Hot work permit, Vessel Entry / Confined Space
Entry Permit & Excavation clearance permit and countersigned by AGM - Manufacturing, EHS
Department shall check the Explosive limit & Oxygen percentage by using Explosive meter &
 5

Oxygen analyser for clearing the Hot work & Vessel entry permit. Safety executive shall record
the Hot work permit, Vessel entry permit & Excavation clearance permit. Safety Executive
shall review all the permit system.

Safety Equipments / PPE’s Maintenance

Executive -Safety shall develop the lists of PPE for each area / operation and the required
PPE are available to all the working employees. Senior Officer – Safety shall review the
maintenance of stocks, and shall raise indents for the requirement of additional PPE items as per
the Specification & Standards. Materials department shall process the indent for procurement.
Safety Executive shall inspect the incoming material at stores as per Specification & physical
measurements mentioned in Purchase Order. Stores department shall maintain the register for
PPE distribution / issues to all employees. Safety Executive shall carryout the maintenance of
SCBA, Eye wash & Body shower etc as per the schedule.

Comply with all Statutory and Regulatory Requirements applicable for paint Industry
EOHS dep shall comply all statutory requirements and maintaining records. The test report
containing details shall be recorded and submitted to reports. Any deviation in submitting
norms shall be informed to DGM-Manufacturing. Monthly reports send to the DGM-
Manufacturing.

Calibration

All safety and environment monitoring instruments are being calibrated as per calibration
schedule. The calibration shall be done with Standards and to get the calibration certificate from
the external authorized agent. Safety Executive shall maintain the calibration certificate with
due date and maintain the history card and records.

Safety Motivation

EOHS Department shall organise the Safety Contests on Safety Slogan, Quiz, Posters,
Fire drill etc., and the winners shall be suitably rewarded. Senior Officer – Safety shall celebrate
National Safety Day and World Environment Day. Hod-EHS shall prepare & publish the Safety
Bulletin and literature related to Safety, Health & Environment. Safety Executive shall maintain
the membership in NSC, TIWMA & Environment update report safety executive shall display
the poster and slogan related to Safety, Health & Environment on the walls of the building.
 6

Safety Executive shall prepare & send the award application related to Safety, Health &
Environment periodically and to get the award certificate.

Operating and Maintenace of ETP/STP/RO/Mechanical Evaporator

EHS Department to ensure operation and maintenance of Sewage water treatment, Trade
effluent, RO and Mechanical Evaporator and tested quality of treated waste water against
TNPCB standards

Developments

Safety Executive shall adopt the following measure with guidance of AGM-
Manufacturing to improvise the safety system.

Modifications of underground fire hydrant relocate to above ground to minimise the

maintenance cost.

Accident / Incident analyses carrying out to help in evaluating the relative need for taking
accident prevention measures.

National Safety Award/Environmental /Award application prepared and submitted to get

the awards.

Monitoring budget & new Personnel Protective Equipments / Spares to taking accident
prevention.

Personnel protection equipment at the plant manual developing to create safety awareness
to usage of Personnel Protective Equipments.

Monitoring the system adherence to the Environmental Management System. (ISO

14001)
 7

1.2 SAFETY POLICY

(Fig – 1.2- SAFETY POLICY)

 8

1. Assurance of safety is the fundamental requirement of all operations performed at our

workplace. In this respect, a commitment to safety must take priority of overall other business
concerns.
2. The assurance of safety also forms the basis of mutual trust among our employees, our
communities and all other members associated with the Bridgestone India Automotive Products.
It is a priceless attribute that is the foundation of sound business operation.
3. In view of this, we at the Bridgestone India Automotive Products hereby declare our
commitment to safety within the workplace and will achieve this through strict adherence to the
following Fundamental Safety Policy.
Fundamental Safety Policy
1. We will faithfully comply with all laws and regulations, and governmental guidelines
concerning safety.
2. We will establish safe production methods in accordance with international safety standards.
3. We will strive to acquire technologies concerning safety matters, including risk assessment,
safety measures and safety management.
4. We will establish an advance risk assessment system and make a continual effort to reduce
long-term risks.
5. We will strive to achieve safety through the efforts of each and every employee regardless of
rank or occupation.
6. We will continually strive to improve workplace safety by maintaining an open line of
dialogue with each and every employee.
7. We will maintain a safe workplace by striving to reduce accidents caused by fire or
earthquakes.
8. As a pillar of auto industry, we will strive to develop technologies to enhance traffic safety and
reduce traffic accidents.
 9

1.3 SAFETY MANAGEMENT

A Safety Management System (SMS) is a systematic approach to managing safety, including
the necessary organizational structures, accountabilities, policies and procedures. As per ICAO
requirements, service providers are responsible for establishing an SMS, which is accepted and
overseen by their State.

(Fig – 1.3- SAFETY MANAGEMENT)

 10

1.3.1 General Principles of Effective Safety Management

PDCA (plan–do–check–act or plan–do–check–adjust) is an iterative four-step management

method used in business for the control and continual improvement of processes and products. It is also
known as the Deming circle/cycle/wheel, Shewhart cycle, control circle/cycle, or plan–do–study–act
(PDSA).

