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Industrial Packaging, lashing Unitization, Issue Date-02.02.

2017
Packaging Tools and equipment’s supply
and technical service

OCCUPATIONAL HEALTH AND


SAFETY MANAGEMENT
SYSTEM
DOC NO-SIG/OHSM-01
COPY NO-01

ISSUE VERSION NO-1.5

DATE OF ISSUE-02.02.2017

REVSION NO-05

REVISION DATE- 11.11.2019

SIGNODE INDIA LTD


BHOJANIA PALACE

NH-33, MANGO

JAMSHEDPUR-831012

PHONE NO- +91 6576565888, 7209065888

www.signodeindia.com

Prepared By-Jeetendra Pandit Approved By-KVT Rao

Signature- Signature-

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Change Authorization History


Document No SIG/OHSM-01
Overall Process Owner BUSINESS HEAD (Metals East)
Process Change Authorization KAM
To be Reviewed By KAM

Version Control
Version No- Prepared By Reviewed By Date Location
1.1 Manager(EHS) Business Head(Metals 02.02.2017 All work Location
East)
1.2 Manager(EHS) Business Head(Metals 10.10.2017 All work Location
East)
1.3 Manager(EHS) Business Head(Metals 12.11.2018 All work Location
East)
1.4 Manager(EHS) Business Head(Metals 13.10.2019 All work Location
East)
1.5 Manager(EHS) Business Head(Metals 11.11.2019 All work Location
East)

Version Control History


Version No Reason for change
1.1 First Issue
1.2 After OFI from internal and external audit
1.3 Reward and consequence Management added, Grievance handling
management added. Signode Priorities Added
1.4 Selection criteria revised as per CSM
1.5 New Logo, New Safety policy, Mission & Vision, EPRP Revised

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INDEX/CONTENT/TITLE PAGE Nos


SL NO-

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1 COMPANY PROFILE  5

2 SAFETY PLEDGE  6

3 SAFETY RESOLUTION  7

4 CARDINAL SAFETY RULE  8

5 CERTIFICATES  9-12

6 MISSION, VISSION & MOTTO  13

7 TERMS & DEFINATION  14-18

8 ABBREVIATION  19

9 INTODUCTION- PDCA  20

10 OCCUPATIONAL HEALTH AND SAFETY POLICY  21

11 SIGNODE GUIDING PRINCIPLE  22

12 HEALTH & SAFETY OBJECTIVE  23

13 ORGANIZATIONAL CHART  24

14 ROLES & RESPONSIBILTY  25-16

15 HIRA  27-30

16 JHA  31-33

17 LEGAL AND STATUTORY COMPLINACES  34

18 EMERGENCY PREPRADENESS & RESPONSE PLAN  35-36

19 GOVERNANCE FRAMEWORK FOR HANDLING EMERGENCIES  37

20 MANAGEMENT ACTION IN CASE OF INCIDENT  38

21 SAFETY DASH BOARD  39

22 PROCESS OF EMPLOYEE SELECTION  40

23 RECRUITMENT & SELECTION, HR PROCESS  41-42

24 HEALTH & SAFETY STANDARDS  43

25 PPE  44

26 PPE STANDARD AND PROCUREMENT  45

27 PPE CHECKING & MONITORING  46

28 ASSET MANAGEMENT  47

29 INSPECTION CHECKLIST  48-49

30 AUDIT PLAN & REVIEW  50-51

31 COMPETANCY ,TRAINING & AWARENESS  52

32 SELF ASSESSMENT (INTERNAL AUDIT)  53-54

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33 THIRD PARTY AUDIT  55

34 REWARD & CONSEQUENCE MANAGEMENT SYSTEM  56-57

35 COMMUNICATION & PARTICIPATION  58-60

36 AMENITIES  61

37 SAFETY CAMAPAIGN  62

38 SELF SAFETY INITIAVTIVES  63

39 HSE PLAN  64-65

41 CLASSIFICATION OF INCIDENTS & INVESTIGATION  66-68

42 OCP  69-70

43 5’S -HOUSEKEEPING  71

44 GRIVENCE HANDLING SYSTEM  72-73

45 JOB EXECUTION PLAN 73-75

46 SAFETY COMMITTEE 75-78

47 METHOD STATEMENT 79-83

Company Profile
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Signode India Limited is a Company of Signode Industrial Group, USA, a global leader in
the industrial bulk packaging industry with a heritage that goes back more than 100 years.

We produce strap, stretch and protective packaging. We also manufacture packaging tools
and equipment that are used to apply the bulk packaging materials. These packaging
products are used to contain, unitize, protect and secure goods during warehousing and
shipment. Our company is a pioneer in the industrial packaging sector with a long history of
customer-focused innovations in materials, processes and automation technology that have
revolutionized the sector.

The objective of Contract Packaging is to provide solution with single point responsibility at
customer’s premises in order to achieve his customer’s satisfaction. Started in 1987 at
BOKARO STEEL PLANT, to prove the equipment supplied to the customer, which was not
able to use to its optimum efficiency by him. We have demonstrated the optimum utilization
and effectiveness of the equipment to the customer by taking up this single point
responsibility of Operating & Maintaining the system.

After seeing the benefits that BOKARO STEEL PLANT has got from this concept, most of the
steel manufacturers like TATA STEEL, TIN PLATE CORPORATION OF INDIA LIMITED,
SAIL-BHILAI and JSW Steel, Essar Steel have also offered similar jobs to SIGNODE. The
success story of Contract Packaging continued and the list of new customers include Jindal
Stainless steel limited, Jamshedpur Continuous Annealing & Processing Company Private
Limited etc.

Presently this business contributes more than ₹400 Crores and is growing faster in view of
the changing trend towards outsourcing, by Indian Industry.

In view of the growth plans for this business, we felt it is necessary to establish, maintain and
implement an effective Safety Management System in place to ensure safer operations &
SATISFIED CUSTOMER.

(KV Trinadha Rao)


BUSINESS HEAD – Metal East

Safety Pledge
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‘’I commit myself to work


Safely, personally and
Ensure that my colleagues
And people working for me
Are committed to safety.

I promise to bring improvement


In my work area and totally
Eliminate occurrence of any
Incident or accident.’’

SAFETY RESOLUTION

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CARDINAL SAFETY RULES


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CERTIFICATES

OHSAS 18001

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ISO-9001

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ISO-14001

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MISSION VISION & VALUES

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TERMS & DEFINITION


3.1 Acceptable risk
Risk that has been reduced to a level that can be tolerated by the Organization having regard to
its legal obligations and its own. OH&S policy (3.16)

3.2 Audit
Systematic, independent and documented process for obtaining “audit evidence” and evaluating
it objectively to determine the extent to which “audit criteria” are fulfilled [ISO 9000:2005,
3.9.1]

NOTE 1- Independent does not necessarily mean external to the Organization. In many cases,
particularly in smaller Organizations, independence can be demonstrated by the freedom from
responsibility for the activity being audited.
NOTE 2- For further guidance on “audit evidence” and “audit criteria”, see ISO 19011.

3.3 Continual improvement


Recurring process of enhancing the OH&S management system (3.13) in order to achieve
improvements in overall OH&S performance (3.15) consistent with the Organization’s (3.17)
OH&S policy (3.16)

NOTE 1- The process need not take place in all areas of activity simultaneously.
NOTE 2- Adapted from ISO 14001:2004, 3.2.

3.4 Corrective action


Action to eliminate the cause of a detected nonconformity (3.11) or other undesirable situation

NOTE 1- There can be more than one cause for nonconformity.


NOTE 2- Corrective action is taken to prevent recurrence whereas preventive action (3.18) is
taken to prevent occurrence.
[ISO 9000:2005, 3.6.5]

3.5 Document
Information and its supporting medium

NOTE- The medium can be paper, magnetic, electronic or optical computer disc, photograph or
master sample, or a combination thereof.
[ISO 14001:2004, 3.4]

3.6 Hazard
Source, situation, or act with a potential for harm in terms of human injury or ill health (3.8), or
a combination of these

3.7 Hazard identification


Process of recognizing that a hazard (3.6) exists and defining its characteristics

3.8 Ill health


Identifiable, adverse physical or mental condition arising from and/or made worse by a work
activity and/or work-related situation

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3.9 Incident
Work-related event(s) in which an injury or ill health (3.8) (regardless of severity) or fatality
occurred, or could have occurred

NOTE 1- An accident is an incident which has given rise to injury, ill health or fatality.
NOTE 2- An incident where no injury, ill health, or fatality occurs may also be referred to as a
“near-miss”, “near-hit”, “close call” or “dangerous occurrence”.
NOTE 3- An emergency situation (see 4.4.7) is a particular type of incident.

3.10-Iinterested party
Person or group, inside or outside the workplace (3.23), concerned with or affected by the
OH&S performance (3.15) of an Organization (3.17)

3.11 Nonconformity
Non-Fulfilment of a requirement
[ISO 9000:2005, 3.6.2; ISO 14001, 3.15]
NOTE- A nonconformity can be any deviation from: relevant work standards, practices,
procedures, legal requirements, etc.
OH&S management system (3.13) requirements.