Fig 1.3.1 General Principles of Effective Safety Management

1. PLANNING - Setting Policy and Formulating a Safety Plan

2. DOING - Delivering Safety Plan
3. CHECKING - Measuring Performance, i.e. monitoring
4. ACTING - Reviewing Performance and acting upon lessons learnt to feed back into
Step 1.
Abnormal Rule
STOP
CALL
WAIT
 11

1.3.2 Safety Organization

 Approximately 180 (Chennai & Manesar ) Employees on company roll and 360 workers are
employed on contractor roll in (BSTVS) which is engaged in the manufacture of different
types of molded rubber products.,

 Safety is given paramount importance at par with Productivity. It is an integral part of every
activity.

 To implement Safety at all levels, SHE (Safety, Health and Environment) Pillar and Safety
Committee are functioning.

 Safety Committee consists of representatives from managerial level and representatives from
workmen category. The Committee meets once in a quarter.

 The Safety Committee will discuss all issues pertaining to Safety. These issues, wherever
required will be sent to concerned department heads for implementation.

 The Safety Officer will coordinate with HODs to resolve safety issues.

 Safety awareness is created amongst all employees by Safety Committee members.

 The common objective of SHE Pillar and Safety Committee is to achieve Zero Accident
through continuous improvement in the field of Safety.

 SHE Pillar continuously strives for Zero accident by undertaking various activities in the shop
floor.

 Safety inspection is carried out daily by Safety Manager in conjunction with respective Cell
Managers. Safety related issues as revealed by employees at work are recorded, scrutinized
and brought to the notice of concerned persons for taking corrective action by raising action
slips.

 The progress of work is constantly monitored to get the desired results.

 Unsafe practices are corrected on the spot itself by giving proper instructions to the erring
personnel and then preparing ONE POINT LESSON for display near the work spot as well as
in the Learning Centre to educate workers to enable them to desist from those practices.
 12

1.4 SAFETY PYRAMID

Fig 1.4 SAFETY PYRAMID

At the safety pyramid’s base you will find a strong foundation of safety violations and unsafe
behaviors. As you move up the pyramid, the severity of the outcome of these behaviors increases.
The next level is the near miss incidents. Unsafe conditions and behaviors have now become the
foundation for an incident, but no one was injured. Once the near miss level has been introduced, the
next level is when people get hurt.
Here you will find your first aid and record only injuries. Once this level has been established, the
recordable injuries begin. People get hurt, need a prescription or have to modify their normal work
duties. Once the trend continues, it leads to lost time injuries. Workers are getting hurt and missing
work. Finally, if the trend continues and you build up enough lost time injuries, the odds are that there
will be a fatality.
Think about the working conditions and safety culture at each of these levels.
How do we keep from moving up the triangle? How do we protect people from losing a life or even
getting a first aid injury or having a near miss?
The key to success is to identify the trends before someone gets hurt. Correct your unsafe behavior,
even when nobody's watching. If a portion of the base is removed, the pyramid never has a chance to
reach the upper level.
 13

1.5 HAZARD

A hazard is a situation that poses a level of threat to life, health, property, or environment. Hazards
can be dormant or potential, with only a theoretical risk of harm; however, once a hazard becomes
"active", it can create an emergency. A hazardous situation that has come to pass is called an incident.
Hazard and possibility interact together to create risk.

Fig 1.5 HAZARD & RISK ASSESSMENT

1.5.1 DEFINITION OF HAZARD

A hazard is simply a condition or a set of circumstances that present a potential for harm.
Hazards are divided into two broad categories:
• Health hazards (cause occupational illnesses)
• Safety Hazards (cause physical harm - injuries)
Hazards are the main cause of occupational health and safety problems. Therefore, finding ways of
eliminating hazards or controlling the risks is the best way to reduce workplace injury and illness.

1.5.2 TYPES OF HAZARD

Hazards are generally labeled as one of five types

1.5.2.1 Physical hazards are conditions or situations that can cause the body physical harm or intense
stress. Physical hazards can be both natural and human made elements.

1.5.2.3 Chemical hazards are substances that can cause harm or damage to the body, property or the
 14

environment. Chemical hazards can be both natural or human made origin.

1.5.2.4 Biological hazards are biological agents that can cause harm to the human body. Some
biological agents can be viruses, parasites, bacteria, food, fungi, and foreign toxins.

1.5.2.5 Psychological hazards are created during work related stress or a stressful environment.A
person can be a hazard when he/she is affected psychological disturbance through -stress,shift patterns
and also can be a hazard when a person is under the influence of alcohol,illness and lack of training.

1.5.2.6 Ergonomic Hazard By its nature, a hazard involves something that could potentially be
harmful to a person's life, health, property, or the environment

1.6 RISK MANAGEMENT

The Regulations set out a risk management approach to each phase of the life cycle of plant. The
approach focuses on the prevention of workplace injuries through identifying hazards and assessing and
controlling the risks they present.

1.7 HAZARD IDENTIFICATION AND RISK ASSESSMENT

 Hazard is a source of danger i.e. material, energy source or operation with the
potential to cause illness, injury or death to personnel or damage to a facility or the
environment.

 The Hazards have been identified for each Activity, Services and Products of BSTVS
based on the process flow, raw materials used, waste generated, Material Safety Data
Sheet, Chemical storage conditions etc.