3.12 occupational health and safety (OH&S)


Conditions and factors that affect, or could affect, the health and safety of employees or other
workers (including temporary workers and contractor personnel), visitors, or any other person
in the workplace (3.23)

NOTE Organizations can be subject to legal requirements for the health and safety of persons
beyond the immediate workplace, or who are exposed to the workplace activities.

3.13 OH&S management system


Part of an Organization’s (3.17) management system used to develop and implement its OH&S
policy (3.16) and manage its OH&S risks (3.21)

NOTE 1- A management system is a set of interrelated elements used to establish policy and
objectives and to achieve those objectives.
NOTE 2- A management system includes Organizational structure, planning activities
(including, for example, risk assessment and the setting of objectives), responsibilities,
practices, procedures (3.19), processes and resources.
NOTE 3- Adapted from ISO 14001:2004, 3.8.

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TERMS & DEFINITION (OTHERS)


CONTRACT-A written agreement between TSL and its contractor(s) to supply manpower,
services, and/or materials or to carry out the whole or part of any work requested by TSL

CONTRACT ADMINISTRATOR (CA)- The Contract Administrator shall be responsible for


managing all contractor safety related activities and shall ensure the overall implementation of
the entire contractor safety management standard.

CONTRACTOR/CONTRACTOR PROPRIETOR (CP)- A person(s) or any non-company entity that


has contracted with TSL to supply manpower, services, and/or materials

CONTRACT EMPLOYEE(S)- Any person(s) who is employed by contractors to carry out the
contracted work. He/she is not employed directly by TATA

CONTRACT OWNER (CO)-Any TATA employee who has overall control of the contract or/and
who certifies contractor invoicing/job during and/or after completion of work.

HIGHER RISK WORK-A Work or part of the Work that has got potential for an injury, property
damage, loss of containments, ill health or a process incident or given consequences have
already happened.

LOWER RISK WORK-A Work or part of the Work where the risk involved in the job is at a
broadly acceptable level or has a very low potential of injury, property damage, loss of
containments, ill health or a process incident.

SITE-Site means the place so designated by owner for Signode including such places in and
around/adjacent, which are for storage of materials, equipment’s and machineries.

SAFETY PLAN-A safety plan is a guide for staying safe from deviation from safety standard and
procedure. Safety plan must be relevant to job and must have adaptability if the condition
changes.

SUBCONTRACTOR-Any entity, person engaged, and / or used by a contractor to assist in


execution of the work. Only one level of sub-contracting is allowed and the use of any and all
subcontractors must be authorized by TSL before contracts are formed. Subcontractors shall be
subject to same registration and selection screening processes required of all.

OWNER /PROPRIETOR/PARTNER/MD-Owner/Proprietor/Partner means U.A.E and includes


its representative, its successors in title and permitted assignees.

WORKS-Work means all the technical & professional services &responsibilities to be performed
by U.A.E as specified, stated, indicated in the contract.

ACCIDENT- An unplanned or undesired event which can result harm to people, property or the
Environment.

INCIDENT- Event that results into an accident or have the potential to lead to an accident. The
term Incident includes “Near Misses”.

NEAR MISS-A Near Miss is an event where no contact or exchange of energy occurred and thus
did not result in personal injury, asset loss or damage to the environment.

Examples: A person trips over an object and falls on the ground but did not get injured
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A hammer fell from a height of 10 m and the people working in the vicinity escaped narrowly
from being hurt.

HAZARD-A Source or situation with a potential for harm in terms of human injury or ill health,
damage to property, damage to the work place environment or a combination of these.

RISK- A measure of the likelihood that the harm from a particular hazard will occur, taking into
account the possible severity of the harm.

HARM-Harm includes death, injury, physical or mental ill health, damage to property, loss of
production or combination of these

UNSAFE ACT OR CONDITION-Any act or condition that deviates from a generally recognized
safe way or specified method of doing a job and thus increases the potential for an accident.

LOST TIME INJURY (LTI)-Work related injury or illness that renders the injured person unable
to perform any of his/her duties or return to work on a scheduled work shift on any day
immediately following the day of the accident.

FIRST AID CASE-“First Aid” as any one-time treatment and any follow-up visit for the purpose of
observation of minor scratches, cuts, burns, splinters or other minor industrial injuries, which
do not ordinarily require medical care.

MEDICAL TREATMENT CASE (MTC)-Work related injury or illness requiring more than first aid
treatment by a physician, dentist, surgeon or registered medical personnel.

FATALITY-Death due to a work related incident or illness regardless of the time between
injuries or illness and death.

EXPOSURE-The measurement of time during which the subject is at risk from a hazard.

ILL HEALTH-Identifiable adverse physical or mental condition arising from and /or made worse
by a work activity and/or work-relate situation

HOUSEKEEPING- A place for everything and everything in its place i.e. maintaining the working
environment in an orderly manner.

RISK ASSESSMENT- The process of analyzing the level of risk considering those in danger, and
evaluating whether hazards are adequately controlled, taking into account any measures
already in place.

AUDIT-Systematic, independent and documented process for obtaining “audit evidence” and
evaluating it objectively to determine the extent to which “audit criteria” are fulfilled.

CORRECTIVE ACTION-Action to eliminate the cause of a detected non conformity or other


undesirable situation.There can be more than one cause for a non-conformity. Corrective action
is taken to prevent recurrence whereas preventive action is taken to prevent occurrence.

PREVENTIVE ACTION-Action to eliminate the cause of a potential non conformity or other


undesirable potential situation.

There can be more than one cause for a potential non conformity. Preventive action is taken to
prevent occurrence where as Corrective action is taken to prevent recurrence.

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PERSONAL PROTECTIVE EQUIPMENT (PPE)-All equipment and clothing intended to be utilized,


which affords protection against one or more risks to health and safety. This includes protection
against adverse weather conditions.

SWL-Safe Working Load: The maximum load that an item can lift in a particular configuration or
application.

TRAINING-The process of imparting specific skills and understanding to undertake.

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ABBREVIATIONS
CAPA CORRECTIVE AND PREVENTIVE ACTION
CEO CHIEF EXECUTIVE OFFICER
DCIC DOCUMENT CONTROL INCHARGE
Prop PROPRIETOR
DCMP DIASASTER CONTROL & MANAGEMENT PLAN
DIR DIRECTOR
DOC DOCUMENT
DT DATE
O&M OPERATION & MAINTENANCE
HIRA HAZARD IDENTIFICATION AND RISK ASSESSMENT
F&A FINANCE & ACCOUNT
F&S FIRE & SAFETY
SOP STANDARD OPERATNG PROCEDURE
HR HUMAN RESOURCES
I/C INCHARGE
IA INTERNAL AUDIT
MA MANAGEMENT APPOINTEE
MAINT. MAINTENANCE
MECH. MECHANICAL
MR MANAGEMENT REPRESENTATIVE
MRM MANAGEMENT REVIEW MEETING
NO NUMBER
CSM Contractor safety management
MA Management appointee
EMS Environment management system
QA Quality assurance
DCIC Documents control in charge
PPES Personal protective equipment’s
SCM Safety committee meeting
EAP Emergency assembly points
EPRP Emergency preparedness and response plan
KPI Key performance indicators
IS Indian standard
KAM KEY ACCOUNT MANAGER

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INTRODUCTION -PDCA

OH&S Policy

Management
Review
Planning

Implementation
Checking and and operation
corrective action

Reference Standards -OHSAS 18001 IS based on the methodology known as Plan – Do-
Check- Act (PDCA). PDCA can be briefly described as follows

 Plan – Establish the objectives and processes necessary to deliver results in accordance
with the organizations’ OH&S policies
 Do – implement the processes
 Check – Monitor and measure processes against OH&S -policies, objectives, targets, legal
and other requirements and report the results
 Act – take actions to continually improve performance of the Occupational Health and
Safety Management Systems

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OCCUPATIONAL HEALTH & SAFETY POLICY

OCCUPATIONAL HEALTH AND SAFETY POLICY

Signode India aspires to achieve “Zero harm to people”. Safety compliance is a condition of
employment with focus on compliance to SIG cardinal safety rules.

We operate our Packaging, Equipment & Supply Chain, business in safe, healthy and
professional manner such that these values become integral part of our everyday culture. We
reward and recognize the safety compliant team and people.

At Signode we are committed to:

 Prioritise OH&S needs with business needs, eliminate hazards and reduce OH&S risks.
 Provide safe and healthy working conditions to prevent work related injuries and ill
health.
 Fulfill legal and other requirements.
 Continual improvement of OH&S system.
 Consult and ensure participation of all employees and workmen in OH&S initiatives
and programs.

This policy shall apply to all employees, vendors & their employees, visitors working at our
facilities & operational contract Sites.