 The Risk Assessment methodology is derived after a brain storming session

comprising of Plant Head, Section Managers, Safety Officer, Medical experts,
Workmen’s Representative, Consultants etc. with various models of the risk
assessment being referred.

 The base risks are inherent risks associated with activity, product and services and
these are identified independent of the existing control methods. The existing control
methods are now subjected to review during risk assessment for its applicability,
availability and verified for its effectiveness.

 The risks potential are rated with respect to scale, severity and probability of
occurrence of the hazards and the associated risks after considering the effectiveness
of the existing controls.
 15

 The residual level of the risk is reflected in the multiplication score of the scale,
severity and probability of occurrence. Those found significant in line with the
criteria defined are considered for appropriate control measures. The rating score
ranges from 1 to 5.

Scale
Defining the spread-ability of the hazard identified to work station alone or to the whole
department or to the factory building or with in factory premises or outside factory
premises. Scale is also defined based on the exposure to number of persons (range such as
1,2 to 5,6 to 15, 16 to 25 and above are considered)

Severity
Severity depends upon how much it will affect the Occupational Health & Safety
performance in line with the defined parameters for temperature, noise, injury, illness,
ergonomics & property damage as mentioned in the guideline.
Probability of Occurrence
Chance/ Frequency of occurrence may happen such as multiple times in a day or once in a
day to week or once in a week to month or once in a month to six months or more than six
months.

1.7.1 Classification of Risk:

Risk categories
Risk is defined as combination of the probability of an event and its consequence. It is divided into
stepped categories as shown in figure 2.

Almost none Some High Will occur

Minor scrapes & bruises I I I II

Slight injury I II II III

Major injury I III III IV

Life threatening injury II III IV IV

 16

Great risk

Danger zone Category IV

Unacceptable risk A
Category III

Zone of concern
B Category II

Risk acceptable under certain

conditions

Safe zone C
Category I
Widely acceptable risk
Minimum risk

1.7.2 Monitoring and review (Criteria for Significance)

In BSTVS the significant risks are identified based on the
Following criteria.

1. All Emergencies- not rated

2. Legal Non Compliance

3. Classification of the Risk – Moderate and above

4. Risk Category 3 & 4

The Significant Risks so identified are made available to all HODs and communicated to all
employees

The Significant Risks are controlled through control methods such as Occupational Health
Management Program, Operational Control Procedure, Emergency Response procedure,
Health Plan, Personal Protective Equipment plan along with improvements in the existing
controls.

1.7.3 Consolidation of physical phenomena causes and counters

measures for finger injuries:

By virtue of the process in BSTVS there are many possibilities for sustaining finger injuries
while at work. To prevent such type of accidents, causes for their occurrence have been
analyzed and counter measures arrived at as follows, Cell wise
 17

CELL PHYSICAL CAUSES FOR COUNTER MEASURES

PHENOMENA ACCIDENT
Mixing a Rubber Caught between the Reverse motion of Rollers to
Compound in Open Rollers. be provided.
Mill Cutting the Training for safe handling of
MILLING samples from Slippage of Knife. hand tools (knife).
Rubber sheet

Doing sheet cutting Slippage of Knife. Scale to be modified

RAW MATERIAL operation and Lug Gloves to be used.
STORES cutting operation in Contact with rotation To provide Guards to avoid
Lug cutting Machine Blade. contact with rotating blade.
Caught between
adjusting Bolts and
To Train in safe work
ejector.
practice.
Attending break
MAINTENANCE
downs Caught between "V" To use hand tools
Belt and Pulley. Caught
between Cylinder Knob
and fulcrum
PHOSPHATING Doing degreasing for While maintenance To Train in safe work
oil and rust remove. works, the worker may practice.
climb on the fencing
area.

While maintenance To provide the proper

works the worker may personal protective
hit by the pipe lines in equipments.
the tank area.
HYDRA Assemble the Slipping hazards. Housekeeping should
ASSEMBLY various child parts maintain.
into single unit.
SHOT BLASTING Metal blank is shot The scrap steel grid To provide the proper
blasted to give may fall on the body personal protective
roughness for equipments.
adhesive purposes
 18

1.8 Risk Assessment Procedure

The risk assessment procedure can best be illustrated in the following way.

Fig 1.8 Risk Assessment

Step 1: Identify Hazards
WHS legislation in New South Wales requires that PCBUs, in consultation with workers identify
all potentially hazardous things or situations that may cause harm. In general, hazards are likely to be
found in the following;
- Physical work environment,
- Equipment, materials or substances used,
- Work tasks and how they are performed,
- Work design and management
In order to identify hazards the following are recommended:
(i) Past incidents/accidents are examined to see what happened and whether the incident/accident could
occur again.
(ii) Employees be consulted to find out what they consider are safety issues,
I.e. ask workers about hazards near misses they have encountered as part of their work. Sometimes a
survey or questionnaire can assist workers to provide information about workplace hazards.
 19

(iii) Work areas or work sites be inspected or examined to find out what is happening now. Identified
hazards should be documented to allow further action. The work environment, tool and equipment as
well as tasks and procedures should be examined for risks to WHS.
(iv) Information about equipment (e.g. plant, operating instructions) and Material Safety Data Sheets be
reviewed to determine relevant safety precautions.
(v) Welcome creative thinking about what could go wrong takes place, i.e. what hazardous event could
take place here?
Step 2: Assess Risks
Risk assessment involves considering the possible results of someone being exposed to a hazard and the
likelihood of this occurring. A risk assessment assists in determining:
- How severe a risk is
- Whether existing control measures are effective
- What action should be taken to control a risk
- How urgently action needs to be taken.
A risk assessment should include:
(i) Identify factors that may be contributing to the risk,
(ii) Review health and safety information that is reasonably available from an authoritative source and
is relevant to the particular hazard,
(iii) Evaluation of how severe the harm could be. This includes looking at the types of
injuries/illnesses/harm/damage that can result from the hazard, the number of people exposed, possible
chain effects from exposure to this hazard.
(iv)Evaluation of how a hazard may cause harm. This includes examining how work is completed,
whether existing control measures are in place and whether they control the harm, looking at
infrequent/abnormal situations as well as standard operating situations. A chain of events related to a
risk may need to be considered.
(v)Determining the likelihood of harm occurring. The level of risk will increase as the likelihood of
harm and its severity increases. The likelihood of harm occurring may be affected by how often the task
is completed, in what conditions, how many people are exposed to the hazard and for what duration.
(vi) Identify the actions necessary to eliminate or control the risk; and
(vii) Identify records that it is necessary to keep to ensure that the risks are eliminated or controlled.
Other risk factors should also be identified as they may contribute to the risk: including
(viii)The work premises and the working environment, including their layout and condition,
 20

(ix)The capability, skill, experience and age of people ordinarily undertaking work,
(x) The systems of work being used; and
(xi) The range of reasonably foreseeable conditions.
The process of assessing the risk is undertaken by reviewing any available information about the hazard
(e.g. legislation, Australian Standards, Industry Code of Practice or guidance material about the hazard)
and by using your personal work experience about what sort harm the hazard could create and how
likely this would be to happen. When determining how likely it is that a person could be exposed to a
hazard, consideration needs to be given to these “exposure factors”:
(i) Whether there are any other risk factors that increase the likelihood of exposure?
(ii) How often is the person exposed (frequency)?
(iii) How long is the person exposed (duration)?
(iv) How many people are exposed?
(v) The likely dose to which the person is exposed?
(vi) Any legislative or recommended exposure levels required by statutory authorities.
 21

1.9 CONTROL MEASURE

Risk control measures must be implemented to eliminate or reduce the risk of injury or harm as far as
practicable. The preferred order of control is:
1.9.1 IMPLEMENT ADDITIONAL RISK CONTROLS
Having identified the hazards in your workplace, assessed their risks and reviewed the existing controls,
all hazards must be managed before people are hurt, become ill or there is damage to plant, property or
the environment. The management of risks in the workplace requires eliminating risks so far as
reasonably practicable in the first instance. Where elimination is not possible, then risks should be
minimized, so far as reasonably practicable. All hazards that have been assessed should be dealt with in
order of priority. The most effective control option/s should be selected to eliminate or minimize risks.
The Hierarchy of Controls (see diagram below) ranks control options from highest level of protection
and reliability to lowest. This should be used to determine the most effective control/s.

Fig 1.9.1 IMPLEMENT ADDITIONAL RISK CONTROLS

1.9.2 HIERARCHY OF CONTROLS

Level 1 Control Measures – Eliminate the Hazard
The most effective control measures eliminate the hazard and associated risks. This can be
achieved through removing the hazard or selecting alternate products or equipment to eliminate the risk.
If a hazard cannot be eliminated then risks can be minimized by lower control measures
Level 2 Control Measures
 22

These are used to minimize the risks and involve one or a combination of the following;
(i) Substitute the hazard:
Substitute a substance, method or material to reduce the risk or the hazard (ii)Isolate the hazard:
Separate the hazard from the workplace or people,
For example;
a. Chemical store room, or a laboratory kept locked except to an authorised person. b. Lock out
procedures on faulty equipment.
c. Appropriate guarding for machinery.
(iii) Use engineering controls:
Modify existing machinery or plant or purchase different machinery or plant to provide a
physical solution. For example; a. Trolleys, hoists or cranes. b. Guard rails.
Level 3 Control Measures
These are control options which should be considered last as they do not control the source of
the hazard but rely on human Behavior or supervision and therefore less effective.
(iv) Administrative Procedures:
Develop work methods or procedures to reduce the conditions of risk,
for example:
a. Written Safe Operating Procedures
b. Job rotation to restrict hours worked on difficult jobs.
c. Staff trained in the correct operating procedures.
(v) Use Personal Protective Equipment (PPE) and training in its use:
Offer the lowest level of protection and should only be used as a last resort to deal with the hazard,
where the hazard cannot be removed or reduced by any other means, for example: a. Handling of
chemicals – gloves, safety glasses, aprons. b. Protecting eyes from flying particles. c. Protecting feet –
safety boots. Consultation with workers is required in the selection and implementation of control
measure in the workplace. Controls may need to be trialled to determine effectiveness and workers
should be involved in the feedback process. Each measure must have a designated person and date
assigned for the implementation of controls. This ensures that all required safety measures will be
completed and documented.
 23