R V S Ramakrishna

Managing Director

Date: 16th October 2019


(This supersedes earlier policy)

The OH&S policy is communicated to all the employees through displays. All the employees are
being made aware of their individual OH&S obligations through training programmes, safety
talks and displays

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SIGNODE PRIORITIES
 Focus on Operational Excellence Safety, Quality, Productivity in all
we do
 Grow revenues profitably and consistently over time
 Deliver cash from the business to return to our share holders
 Develop and support our people to ensure team success
 Implement and maintain compliance with Sarbanes- Oxley (SOX)
control standards

SIGNODE GUIDING PRINCIPLES


 All injuries can be prevented.
 Employee involvement is essential.
 Management is responsible for preventing injuries.
 All operating exposures can be safeguarded.
 Training employees to work safely is essential.
 Management audits are mandatory.
 Working safely is a condition of employment.
 All deficiencies must be corrected promptly.
 We will promote off the job safety for our employees.

SIGNODE CORE PRINCIPLES


 Safety and health.

 Highest ethical behavior.

 Environmental stewardship.

 Respect for people.

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Health & Safety Objectives


1. Zero Fatality
2. Zero LTI
3. Severity Index < 2.5
4. ZERO tolerance on Cardinal Rule Violation.
5. Minimize and eliminate safety violations of Severity index 4 & 5

Hierarchy of Hazard Control


1. Elimination
2. Substitution
3. Engineering Control
4. Administrative Control
5. PPEs

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ORGANISATIONAL CHART

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ROLES & RESPONSIBILTY


1. BUSINESS HEAD

Responsibility:

 To ensure that OHS management system requirements are established, implemented


and maintained in accordance with OHSMS.
 To review and monitor OHS performance.
 To initiate independent reviews and evaluation of the OHS by external agencies,
whenever required.
 To conduct line-walk with senior representatives and review.
 To maintain all the relevant OHS documents.

2. KAM (KEY ACCOUNTS MANAGER)

 To maintain a proper management system.


 To ensure, implementation of all safety norms related to OHSMS
 To ensure yearly medical check-up during gate pass renewal.
 To provide and facilitate the employers with standard quality of PPE”S and tools as per
TATA STEEL standards with reference to Safety Representative.
 To report on the performance of OHS in his area.
 To ensure all the relevant OHS related documents.

3. SAFETY MANAGER

 To carry out safety inspections in order to observe the physical conditions of work.
Practice and procedures followed by workers.
 To advice the purchasing and store department in ensuring availability of high quality
PPE”s .
 To advice in safety aspects in all job and to carry out detailed job safety on scheduled
job.
 To organise awards, campaigns, competition and other activities to promote and
maintain safe conditions of workplace.
 Audits, observation, compliance.
 To ensure all the relevant OHS documents and records.

4. SITE INCHARGE/ SITE SUPERVISOR

 To maintain and ensure safety, quality, disciplinary conditions at work.


 To deploy and distribute manpower as per job.
 To ensure the work done at workplace/site is done with respect to SOP provided.
 To co-ordinate with the department of TATA STEEL and our management.
 To ensure every worker and staffs responsible at one’s site are in proper PPE, if not than
to facilitate them with proper requirements.

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5. SITE SAFETY SUPERVISOR

 To carry out safety inspections in order to observe the physical conditions of work.
Practice and procedures followed by workers.
 To advice the purchasing and store department in ensuring keeping of high quality
PPE”s .
 To advice in safety aspects in all job and to carry out detailed job safety on scheduled
job.
 To organise awards, campaigns, competition and other activities to promote and
maintain safe conditions of workplace.
 Audits, observation, compliance.

6. WELDER

 Checking the working condition of welding machine


 Wear PPEs and strictly adhering to the SOPs
 Maintaining good housekeeping and Safety at the shop floor
 Understanding Welding operations and welding as per unitization style

7. HELPER

 Understanding Packaging & Unitization operations and working accordingly


 Wear PPEs and strictly adhering to the SOPs
 To ensure safe working environment in Workplace and surrounding area.
 Maintaining good housekeeping and Safety at the shop floor

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HIRA
Hazard Identification and Risk Assessment (HIRA)
Introduction

Hazard Identification and Risk Assessment is in-depth examination of activities to be


performed by dividing them in steps and sub steps. Hazards associated with each step and
sub step are identified and preventive measures are suggested to
eliminate/minimize/control these hazards.

Objective

Objective of this procedure is to provide guidelines for hazard identification and risk
assessment of all activities to be performed at TSL site with a view to make the persons
engaged in jobs to aware about the hazards associated with such job and to establish
preventive measure prior to taking up the job.

Scope

This procedure is applicable to all critical activities to be performed by Signode at Tata


work site.

Responsibilities

Supervisors shall ensure that all critical activities to be performed under their scope of
work are listed in order to complete Hazard Identification and Risk Assessment. They
should further ensure that HIRA of such activities are made and approved by them and
Safety Supervisor. Execution team shall be responsible to implement the same during
execution of the job.

Methodology

Supervisor shall appoint a team inclusive of Safety supervisor for preparation of risk
assessment for the jobs to be carried out in his area. All routine and non-routine activities
need to be identified. Identify activities carried out by contractors and the job offloaded to
contractors (indirect activities).

List out all the activities in the form.

Step – II Observe tasks being carried out at site / workplace. Make site assessment.

Review documented procedure – Record the gaps.

Review accident record and its analysis – note down root causes.

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Review health / toxicological data of persons engaged in sensitive activities as defined


under The Factories Act, 1948

List out all actual and potential hazards.

Identify hazards related to activities under normal, abnormal and emergency conditions.

Identify unsafe conditions and practices through site inspection related to activities that are
identified in Step-I and record the same under the column “Existing” and “Gaps” in
“Adequacy of Measure”.

Step - III

Determine risks based on hazard involved considering likelihood and consequence based
on existing control measure and gaps.

Step - IV

Carry out risk assessment as per the guideline and Identify tolerable and non-tolerable
risks.

Step - V

Carry out feasibility study on identified non-tolerable risk in order to eliminate / reduce or
control based on:

Technology, Availability, Physical Improvements

Further Feasibility Study Required

Technique/Training & Competency

Required Operational Feasibility

Economical Viability

Step - VI

Determine risk management measure in terms of:

Operational Control

Management Programs

Emergency Prevention, Preparedness & Response Procedure to minimize the risk to


acceptable/trivial level

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Guideline for Risk Assessment:

Likelihood of Event
Description Frequency (events per year) Frequency Category

Very likely to occur > 1 to 10^-1 F-1


Likely to occur atleast
once in the lifetime of
the process 10^-1 to 10^-2 F-2
Unlikely to occur in the
lifetime of the process,
but possible 10^-2 to 10^-3 F-3
Very unlikely - not
expected 10^-3 to 10^-4 F-4
Extremely unlikely - not
realistically expected to < 10^-5 F-5
occur

Level of Consequence

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Risk Matrix

Risk Definition

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The HIRA will be carried out in below mentioned format.

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JOB HAZARD ANALYSIS (JHA)


A job hazard analysis (JHA), sometimes referred as job safety analysis (JSA), is a
method to identify existing or potential hazards associated with each step or task of a
job and integrate solutions to reduce exposure to those hazards. How to conduct a
JHA? There are five basic steps in the JHA process:

1. Selecting the Job

JHA need to develop for all jobs, but give priority to those jobs in which workers have
been injured or have a greater risk of injury.
When a new job is introduced, complete a JHA and train your workers.

2. Break Down the Job into Steps List down the basic job steps – (e.g. Observe an
experienced worker completing the job, Ask workers to write the steps they take when
completing the job, Consult multiple people familiar with the job etc.)

3. Identify the Existing & Potential Hazards

 Ask questions to identify the hazards such as:


 Is the worker at risk for a slip, trip, or fall?
 Is the worker exposed to fumes or dust?
 Does the equipment or machinery used pose any hazards?
 Are there missing shields or guards, exposed pinch points, possible crush points,
or potential entanglement areas?
 Do any of the hand or power tools pose any hazards? Does a tool have missing
shields or guards, a frayed power cord, or cracked handles? Does the tool lack a
ground fault interrupt?
 Could a worker sustain an injury from lifting, pushing, or pulling?
 Is the worker exposed to excessive noise or vibration?
 Are there environmental issues, such as weather, that could affect the safeness
of the job?
 Are workers wearing the appropriate personal protective equipment (PPE)
for the job?
 Is there adequate lighting in the workspace?
 Can the operator receive a strain or sprain due to bending, twisting, and lifting
while performing any of the steps?

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 Can the operator receive a crushing injury to do be caught in, on or between


equipment?
 Can they receive a burn or irritation due to contact with chemicals, heat, or other
physical or biological hazards?
 Could a chemical or material release occur?

4. Make Recommendations to Reduce/Eliminate or Control Hazards for each step

 Focus should be given to eliminate the hazard by modifying the process,


changing the equipment, or improving the environmental conditions.
 Where hazards cannot be eliminated, provide engineering controls (barriers,
interlocks, tools, etc.) that can reduce or eliminate hazardous conditions.
 Administrative control (procedures, training, limit the exposure time, etc.)
should be applied to the task where elimination and engineering are not feasible.
 When all the previous controls cannot provide hazard reduction, personal
protective equipment (PPE) should be considered (i.e. gloves, respirators,
specialized clothing, etc.).