CHAPTER 2

LITERATURE REVIEW

2.1 Summary of the literature review

1. Application of Hazard and Operability Study (HAZOP) in Evaluation of Health, Safety

and Environmental (HSE) Hazards, May 2012, University of Hamadan Medical Science
Iraj Mohammadfam1
Risk assessment and management techniques are used in industrial activities to reduce accidents by
applying preventive and protective methods. In this article a preventive approach called Hazard and
Operability Study (HAZOP) was used. The application of HAZOP, a process hazard identification and
control method, has been demonstrated in the fatty acid unit of Golnar Oil Company, northwest of
Tehran Province. The results of the study identifies 58 types of hazard of which 45.6% were
unacceptable, 27.1% were unsafe, 18.6% were acceptable but needed reconsideration, 8.7% were
acceptable with no need for any corrective action. To prevent any catastrophic consequences, we
recommend: (1) installing pressure switch and flow switch on the product-receiving lines, and (2)
conducting regular and periodic HSE audit.

2. Integration of safety instrumented system with automated HAZOP analysis: An

application for continuous biodiesel production, February 2011, Center for Advanced Studies
in Industrial Technology
C. Jeerawongsuntorn,
Integration of a humanemachine interface (HMI) with hazard and operability (HAZOP) analysis is
proposed in this work. This concept can potentially lead to the identification of some unexpected
deviations, and radically decreases the time necessary for hazard identification. A continuous biodiesel
production was simulated. This can be divided into two cases, covering both conventional and reactive
distillation. Soybean oil (trioleic, trilinoleic and tripalmitic) at 1000 kg/h as raw material is converted to
99 wt% pure biodiesel. The HMI was designed to improve these processes by combining automatic
HAZOP analysis. With this approach, users can receive sufficient information from the simulation to
analyze the optimum operation and safety. Severity levels are also provided to classify the actions in the
process. Severity levels 1 and 2 are concerned with operating conditions, which are 58e64 _C, and 50
e150 kPa. If the analysis shows severity level 3, the safety instrumented system (SIS) will automatically
manage the operation in order to reduce/restrain the amount of damage at this level. This proposed
system could minimize the damage and also improve the overall quality of the process.
 24

3. Intelligent systems for HAZOP analysis of complex process plants , February 2000, Purdue
University.
Venkat Venkatasubramanian
Process safety, occupational health and environmental issues are ever increasing in importance in
response to heightening public concerns and the resultant tightening of regulations. The process
industries are addressing these concerns with a systematic and thorough process hazards analysis (PHA)
of their new, as well as existing facilities. Given the enormous amounts of time, effort and money
involved in performing the PHA reviews, there exists considerable incentive for automating the process
hazards analysis of chemical process plants. In this paper, we review the progress in this area over the
past few years. We also discuss the progress that has been made in our laboratory on the industrial
application of intelligent systems for operating procedure synthesis and HAZOP analysis. Recent
advances in this area have promising implications for process hazards analysis, inherently safer design,
operator training and real-time fault diagnosis. © 2000 Published by Elsevier Science Ltd. All rights
reserved.

4. Experimental research on physiological index at the heat tolerance limits in China, June
2006, Tianjin University.
Shilei Lu_, Neng Zhu
In this study, the heat stress and heat tolerance of 148 male volunteers were examined under different
climatic conditions in a stainless steel climatic chamber. The conditions were 30 to 421 dry bulb
temperature and 40 to 80 percent relative humidity. The subjects, aged from 19 to 26 years old,
performed various activities at the metabolic heat of 175, 349 and 580 W, respectively. The exposure
durations and resulting heat stress were determined by measuring oral temperature, skin temperature,
heart rates, blood pressure and sweating responses. The study proposed physiological limit values at
exposure limits. Moreover, the study suggested that physiological measures from the experiments
should be applied to evaluate the classification of extreme heat working environments in China. r 2006
Elsevier Ltd. All rights reserved.

5. Thermal comfort temperature range for factory workers in warm humid tropical climates,
November 2007. University of Moratuwa
S. Wijewardanea, M.T.R. Jayasingheb,_
The ability to operate factory buildings as free running will be very useful in the context of saving
energy needed for providing adequate thermal comfort for workers in warm humid tropical climatic
conditions. The upper limits of thermally comfortable temperatures were established with comfort
 25

surveys carried out in three factory buildings without much ventilation. The surveys were then repeated
to determine the effects of ventilation as well. The comfort surveys indicated that workers acclimatized
to warm humid climatic condition could tolerate up to 30 1C without much ventilation when engaged in
light factory work. This comfort temperature limit can be increased up to 34 1C when indoor air
velocities are maintained as high as 0.6ms_1. It is also shown that these studies validate the earlier
predictions of adaptive models for warm humid climates. The ability of workers to tolerate elevated
temperatures could be used to highlight some concepts that can be considered in the planning of large-
scale industrial parks, so that factories could be operated with minimum energy allocated for providing
thermal comfort. r 2007 Elsevier Ltd. All rights reserved.
 26

CHAPTER 3
PROBLEM IDENTIFICATION
3.1 Degreasing machine & Moulding Machine
Department: Production Area: METAL BLANK PREPARATION