5. Evaluation and Follow-Up

 Evaluate the effectiveness of the JHA after any injury or illness


 Review the causes of the injury or illness
 modify or update the JHA to reflect any changes
 Review all JHA changes with workers

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Please refer JHA for CONTROLS & RESPONSES AGAINST POSSIBLE HAZARDS
associate with each activity in below mentioned format.

JOB HAZARD ANALYSIS Doc no- Frmt/Jha-01 Revision-00

Department & section

Location of Job:

Job description

Team

Safeguard / controls to be
Sequence of Basic Job Steps Potential Hazards Responsibility
put in place

Special skilled
Required PPE Required Tools & equipment Required Training
employees

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Legal and Statutory Compliance


1.0 Purpose: To identify and meet the all applicable legal and other requirements

2.0 Responsibility: HR & Safety personnel.


HR & Safety Personnel may delegate the task to specific functionaries.

3.0 System :

3.1 Procedure is established;


a) To identify all the applicable legal requirements and other requirements to
which the organization subscribes related to Occupational Health & Safety.
b) To determine how these requirements are apply to Occupational Health &
Safety.

3.2 The above requirements are taken into the account while establishing the OHS
System

3.3 The applicable requirements are communicated to the concerned employees and
other relevant interested parties.

3.1 The designated personnel maintain a list of applicable legal and other OHS
requirements, and updates periodically with the help of external agencies.

3.2 The relevant information is communicated to all the concerned/interested parties


through e-mails, displays and circulars.

3.3 Respective OHS Management System Procedures defines personnel responsible for
statutory reporting; obtaining permits, approvals and consents under various acts
and rules.

4.0 Reference Documents: Legal register & Legal compliance register


5.0 Records Retention period
Legal Register Permanent

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Emergency Preparedness and Response Plan

1. PURPOSE & SCOPE:

The purpose of this procedure is to identify and prevent the occurrence of potential
environmental and OH&S emergency situations and to respond to the emergency situations
after its occurrence. This also helps in preventing and mitigating environmental impacts

2. RESPONSIBILITY: ALL working dept. of Signode


3. PROCEDURE

3.1 Defining Environmental & OH&S Emergency

An unexpected event that has significant impact on environment & OH&S and which needs
immediate action to be taken is treated as an emergency.

3.2 Identification of Environmental & OHS Emergency


situations in Plant The following event is identified as potential
emergency situations in Plant.

i) Fire Hazard
ii) Road incidents
iii) Fire incident
iv) Electric shock
v) Cut Injury
vi) Health issue
vii) Wagon Derailment

Roles & Responsibilities


Packaging Associates – They will inform to shift supervisor/ Safety supervisor/ Shift
In charge

Shift Supervisor/ Safety Supervisor – Examine the injured and the injury. If first aid
required then first aid medicines or first aid measures to be taken. If stretcher is needed
then it can be used. They will inform to Shift In charge

Shift In charge – He will inform to Site in charge. And if emergency services like
ambulance & fire department to be called then he will call them.

Site In charge – He will inform about the incident to all concerned persons like – Line manager,
safety head, and other concerned persons.
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Safety Supervisor – If there is emergency evacuation to be done then he will guide all persons
towards Emergency exit and Emergency Assembly Point

Note. We will follow the departmental EPRP system which is made by various dept. of
TATA.
We will participate in mock drills conducted by TATA and will act as per their directives
in case of mock drill and real emergency.

Emergency Contact No-(TSK)


First Aid Centre – 9040003106

Ambulance – 06726-605200

Gas Safety – 9040003109

Road Safety – 9040003110

Fire Service- 9040003102/03

Shift Safety – 9040090901

Security control Room- 06726-606061

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Governance framework for handling Emergencies

Incident /
Emergency

First Responder (Site


Supervisor

Emergency Response
Team of TATA

Confirmation of
Event

Decide course of Inform Area


action Incharge

Inform Tata Steel Emergency


Number

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Management action in case of incident/Accident at customer location

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SAFETY DASHBOARD
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Safety dashboard will be displayed in front of the office so that lead and lagging indicators will
be visible to all the working crew, employee, visitors and other interested parties.

Safety dashboard will be updated daily by site safety supervisor.

Procedure for selection and deployment of employees


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Purpose: Filling of employee’s vacancy for getting job done, to improve quality and
safety performance of the company and completing work timely as allotted by
customer.

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COMPETANCY MATRIX

S. No Designation Educational Technical Work


Qualification Qualification Experience
1 Business Head Graduate BTECH/MBA 10 Years
2 Site In Charge Graduate BTECH/Diploma/ 5 Years
(Manager) MBA
3 Safety Manager Graduate PDIS 5 Years
4 Shift In Graduate BTECH/Diploma/BSc 2 Years
charge/Supervisor
5 Safety Supervisor Graduate BTECH/Diploma/BSc 2 Years
+PDIS
6 Welder Certified by
TATA
7 Helper Certified by
TATA

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Training (To assess the capability of work force)


Purpose: To establish, implement and maintain procedure for ensuring
that:

i. Training needs of all the personnel whose work may create a significant
impact upon the non-acceptable OH&S risk in the work place are identified
and appropriate training imparted to them taking in to account their
responsibility, ability, language, skills and literacy; so that they are aware of

 Actual or potential consequence of their work and behaviour.


 Their roles and responsibilities in safety performance enhancement
and emergency situations.

ii. Personnel performing the tasks are competent on the basis of


appropriate education, training and/or experience.

iii. To promote and encourage employees by promotional scheme for skill


development.

Procedure:

i. Safety department is responsible for the implementation of this


procedure in their respective areas.

ii. All the site of Signode India Limited, which are preparing for the
occupational health and safety management systems have a procedure on
training. The Training needs of all the personnel whose work may create a
significant impact upon the OH&S risk in the workplace are identified as
per the above procedure considering their level of literacy, skill, language,
and risks.

iii. While identifying the training needs of the employees at each relevant
function are level including their roles and responsibility, following areas
are considered-

 General awareness for achieving conformance with safety principles


and policy.

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 Relevant safety rules and regulation and other requirement including


safety standards.
 Hazard/Risk Assessment process
 Significant and unacceptable Hazard
 Emergency preparedness and response requirement
 Site safety observation
 Training on incident learning

iv. Training needs of all the personnel are identified based on their job role,
competence and skill.

V. A yearly training plan will be made and same to be followed to attain


desired level of safety performance and achieve the set objectives.

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Health & Safety Standards


Sl No Standard Title
1 SS/ENGG-05 Welding and Cutting
Personal Protective Equipment & clothing standard
2 SS/GEN-58
general specification
3 SS/GEN-36 Fire Prevention
Incident classification & reporting procedure of incident
4 SS/GEN-08
investigation
5 SS/GEN-45 Management of first aid cases in shop floor
6 SS/GEN-52 Material storage and handling
7 SS/GEN-12 Driving safety standard
8 SS/GEN-19 Access and visitor control security procedure
9 SS/GEN-25 Work permit system
10 SS/GEN/24 Track line safety inside Tata Steel works
11 SS/ENGG/13 Barricading
12 SS/GEN/27 Post incident and disaster management
13 SS/GE N/09 Equipment and machine guarding
14 SS/GEN/29 Transportation Safety
15 SS/ENGG/02 Storage and handling of Gas cylinder
16 SS/GEN/54 Contractor safety management standard
17 SS/GEN-39 Guidelines for effective functioning of contractor AIC

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PPE

List the activity wise use of Personal Protective Equipment (Matrix)

PPE
Selection
Activity

Head foot Hand Eye Ear Body Respiratory

Mandatory / Safety Safety Shoe Safety Florescent Jacket


Minimum PPE for Helmet goggles
entering into site

Mandatory / Safety Safety Shoe, Leather Safety Denim Jacket Nose Mask
Minimum PPE for Helmet Leather Shin gloves goggles &
Welder Guard & Gum Face Shield
boot when wagon
is wet

Helper Safety Safety Shoe & Cotton Safety Florescent Jacket


Helmet Shin Guard gloves goggles

*Note- Looking into the Covid -19 and preventing its transmission Nose Mask & Face shield has
been made mandatory for all.

For any doubt, we will refer SAFETY STANDARD SS- GEN-58) of TATA

We shall provide and ensure that our employees use PPE which is specified by Tata Steel and
certified by IS/EN/ANSI standard.

List of specified PPE is mentioned below.

SL no PPE Standard

01 Safety Shoe ISO 20345

02 Safety Helmet (FRP) IS2925. Or EN 397.

03 Safety goggles ANSI Z87.1 2003 Or EN166.

04 High visibility Jacket EN 471

05 Safety Gloves EN 420

06 Spatter protection Jacket EN 11612

07 Gum Boot ISO 20345

08 Face shield CE EN66

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PPE STANDARD & PROCUREMENT

Safety Helmet- Safety helmets for head protection shall be used by all personnel at work area at all
times. The safety helmets shall be of ISI approved only. It is our organization’s policy to follow ‘no
helmet, no work’ rule. Applicable Indian Standard for protective footwear is IS 2915 and only the
approved makes shall be procured and used.