List of Activities carried out by BRIDGESTONE / Contract Workmen / Sub-contract

Sl. No
1 Degreasing

2 Shot blasting

3 Phosphating

4 Maintenance of Phosphating Machine

5 Adhesive coating

Department: Production Area: ASSEMBLY

List of Activities carried out by BRIDGESTONE / Contract Workmen / Sub-contract

Sl. No
1 Pre Swaging

2 Hydro Mount Assembly

3 Dynamic testing

4 Auto Painting

5 Baking /Tower Oven

6 Body bracket assembly

7 Aluminum bracket assembly

8 Part Inspection

Department: Production Area: MOULDING

List of Activities carried out by BRIDGESTONE / Contract Workmen / Sub-contract

Sl. No
Compressor Startup & Operation

1 Injection Moulding operation

2 Compression moulding

3 Deflashing / Buffing

4 Mould Maintenance, Changing & Cleaning

 27

3.1 Degreasing Machine

Fig 3.1 Degreasing Machine

 28

3.2 Injection Moulding operation

Fig 3.2 Injection Moulding operation

 29

3.3 Degreasing & Molding Machine Hazard & Risk Assessment

Sl. No. Activity R / NR Hazard Risk

Chance for skin contact

due to handling with Skin Irritation
degreasing chemicals
Exposure to Chemical Discomfort
Chance for hot water
contact with skin while
Burn Injury
mixing the degreasing
chemical
Exposure to heat
Discomfort
Radiations
1 Degreasing R Chance for hit against
with sharp edges of Cut Injureis
projections
Failure of safety device Injury
Metal component falling
Injury
while loading
strains on
Loading & unloading the
muscles,
components
joints
Chance for Physical
hazard due to slip by Injury
slipary surface floor

Slippery/uneven ground Injury

Injection Exposure to rubber flashes
Eye irritation
2 Moulding R during moulding
operation Chance for slippage due to
Injury
spillage of oil
 30

Chance for hit against with

Cut injury
sharp edges of projections
Lying wires and cables on
Injury
surface
Flying objects Injury
Falling of objects Injury
Exposure to compressed air Discomfort
Caught in between Injury
Handling hot objects Burns
Exposure to Moving parts
Injury
due to Inadequate guards
Exposure to noise during
Discomfort
operation
Failure of safety device Injury
Musculoskeltal
Improper Working posture
disorders
Exposure to Hot Vapours Discomfort
Improper Push & Pull of Musculoskeltal
Mould disorders
Musculoskeltal
Improper Lifting
disorders
Exposure to heat radiation Discomfort
Slippery/uneven ground Injury
Exposure to rubber flashes
Eye irritation
during moulding
Chance for slippage due to
Injury
spillage of oil
Chance for hit against with
Compression Cut injury
sharp edges of projections
3 moulding R
Operation Lying wires and cables on
Injury
surface
Flying objects Injury
Falling of objects Injury
Exposure to compressed air Discomfort
Caught in between Injury
Handling hot objects Burns
 31

Exposure to Moving parts

Injury
due to Inadequate guards
Exposure to noise during
Discomfort
operation
Failure of safety device Injury
Musculoskeltal
Improper Working posture
disorders
Exposure to Hot Vapours Discomfort
Musculoskeltal
Improper Lifting
disorders
Exposure to heat radiation Discomfort
Chance for hit against with
Cut injury
sharp edges of projections
Lying wires and cables on
Injury
surface
Flying & Splashing of
Eye Injury
objects during Buffing
Deflashing / Falling of objects Injury
3 R
Buffing Handling hot objects Burns
Exposure to Moving parts
Injury
due to Inadequate guards
Exposure to noise during
Discomfort
operation
Musculoskeltal
Improper Working posture
disorders
Slippery/uneven ground Injury
Chance for slippage due to
Injury
spillage of oil
Mould Chance for hit against with
Cut injury
Maintenance, sharp edges of projections
4 R
Changing & Head impact due to
Cleaning Injury
Restricted access
Flying objects while mould
Injury
cleaning
Falling of objects & mould Injury
 32

Vision obstructed while

shifitng mould using hand Injury
trolley
Exposure to compressed air Discomfort
Caught in between Injury
Touching of Hot surface Burns
Exposure to Moving parts
Injury
due to Inadequate guards
Failure of safety device Injury
Musculoskeltal
Improper Working posture
disorders
Improper Push & Pull of Musculoskeltal
Mould disorders
Musculoskeletal
Improper Lifting
disorders
 33

CHAPTER 4

METHODOLOGY

There are various methodologies are there to find out the hazards for each operation and for the
mitigation operations. From that I choose Risk assessment procedure technique to find out the control
measure to minimize the human and machine collision at processing plant
4.1 Risk assessment procedure
ISO/IEC Guide 51 requires the following steps to be taken in the risk assessment procedure.

Start

Clarification of use and

reasonably foreseen
A. misuse

Identification of hazard Risk

sources
B. analysis
Risk reduction
C. Risk estimation

D. Risk evaluation Risk assessment

No Acceptable risk

achieved?