Safety Shoe- safety shoes are nearly as crucial as protective headgear. Safety shoes prevent any
potential hazards against sharp objects, live electric wires, slippery surfaces etc. Must be used by
all persons at work at all times. Applicable Indian Standard for protective footwear is IS 6519:1971
and only the approved makes shall be procured & used.

Safety Googles- Safety goggles protect the eyes from particulates, dust, chemicals, water etc. Must
be used in areas where dust is present in the work area; generation of dust occurs like in cutting &
grinding works, carpentry etc.; possibility of smoke or chemical fumes. Applicable Indian Standard
for protective eye wear is IS 5983:1980 and only the approved makes shall be procured and used

Reflective Vests- Reflective waists makes the persons at work more visible from a distance to
others helps in improving the visibility of a person’s presence at work, must be used by all persons
at work at all times at shop floor. Applicable Indian Standard for reflective vest is IS 15809:2008
and only the approved makes shall be procured and used.

Safety Gloves- Persons that need to handle objects that can be hazardous if not handled carefully
must wear protective gloves. As a good practice, any person required to touch a material that form
part of a permanent structure must do so by wearing protective gloves. Applicable Indian Standard
for protective gloves is IS 4770:1991 and only the approved makes shall be procured and used.

Spatter proof jackets-Persons that need to wear spatter proof jackets at the time of welding must
wear protective gloves. Applicable Indian Standard for spatter proof jacket is EN 11612 and only
the approved makes shall be procured and used.

Welding shield to be used by welders to protect from harmful rays that gets emitted during
welding. Applicable standard for welding shield is CE EN66

Procurement of PPE will be done from selected vendors dealing with sales of PPE of standard
quality and no deviation in the PPE quality will be accepted. If through site audit and users
feedback it is known that the PPE is not good enough or it not providing sufficient life, In such
cases it will be taken up with the vendor and will be accepted when new lot supplied is
rechecked and verified to meet all requirement relating to quality, comfort and life.

PPE Purchasing must ensure that:

 It is suitable for the task undertaken.

 It is comfortable and fits the individual.

 All PPE carries a IS mark.

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PPE Checking & monitoring

We have a system of checking / monitoring the condition & availability of PPE’s at least weekly
once in below PPE Compliance checklist. Personal and general issue PPE is in good condition
prior to use, and if it is not in good condition then they must bring the matter to the attention
of their supervisor for an immediate replacement

ITEM REPLACEMENT

SAFETY HELMET 2 YEARS


SAFETY SHOE 1 YEAR
REPLACE EARLY IF
HI VIZ JACKET 6 MONTHS
FOUND DAMAGE
FR JACKET 1 YEAR

SAFETY GOGGLES 4 MONTHS

HAND GLOVES 1 MONTH

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Asset Management:

Purpose: The purpose of this manual is to set forth the regulations and procedures
governing the control and reporting of assets present at our work site. It is intended to
assist personnel in implementing and maintaining an effective property control
program.

Scope: For all the tools, machines and equipment’s used at site to perform day to day
activity such as welding, lashing and other work related to wagon unitization.

Responsibility: Site in charge

Procedure: All the tools, machines and equipment are used at site should be properly
recorded, inspected and maintained /repaired if any problem in those is detected .
All the tools, machines and equipment’s should have an individual unique no to track
and monitor those.

Unique no of that tool, machine and equipment should be displayed in it for recognition.

The entire asset should be physically inspected at a given period as mentioned below.

Name of Done by Physical


the Third party competent Inspectio Responsibility
equipment person n

Welding
Yearly Once Weekly Site supervisor & safety Supervisor
machines

Portable
Yearly Once Weekly Site supervisor & safety Supervisor
hand tools

Issues detected during inspection will be rectified before bringing it in use.

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TOOL INSPECTION FORMAT IS AS BELOW-

FORM
NO:SIG/OHS/TIC-01

TOOLS INSPECTION CHECKLIST

Date Shift Time

OK/NOT OK/NOT Name of


Name of Tool ID No OK Name of Tool ID No OK Tool ID No OK/NOT OK

S/ S/ S/
T/1 S/1 C/1

S/ S/ S/
T/2 S/2 C/2

S/ S/ S/
T/3 S/3 C/3

S/ Manual S/ S/
Manual Tensioner Strap Cutter
T/4 Sealer S/4 C/4

S/ S/ S/
T/5 S/5 C/5

S/ S/ S/
T/6 S/6 C/6

S/ S/ S/
T/7 S/7 C/7

Remarks Remarks Remarks

Checked By Reported To

Signature Signature

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Welding machine inspection format is as below-

DAILY WELDING MACHINE INSPECTION


DATE
TIME: INSPECTED BY:
:
Welding Machine No. MC NO- MC NO- MC NO- MC NO-
Sl.No. Check Points OK/NOT OK OK/NOT OK OK/NOT OK OK/NOT OK REMARKS
1 Identification of machine
2 Electrical connection through
ELCB/RCCB
3 Condition of ELCB/RCCB
4 Condition of machine body
earthing
5 Condition of Juction Box earthing
6 Condition of Welding Cable
Connected(Machine Side)
7 Condition of Lugs
8 Condition of Earthing Lugs
9 Condition of Electric Connection in
Junction Box
10 Condition of Juction Box
11 Condition of Machine Body
12 Condition of Glands
13 Condition of Welding Cable
14 Condition of Welding Holder
15 Condition of Earthing Holder
16 Condition of Welding cable
Connected(Holder Side)
17 Flammable material, if any, are
cleared
18 Fire Extinguisher near by
20 No loose connection
21 Condition of Welding screen
22 Condtion of Rubber mat
Site Supervisor- Site In charge
SIGN-

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Audit Plan & Review

Safety audit will be done by site supervisor and site safety supervisors, the audit points will be
noted down on the safety audit form and audit points will be reviewed on monthly basis.

Safety Audits will be done to find lapses regarding housekeeping, PPE & its usage, behavioural
safety, tools and equipment’s, Hygiene, electrical safety etc.

Root cause analysis will be done for severity 4 & 5 observations.

Audits frequency will be as such

Audit done by Nos. of audits

Site safety supervisor 4 nos. /month along with site supervisor

Proprietor 1 line walk /month (along with CO)

Description of Severity rating:-

1= Untidy area, minor issues, sets poor example

2=Restricted access, unacceptable trash, disorderly

3=Rule or procedure violation, potential injury

4=Unsafe condition, serious injury potential

5= Immediate serious injury potential, stop activity immediately and correct

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Review of the audit observations will be done on Monthly basis in below


mentioned format.

Month
Measurement Matrix-Safety KPIs Sites
Sl No Lead Indicators TSK
1 No of risk assessments/JSA
2 No of safety talks/meetings conducted
3 No of training programs conducted
4 No of safety audits conducted
5 No of safety deviations observed during the audit
6 No of safety improvements
7 No of driving observations
8 No of safety promotional activities-Suraksha Jagriti etc
9 No of safety suggestions received/accepted/implemented
10 No of Tool Box Talk
Sl No Lag Indicators
1 No of Near miss
2 No of first aid injuries (FAs)
3 No of medically treated injuries (MTIs)
4 No of restricted duty injuries (RDI)
5 No of Loss time injuries (LTI)
6 Incident rate (LTI+RDI+MTI)

Audit / Observation Summary

Sl Date of Observation Observation Corrective action


No Audit type Audited by Description suggested/implemented Status

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Monthly safety review-

Site team shall conduct a monthly review on safety aspects. Such review will include
current audit results, injury, illness summary, safety meeting summary, hazard reviews
of upcoming work, incident, injury and near miss and compliance to safety standards.

SELF ASSESSMENT (INTERNAL AUDIT)


Purpose
 Establishing Auditing procedure in order to verify whether it conforms to the
planned arrangements of safety management system
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 It has been properly implemented and maintained; and


 It is effective in meeting the organisation’s policy and objectives
 To review the results of previous audit
 Provide information on the results of audit to Management
Scope: This covers all functions, concerned with EHS Management Systems

RESPONSIBILITY
KAM is responsible for planning, scheduling and conducting internal audits periodically
to assess the adequacy, implementation and continued maintenance of the EHS and its
effectiveness.
Procedure
Internal Audit annual plan shall be made in such a way that each function shall be
audited at least once in a year or more frequently, if required. The plan may be revised
taking into consideration of the status and importance of process and the areas to be
audited, as well as the results of previous audits.
 The internal audit schedule shall be communicated to auditors, auditees.
 Internal audits shall be conducted by trained and qualified personnel. While
scheduling the internal audits, it shall be ensured that auditors shall not audit
their own work.
 In case of non-conformity, a non-conformity report shall be issued by the auditor
and auditee’s signature shall be obtained.
 Auditee shall indicate the proposed corrective actions with the time frame on
non-conformance report, without undue delay.
 Auditee shall inform the auditor when the corrective action is completed.
 Auditor shall verify the implementation and effectiveness of the corrective action
and certify the same on NCR. He will also indicate any follow–up action, if
required. Further, during the internal audits, the auditor shall also verify the
effectiveness of the corrective action taken in respect of the previous audit non–
conformities and record the same on Internal Audit report.
 On completion of internal audits as per schedule, the auditor shall submit his
audit report along with NCRs to KAM.
 Auditor shall prepare a consolidated report on completion of each round of
Internal Audits and submit the same for Review.
 In case of delay beyond agreed time frame for taking corrective action, the
concerned auditee shall communicate the revised time frame to Auditor in
writing stating the reasons for delay.
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 The results of internal audits and corrective actions shall be discussed at the
meeting and form an integral part of safety review.
Reference Documents: CSM audit format will be used to conduct internal audit.

Records: Internal audit report.

THIRD PARTY AUDIT


Third Party audit is planned and done check the existence of safety management
system. This can be done by certifying accredited body/consultanat so that an unbiased
and true observation of the organization can be done.
Similarly it will do to check.
 Documenting of information to monitor performance.
 Applicable operational controls.
 Conformity with the Objectives and Targets.

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 Both qualitative and quantitative measures and monitoring frequency and


method depending up on the OHS Objectives.
 Monitor the effectiveness of the controls for health and safety.

Third party audit can also be done by auditors as specified by TATA Steel time to
time.

Records- Third Party audit OFI &NC report


CSM Audit Report.

Reward & Consequence management system


PURPOSE- It is essential that all Signode personnel, including contractor & contractor
employee for work at the Company, comply with the safety rules & procedure
applicable in the Company. To promote compliance Company will reward the safety
behaviours which lead to good performance and will impose disciplinary actions for
violations of specific identified rules deemed essential by the Company.
SCOPE- This Standard applies to all categories of Signode Energy personnel, including
contractors, & contractor employee for work at the Company.
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REWARD & RECOGNITION FOR GOOD SAFETY PERFORMANCE

Through various initiatives, the following good safety performance shall be recognized:
• Any out of the ordinary intervention by an individual. (Safety champion award)
(Yearly Once)
• Outstanding periods of high safety performance by teams. (Safety champion award)
(Yearly Once)
• Initiatives that have led to a demonstrable increase in safety awareness and/or
performance. (Star employee award) (Quarterly once)
• Best safety follower of the month for 100% adherence to SOP, PPE and safety rules.
(Best Safety follower of the month) (Monthly once)
Best safety suggestion of the month for giving best suggestion which when
implemented can make work area or activities safer. (Best Safety Suggestion of the
month) (Monthly once)

• Any other safety achievement that warrants recognition. (Award to winner of spot
quiz, safety drawing, & Safety slogan award etc.)

Consequence management shall apply to following violations-


• Appearing at work under the influence of drugs or alcohol.
• Carrying any kind of arms or weapons at the place of work.
• Walking under a suspended load.
• Violating requirements of permit to work.
•Not following company cardinal and safety rules and procedures.

The Consequence Management will be as such.


1st Safety Violation: Counselling by Site In charge & inform the service provider.
2nd Safety Violation: Warning letter issued (if repeated within Six Months from 1st
violation) to the workmen who has violated the rule.
3rd Safety Violation: Workmen to be suspended from work for minimum 3 days and
Penalty deducted from the service provider’s monthly bill (if repeated within Six
Months from 2nd violation)
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4th Safety Violation: The concerned workmen is disqualified from working with
SIGNODE with an information to the service provider (if repeated within Six Months
from 3rd violation)

NOTE- For appearing at work under the influence of drugs or alcohol or for violations
that lead, or could lead to disastrous consequences, a single violation shall lead to
dismissal.

REPORTING-
Violations may also come to light as a result of incident investigations, audits, reviews
or inspection of Company records.

COMMUNICATION & PARTICIPATION


Introduction & Purpose-The purpose of this procedure guidelines and instruction for
communicating the effectiveness of the safety management system, including safety
requirements , Objectives, policies and achievements as well as product and process
performance information.
It plays a very vital role & important function of any management. The communication
towards safety is more effective through safety meetings, safety talks, mass meetings,
line walk,display of posters & banners, distribution of booklets & leaflets, display of
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warning signs / SOPs / Do's & Don'ts, SMS thru' mobile, practical demonstration,
training program, mass awareness program, e-mails, audio visual aids, safety theme of
the month, etc.
Terms & Definition- The process of transmitting ideas thoughts, information etc.
between and among people within an organisation.

One way communication- Communication in which message is delivered from


management to bottom through notices, policies and procedures. This communication
is received by site manager who in turn delivers or aware it to bottom line workers
through different forums but no feedback or suggestions are entertained on its behalf.
company will provide current safety news and activities, safety reading materials, signs,
posters and a bulletin board for easy access to information and this all information will
act as one way communication.
Two Way Communication- Communication in which message is being delivered from
top to bottom and vise versa. In this communication meetings top management send
message directly to bottom line peoples and in return feedback and suggestions are
taken and implemented at site. It is this company's policy to maintain open
communication between management and staff on matters pertaining to safety. All
input regarding safety is considered important, and employees are encouraged to
actively participate in the company safety program. Employees should feel free to
express any safety concerns during safety meetings, individually to supervisors or in
writing on the Safety Hazard Notice. All safety suggestions will be given serious
consideration and each will receive a response.
Different modes of two way communications are-
1. Tool box talk.
2. Safety Meeting.
3. Mass meeting.
4. Line walk.

Tool Box Talk-

 Tool box talk shall be conducted before the starting of the work.
 Tool box shall be conducted in the shifts.
 It shall be particularly based on the SOP of the particular job to be carried out.
 Other than SOP different accident alerts and knowledge based discussion will
also be done.
 Tool box shall be conducted by the supervisor.
 An attendance shall be taken after the tool box talk.

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Safety Meeting-

 Safety meeting shall be conducted once in a month by the site in charge


 Safety supervisor will note down all the points discussed in the safety meeting
 The actionable points shall be recorded as minutes of meeting
 The following points shall be discussed in safety meeting:

 Any accident/incident of the site, its learning


 Audit observations from site audit, proprietor line walk
 NM reported
 Safety & health issues of the workers
 Amenities etc.

Mass Meeting
Mass meeting shall be conducted at least quarterly once by safety Manager/Key
accounts Head/Higher management.
Workers of the contractor partners must be present in the departmental mass meeting.

 Agenda of mass meeting will be-


 Discuss incidents that have occurred in your company since the last meeting.
 Any follow-up that has been done as a result of investigations into incidents,
Incidents that have happened in other companies. ƒ
 Updates to the company’s Accident Prevention Plan from “lessons learned.
 Discuss the results of recent safety inspections. ƒ
 Follow up on assignments for eliminating or controlling identified hazards. ƒ
 Encourage employees to identify any unsafe conditions or tasks, and discuss
ways to eliminate or control the hazards. ƒ
 When appropriate, assign responsibilities for eliminating or controlling
identified hazards. ƒ
 Discuss any new safe work procedures or other policies and procedures that
need to be implemented. ƒ
 Safety Topic of the Month: a presentation and discussion on the chosen topic.
 Open forum- Anyone who has a concern about safety and health should bring it
up for discussion.
LINE WALK
Stated simply, management workarounds put higher managers in the field to observe
work in progress and then identify and discuss opportunities to enhance the safety of
that work with the workers involved.

 Line walk must be – and must be perceived as – a partnering between


management and employees to focus on safety improvement. Workers are the
individuals closest to the work and know better than anyone what the hazards
are and how well the controls (if any) are working. When the workers are
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engaged as partners in the safety improvement process, they are much more
likely to see themselves as a genuine part of the safety solution.
 It must focus on work – not merely conditions or a specific set of behaviours.
Observing actual work activities is the best way for managers to understand the
overall effectiveness of the safety effort. The goal is not to monitor compliance
with safety rules (which may or may not enhance worker safety) but to evaluate
the overall safety of work activities during their conduct.
 Generally, five to 30 minutes is generally adequate unless the line walk involves
a particularly critical work activity.
Advantages of Line walk-

1. Enhance Employee Morale-Employees react positively to management interest in


their work, not to mention the visible concern for their welfare.
2. Build Better Understanding of Operations-Many of these insights simply cannot be
obtained from behind a desk.
3. Build Positive Management/Employee Relations-Line walk can serve as the basis for
positive employee/supervisor interactions for any organizational issue. Although it is
important that safety line walk do in fact focus on safety, success in this area can lead to
better cooperation across the board.
4. Identify Opportunities for Improvement-Line walk do more than just sell safety. They
nearly always identify specific opportunities for improvement – many of which go far
beyond safety.

AMENITIES

We are providing amenities to our employees as per welfare act with the help of Tata
steel and by us.