Yes

End 【 Figure 4 Risk assessment 】

 34

A. Clarification of use and reasonably foreseen misuse

Before assessment, the first step as PL (product liability) measure is to
identify hazards considering reasonably foreseen misuse of the equipment or
system in question besides its intended method of use. In Bridgestone, users
of equipment or systems are assumed to be those who “have received the
designated training” and not untrained or new personnel. Foreseeable misuses
of teammates who have received the designated training include common
carelessness, quick actions due to reflex and short cut actions but not intended
suicide.
B. Identification of hazard sources
Include all hazard sources that exist in the equipment. For risk assessment all
hazard sources for which designers or users have to take measures of some
kind with safety devices are identified.
C. Risk estimation
Risk estimation means the procedure of deciding risk evaluation points for
risk sources following the matrix on figure 2.
D. Risk evaluation
Risk evaluation consists in the confirmation of the risk category according to
the evaluation points given to a risk and to whether a safety level has been
achieved, also in this step it is evaluated and decided if risk reduction is
necessary. In this manual the safety level of widely acceptable risks is less
than five risk evaluation points. It means a risk lower than categoryⅠ.
For risks categoryⅡ, if measures are technically impossible or if
implementation cost is
high and/or with no proportionate results such risks will be approved as
“residual risks” for which soft countermeasures will be entrusted to the
production section and its teammates. Accordingly, risks with more than six
risk evaluation points will be controlled with soft countermeasures as residual
risks.
* “Risk analysis” is up to step C, deciding risk evaluation points but the range of
risk assessment as shown in the flow chart of figure 4 covers risk evaluation and
judging if the risk achieve an acceptable level.
 35

* Now, risk assessment adopted in this manual targets existing production

equipment and systems but in case of design/conception of new equipment the
same identification of hazard sources is implemented and risk assessment is
performed reducing risks from the design stage. Estimation and evaluation are
conducted in the same way.

4.3 Risk assessment procedure work sheet

Fig 4.3 Risk assessment procedure work sheet

 36

4.4 Moulding Machine

Fig 4.4 Molding Machine

 37

4.5 Degreasing and Phosphating Machine

Fig 4.5 Degreasing and Phosphating Machine

Fig 4.5.1 Degreasing Machine Kaizen Theme

 38

Fig 4.5.2 Why Why analysis

Fig 4.5.3 Nature of Problem

 39

Fig 4.5.4 The Noise Pollution

Fig 4.5.5 Counter Measure of Noise Pollution

 40

CHAPTER 5
IMPLEMENTATION
5.1 Degreasing & phosphating Machine
5.1.1 WI Monitoring
Bridgestone India
Automative Products (P)
WORK Prepare Checke Approve
LTD, ChennaiBridgestone
INSTRUCTIO d d d
India Automative Products
(P) LTD, Chennai N
MFG/WI/27

Process Work Item

Checking Approval No:
Metal blank
PHOSPHATING Chlorate
preparation BT410No.98WI-6
Content
PURPOSE
The purpose is to check the Chlorite
content of PB-T862 BS solution.

SCOPE
Determine the Chlorite content of PB-T862
BS solution.

APPARATUS REQUIRED
Beaker - 250
1 ml
2 Pipette 10 ml
Conical flask
3 250 ml
Burette 50
4 ml
Measuring
cylinder 50
5 ml

REAGENT
 41

S
Bath
Solution (10
1 ml)
Sodium Carbonate
2 Anhydrous (Na2CO3)
3 HCL (35%)
Potassium
4 Iodide (KI)
0.1 N Sodium Thio Sulphate
5 (Na2S2O3)

PROCEDURE
Take 10 ml of the bath
1
solution into conical flask.
Add 0.5 - 1.0 gm (5 to 6 spatula) of Sodium Carbonate
2 Anhydrous (Na2CO3), and then add about 10 ml of HCl and
mix thoroughly.
Add 2-3 gm of Potassium Iodide (KI), and then add about 20
3
ml of HCl and mix thoroughly.
Then add about 100 ml of Distilled
4
water shake thoroughly
Leave the solution around
5
10-20 seconds.
Then titrate against 0.1 N Sodium Thio Sulphate (Na2S2O3)
6 until appearance of the solution change from yellow to
colorless.
The volume in cm3 0.1 N Sodium Thio Sulphate (Na2S2O3)
7 required to calculate Chlorate (ClO3) content as following
formula.
ClO3 = 0.139
8 X ml of titre
value