1. Transportation
2. Accommodation & Fooding
3. Rest Room
4. Drinking water
5. Fan & Cooler
6. Sponsored Trainings
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7. Company’s Picnic
8. Get-togethers
9. Medicals Facilities
10. Healthy Working Environments
11.Annual Bonus and Leave encashment

Statutory Welfare Schemes:

1. Drinking Water: Sufficient drinking water and water coolers are installed by Signode
for safe hygienic drinking water.
2. Facilities for sitting: Tables and chairs are made available at site for sitting while at
site.
3. First aid appliances: First aid appliances are to be provided and readily assessable so
that in case of any minor accident initial medication can be provided to the needed
employee.
4. Latrines and Urinals: A sufficient number of latrines and urinals are provided near
work place and are also to be maintained in a neat and clean condition.
5. Rest rooms: Adequate numbers of restrooms are provided to the workers where they
can rest after work.

SAFETY CAMPAIGN-
Signode India runs many safety campaigns though out the year. These safety campaigns
are theme based because every special topic needs special focus. Every campaign that
we run has different agenda and contents. The campaigns are so designed so that the
message of campaign gets clearly communicated to all of our working crew. Safety
campaign may contain of safety trainings, safety drawing, safety slogans, safety
suggestions & most importantly safety observation relating to the theme of the
campaign.
The campaign is generally brought to conclusion by rewarding the efforts and
participation.

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Safety calendar for main safety campaign are as such-

Special campaign calendar

February Road Safety week

March National Safety week

June World environment day

June World Yoga Day

Aug Slip Trip and Fall

Nov Housekeeping (5S)

Dec CFT Audit

Two Times a year Campaign on Incident Learning

SELF SAFETY INITIATIVES

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Purpose-
Self-safety initiatives-Create a culture of continuous improvement where all employees
are actively engaged in improving the company. Nurture this culture by organizing
events focused on improving specific areas of the company.

Requirement & Scope-


Self-safety Initiatives is a strategy where employees at all levels of a company work
together proactively to achieve regular, incremental improvements to the process and
work place condition. In a sense, it combines the collective talents within a company to
create a powerful engine for improvement.

THE DUAL NATURE OF Self safety Initiatives (Kaizens)-It is part action plan and part
philosophy.

 As an action plan, Kaizen is about organizing events focused on improving


specific areas within the company. These events involve teams of employees at
all levels, with an especially strong emphasis on involving plant floor employees
 As a philosophy, Kaizen is about building a culture where all employees are
actively engaged in suggesting and implementing improvements to the company.
Kaizen works hand-in-hand with Standardized Work. Standardized Work
captures the current best practices for a process, and Kaizen aims to find
improvements for those processes.
 Note the emphasis on current; Standardized Work is living documentation (it
continually evolves through Kaizen).

HSE PLAN

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To drive health safety and environment following events will be carried out at set plan and
schedule as shown below.

Sl No Event Schedule Responsibility

1 Tool Box Talk Daily Site Supervisor

2 Welding machine physical Weekly Site supervisor/safety supervisor


Inspection

3 Hand tools physical inspection Weekly Site supervisor/safety supervisor

5 Safety Audit Monthly -4 Site safety supervisor along with Shift


Incharge

7 Mass Meeting Monthly Site In charge

8 Safety Meeting Monthly Site In charge

9 Line Walk Monthly Prop./Site In charge

10 Safety Dash Board Will be Site safety supervisor


updated
Daily

11 Near Miss Reporting & RCA As & when Site In charge/Site supervisor/Site
safety supervisor

12 Other Injury incidents reporting As & when Site In charge/Site supervisor/Site


& RCA safety supervisor

13 Trainings & awareness sessions As per Site In charge/Site supervisor/Site


safety safety supervisor
calendar

14 PPE Compliance check Weekly Site safety supervisor

15 Special safety drives and As per Site In charge/Safety Supervisor


campaign safety
calendar

16 Annual Assessment Annually Site In charge/Safety Manager

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17 Safety review Monthly Site In charge /Site supervisor

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Classification of incidents and its investigation


NM- A near miss, "close call", or "nearly a collision" is an unplanned event that has the potential
to cause, but does not actually result in human injury, environmental or equipment damage

FAC ( First aid cases)- If victim was joined his regular duty after taking first aid from First Aid
Centre.

LTI (Lost time injury)- If victim / injured person do not report his regular duty after next
schedule shift

Fatality - If victim is dead during Job execution

 All injury shall be reported & accident register shall be maintained


 All injury shall be investigated and reported.
 Investigation shall be done by Line management
 The immediate causes and the root causes shall be found out

CAPA (corrective action and preventive action) shall be implemented

Why-Why Analysis

It is a method of questioning that leads to the identification of the root cause(s) of a problem.

What is the purpose of a why-why analysis?

A why-why is conducted to identify solutions to a problem that address it’s root cause(s).
Rather than taking actions that are merely Band-Aids, a why-why helps you identify how to
really prevent the issue from happening again.

How to conduct a why-why analysis?

 First start with the problem you’d like to solve. Then ask, “Why is x taking place?” You
will end up with a number of answers. Jot these down.
 Repeat the process for each of the answers to the first question.

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 Repeat the process for each of the answers to the second ‘why’ and continue until you’ve
asked why 5 times.
 When you’ve hit the 5th why, you usually have determined some root causes. Now you
can identify specific action plans to address those root causes.

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Below mentioned format will be used to investigate Near miss & accidents.

Accident/Incident Report

Title of Accident/Incident:

Date Time

Shift CP site

Shift In
Site Leader
Charge

Details of Near Miss:

Problem Statement:

Corrective & Preventive Actions:

Reported By:

Nam Designati Sig


e: on n

OCP
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1.0 PURPOSE- This process describes the details of scrap management, hazards and prevention
related to welding such as electrocution & fumes generated.
2.0 SCOPE- This procedure is applicable to all the employee, contractor, contractor employee
and visitors at our site.
3.0 PROCEDURE-

SCRAP MANAGEMENT- The scrap management system at Rail siding area & CPDY (RMHS)
includes streamlining the process scarps which is generated in the job of Wagon Unitization.

The procedure of scrap disposal is as follows.

 Collecting different types of scraps which is generated in the process of wagon


unitization mainly metal straps.
 Accumulating all the waste straps in different places in the corner areas of yard.
 The straps collected are folded to reduce the length size so that it can load in trolley to
shift it in designated waste yard.
 Once the straps are folded, it is put it in the hand pulled trolley from all the accumulated
points.
 Than the straps are dumped at a designated place allotted by TATA steel.
 These straps are again collected from that designated area at regular intervals by a
TATA steel authorised vendor to prevent over spillage of straps.

Hazard - Sharp edges of strap

Risk- Cut injury to hands while collecting and shifting these straps.

Precautions- Hand gloves to be used while performing the activity.

Control Plan-

 Compliance of hand gloves will be checked by observation made by audit and while
checking PPE compliance through checklist.
 Training of PPE will be imparted as per training calendar.
 Counselling will be done if anyone found with PPE Violation.

WELDING ACTIVITY- This process is carried out to weld hooks and klits on the wagon deck
which is a part of wagon Unitization.

The procedure of welding hook & klits is as follows.

 The welder will check the welding machine & its cables visually and report to supervisor
if any rectification needed such as insulating of cable joints etc.
 The welder will climb on the wagon using ladder.
 Weld the hook and klits.
 Gets down the wagon using ladder.

Hazard- Power current, UV rays from welding, hot spatters, Generated Fumes.

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Risk- Electrocution/electric shock, Eye problem, asphyxiation, burn injury & fire.

Precaution-

 Welding power connection is done through tripping device (RCCB 30 Ma)


 Welding machine is kept on wooden pallet with rubber mat over it.
 Body earthing of the welding machine is done.
 Earthing cable of welding machine will be connected in same wagon in which welding is
done.
 Welders face shield to be used to protect from UV rays.
 Welders FR jacket is used by welders while welding.
 Flammable materials are cleared from wagon before welding.

Control Plan-

 Welding machine will be checked weekly with welding checklist.


 PPE compliance checklist will be followed to check that all required PPE are used by
welders.
 Safety observations will be done through Safety audit to check all other safety
compliance while welding.
 Training on welding safety will be carried out as per training calendar.

Emergency – Emergency will be handled as per on Site emergency plan.

5’S (HOUSEKEEPING)
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5S is a system to reduce waste and optimize productivity through maintaining an


orderly workplace and using visual cues to achieve more consistent operational results.
Implementation of this method "cleans up" and organizes the workplace basically in its
existing configuration, and it is typically the first lean method which Signode has
implemented.

The 5S pillars, Sort (Seiri), Set in Order (Seiton), Shine (Seiso), Standardize (Seiketsu),
and Sustain (Shitsuke), provide a methodology for organizing, cleaning, developing, and
sustaining a productive work environment
5S is a cyclical methodology: sort, set in order, shine, standardize, sustain the cycle. This
results in continuous improvement.
1’S- Sort. Sort, the first S, focuses on eliminating unnecessary items from the workplace
that are not needed for current production operations.
2’S- Once the clutter that has been clogging the work areas is eliminated and remaining
items are organized, the next step is to thoroughly clean the work area. 
3’S- Set In Order focuses on creating efficient and effective storage methods to arrange
items so that they are easy to use and to label them so that they are easy to find and put
away.
4’S- Once the first three 5S's have been implemented, the next pillar is to standardize
the best practices in the work area. Standardize, the method to maintain the first three
pillars creates a consistent approach with which tasks and procedures are done.
5’S- Sustain, making a habit of properly maintaining correct procedures, is often the
most difficult S to implement and achieve.