SPECIFICATION

Chlorate content is 0.7 -

1.1 g/l.
 42

Reason for New, Revision : Company name changed Page :1/1

Rev : 1
11-09-
Enactment date
2012
Notice □ Regular □ Limited period : ~
 43

5.1.2 Noise Level Measurements

 44

No. of hours exposed Sound level dB

8 90
6 92
4 95
3 97
2 100
1.5 102
1 105
0.5 110
0.25 or less 115

5.1.2 Noise Level Layout

 45

Noise level in phosphating unloading area

Without
S. With rubber Noise Reduced
Date Part no rubber
NO mate reduced level Percentage
mate
1 7DM0001-11 114 96 18 15.79%
2 05-04- 2DM0003-13 109 98 11 10.0917431
3 2021 1G0506-12 117 104 13 11.1111111
4 506-11 121 107 14 11.5702479
5 7T0404-11 111 95 16 14.4144144
6 7T0402-11 110 97 13 11.8181818
06-04-
7 1A0500-11 116 101 15 12.9310345
2021
8 1A0500-13 114 98 16 14.0350877
9 7T0407-11 119 106 13 10.9243697
10 2DM0001-11 116 102 14 12.0689655
11 RA6225-13 107 96 11 10.2803738
07-04-
12 7T0407-11 113 100 13 11.5044248
2021
13 7T0407-12 110 98 12 10.9090909
14 4T0175-11 114 99 15 13.1578947
15 2P0005-11 116 102 14 12.0689655
16 1A0500-13 120 104 16 13.3333333
17 08-04- 4T0402-11 114 96 18 15.7894737
18 2021 RA5195-13 111 98 13 11.7117117
19 4T0175-11 116 104 12 10.3448276
20 2TT0025-11 113 99 14 12.3893805
21 2DM0001-11 114 96 18 15.7894737
22 2DM0003-13 109 98 11 10.0917431
09-04-
23 4T0175-11 122 104 18 14.7540984
2021
24 2TT0025-11 114 96 18 15.7894737
25 7T0407-11 120 105 15 12.5
Total Noise reduction 2860 2499 361 12.62%
 46

5.1.3 Noise Level without Rubber sheet

Fig 5.1.3 Noise Level without Rubber sheet

5.1.3 Noise Level with Rubber sheet

Fig 5.1.3 Noise Level with Rubber sheet

 47

5.1.5 Trail ( After Rubber Sheet Installation)

Fig 5.1.5 Trail ( After Rubber Sheet Installation)

5.1.6 Noise Trend Level

Fig 5.1.6 Noise Trend Level

 48

5.2 Molding Machine

5.2.1 Why Why Analysis

Fig 5.2.1 Why Why Analysis

 49

5.2.2 WI Standard Mold alignment Table

Fig 5.2.2 WI Standard Mold alignment Table

 50

5.2.3 Safety Q Point

Fig 5.2.3 Safety Q Point

 51

Fig 5.2.3 Safety Q Point

 52

5.2.4 Mold Handling Method

Fig 5.2.4 Mold Handling Method

5.2.5 Abnormal Condition during Mold Operation

Fig 5.2.5 Abnormal Condition during Mold Operation

 53

5.2.6 Mold Normal Position

Fig 5.2.6 Mold Normal Position

5.2.7 Training Record for Mold Handling in Injection Machine

Fig 5.2.7 Training Record for Mold Handling in Injection Machine

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CHAPTER 6
CONCLUSION
This project was taken for the need of safety operation in Degreasing and Moulding
machine because there are many activities to be done in machine operations like
loading/unloading the Mettals and to move the materials from one place to another place.

To avoid these kind of hazards need to provide control measure. The control measures to
minimize the hazards. This project discussed about accident, injuries to the operator
and Physical hazards on the machine while operating of the persons in front of the
machine. In order to avoid these accidents and cut hazards the Hazard
identification and Risk assessment have to be carried out on fabrication industry.
Observed the workplace and its egress to identify where and why the incidents
happen. The incident reports are studied to find the severity of the incidents and
also to observe the likelihood of those incidents.

A detailed structural of the Degreasing and Moulding machine and its non-
compliance factors had been mentioned to rectify in the further periods. Until the
rectification some suggestions had given which has to be followed by the
employees to free from the incidents which may create massive accidents. A
details Hazard identification and Risk assessment study will be conducted in
phase-2 to identify the risk and effective control measures will be identified
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7. REFERENCE

1. Iraj Mohammadfam, Amene Sajedi

Application of Hazard and Operability Study (HAZOP) in Evaluation of Health,
Safety and Environmental (HSE) Hazards. May 2012, Department of
Occupational Health and Safety, Faculty of Health, University of Hamadan
Medical Science

2. C. Jeerawongsuntorn, N. Sainyamsatit Integration of safety instrumented system

with automated HAZOP analysis: An application for continuous biodiesel
production, February 2011, Center of Excellence for Petroleum, Petrochemicals,
and Advanced Materials, Center for Advanced Studies in Industrial Technology,
Department of Chemical Engineering, Faculty of Engineering

3. Venkat Venkatasubramanian *, Jinsong Zhao Intelligent systems for HAZOP

analysis of complex process plants, February 2000 Laboratory for Intelligent
Process Systems, School of Chemical Engineering, Purdue University, West
Lafayette, IN 47907, USA

4. Shilei Lu_, Neng ZhuExperimental Research on Physiological index at the heat

tolerance limits in China, June 2006. School of Environment Science and
Technology, Tianjin University, Tianjin

5 .S. Wijewardanea, M.T.R. Jayasingheb, Thermal comfort temperature range for

factory workers in warm humid tropical climates. November 2007. EMEC Consultancy
Services, Colombo, Sri Lanka,Department of Civil Engineering, University of Moratuwa,
Moratuwa, Sri Lanka

6. Factories Act, 1948 - Provisions On Safety

Statutory importance is attached to Safety in Industry. The Government has enacted the
Factories Act 1948 wherein exclusive provisions have been made towards Safety. The
respective State Government has also enacted Rules to give effect to the provisions of
Factories Act.