We at Signode at committed to implement 5S and hence in order to achieve this-

 Training on Housekeeping (5’S) will be imparted to working crew.


 Campaign on housekeeping will be driven.
 Observation related housekeeping will done to find gaps and improve
housekeeping.
 Reward on housekeeping will be given to best housekeeping concerned
workmen.
 Weekly checklist on housekeeping will be filled to have an through check of work
site.

Grievance handling system


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Grievance may be any genuine or imaginary feeling of dissatisfaction or injustice which


an employee experiences about his job and it’s nature, about the management policies
and procedures. It must be expressed by the employee and brought to the notice of the
management and the organization.

Grievances take the form of collective disputes when they are not resolved. Also they
will then lower the morale and efficiency of the employees. Unattended grievances
result in frustration, dissatisfaction, low productivity, lack of interest in work,
absenteeism, etc. In short, grievance arises when employees’ expectations are not
fulfilled from the organization as a result of which a feeling of discontentment and
dissatisfaction arises. This dissatisfaction must crop up from employment issues and
not from personal issues.

Grievance may result from the following factors-

a. Improper working conditions such as strict production standards, unsafe


workplace, bad relation with managers, etc.
b. Irrational management policies such as overtime, transfers, demotions,
inappropriate salary structure, etc.
c. Violation of organizational rules and practices

The HR should immediately identify all grievances and must take appropriate steps to
eliminate the causes of such grievances so that the employees remain loyal and
committed to their work. Effective grievance management is an essential part of
personnel management. The managers should adopt the following approach to  manage
grievance effectively-

1. Quick action- As soon as the grievance arises, it should be identified and resolved.
Training must be given to the managers to effectively and timely manage a
grievance. This will lower the detrimental effects of grievance on the employees
and their performance.
2. Acknowledging grievance- The manager must acknowledge the grievance put
forward by the employee as manifestation of true and real feelings of the
employees. Acknowledgement by the manager implies that the manager is eager
to look into the complaint impartially and without any bias. This will create a
conducive work environment with instances of grievance reduced.
3. Gathering facts- The managers should gather appropriate and sufficient facts
explaining the grievance’s nature. A record of such facts must be maintained so
that these can be used in later stage of grievance redressal.
4. Examining the causes of grievance- The actual cause of grievance should be
identified. Accordingly remedial actions should be taken to prevent repetition of
the grievance.

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5. Decisioning- After identifying the causes of grievance, alternative course of actions


should be thought of to manage the grievance. The effect of each course of action
on the existing and future management policies and procedure should be
analyzed and accordingly decision should be taken by the manager .
6. Execution and review- The manager should execute the decision quickly, ignoring
the fact, that it may or may not hurt the employees concerned. After
implementing the decision, a follow-up must be there to ensure that the
grievance has been resolved completely and adequately.

Employee, Sub contract employee, Visitor can take up their grievances directly to speak
up cell or regional HR personnel ,whose contact number has been displayed at site-

Speak Up Cell NO- 000-117

Regional HR personnel no- 7091495526

The grievances collected will be kept confidential; depending on the option suggested
by the person reporting the grievance.

An effective grievance procedure ensures an amiable work environment because it


redresses the grievance to mutual satisfaction of both the employees and the managers.
It also helps the management to frame policies and procedures acceptable to the
employees. It becomes an effective medium for the employees to express t feelings,
discontent and dissatisfaction openly and formally .

JOB EXECUTIUON PLAN

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Signode India at Rail siding has a contract of wagon unitization at Rail siding section.

The activity of wagon unitization includes coil strapping in wagon

To conduct the activity safely HAZARD involved in each of the activity has been identified
through JHA, Further risk assessment is also done to prioritize the risk that needs control
measure so that risk can be converted into acceptable risk and the activity can be done
without any injury.

Main hazards of the site are-

1) Heavy vehicle movement with suspended load.


2) Material handling
3) Forks lift movement and its operation.
4) Over Head EOT Crane

These hazards were found after through assessment of the site and its condition; taking care
of which SOP of the job (Wagon Unitization) is developed.

 JHA to be made by- Site manager, Safety personnel in coordination with crew
members
 HIRA to be made by – Site Manager, Safety personnel in coordination with crew
members
 SOP to be made By- Site manager in coordination with Safety personnel and
approved by CO of the contract.

SOP of the work has been developed listing all the sub activities that is done to complete the
task of Coil strapping and hazards along with its control measures is incorporated in it, and
communicated to all working crew through different plots such as –

1) Daily Tool Box Talk.


2) Training on SOP.
3) Site induction at the time of joining.

 Daily tool box talk to be conducted by- Shift Supervisor.

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 Training on SOP- To be conducted by safety supervisor.


 Site Induction at the time of joining- To be done by Shift supervisor.

In order to curtain down any risk that arises due to behavioural issue, reward and
consequence management is in place to motivate employee towards safe working culture
and punishment for any unwanted deed that creates possibility of accident at site.

Since machine is also involved in the job, machine healthiness is regularly checked and
repaired as and when required. Any problem that is detected during inspection or if
reported by any packaging associate is attended immediately.

In order to meet any kind of emergency situation, emergency situation for the place of work
has been identified.

1) Emergency situation for Rail Siding area is –mentioned emergency preparedness


plan.
 Emergency plan- To be made by Safety personnel along with Site manager after
analysing the emergency situation that can happen at site.
 Training on emergency plan- To be conducted by Safety supervisor

Emergency response plan has been made and communicated to our entire employee
through emergency preparedness training and mock drill that is conducted by dept. as per
their mock drill plan to know the exact response time and preparedness towards emergency
situation.

Site Safety audit is done to find out other unsafe act and condition that is prevailing at site
and corrective action is taken to close the issues.

 Safety Audit- To be conducted by site supervisor along with safety supervisor.

Monthly safety review is done to monitor and track lagging and leading indicators and also
to check that all open issues that was observed during safety audit is being closed or not.

 Safety Review- To be done by safety manager along with site manager.

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Safety meeting is conducted at site to discuss on site safety problems and to find solution to
it.

 Monthly safety meeting- To be conducted by Site manager along with site team.

Competent manpower is hired through a set employee selection process.

 Hiring of competent manpower- To be done by HR

Roles and responsibility of all employees is clearly mentioned so that everyone knows their
job description and act similar

SAFETY COMMITTEE
Purpose- It’s a means of two way communication between management and working crew
to enhance safety at work place by discussing on safety issues and taking decision so that
safety issues can be closed.

Scope-To our work area- rail siding (RHMS –Tata steel , Jajpur)

Objectives of safety committee-

 Reduce the incidence of injuries and illness in the workplace


 Work as a team to brainstorm and implement ideas that will improve safety in the working
environment
 Act as a means of communicating safety information to all employees
Members of safety committee consists of-
1). Chairperson (Site Manager)- His role & responsibility are as such-

♦ Prepare agenda for next meeting

♦ Arrange for meeting place

♦ Notify members of meeting

♦ Arrange program

♦ Set time schedule for meeting

♦ Arrange all seating for members

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♦ Review previous minutes and material for meeting

♦ Conduct meeting

Note- Chairman can also delegate his role and responsibility to Key account head or key
account manager in his absence.

2). other members

-Safety Manager

-Safety Supervisors

-Shift In charge

- Some PA as per availability

Roles and responsibilities of other members

♦Report unsafe conditions and practices

♦ Report all accidents or near misses

♦ Review injury accidents, illnesses and death investigations

♦ Contribute ideas and suggestions for improvement of safety

♦ Influence others to work safely

♦ Make or assist in inspections

Description-

Safety committee members will meet at least once in two months and discuss on safety
issues, MOM of the meeting will be prepared and circulated to all committee members
electronically or by verbal communication.

The MOM of the meeting will be retained in file for future reference and audits.

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METHOD STATEMENT
Signode India at Rail siding has a contract of wagon unitization at Rail siding
section.

The activity of wagon unitization includes coil strapping in wagon

To conduct the activity safely HAZARD involved in each of the activity has been
identified through JHA , Further risk assessment is also done to prioritize the
risk that needs control measure so that risk can be converted into acceptable
risk and the activity can be done without any injury.

Main hazards of the site are-

5) Heavy vehicle movement with suspended load.


6) Material handling
7) Forks lift movement and its operation.

SOP of the work has been developed listing all the sub activities that is done to
complete the task of Coil strapping and hazards along with its control
measures is incorporated in it, and communicated to all working crew through
different plots such as –

4) Daily ToolBox Talk.


5) Training on SOP.
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6) Site induction at the time of joining.

In order to curtain down any risk that arises due to behavioural issue, reward
and consequence management is in place to motivate employee towards safe
working culture and punishment for any unwanted deed that creates
possibility of accident at site.

Since machine is also involved in the job, machine healthiness is regularly


checked and repaired as and when required. Any problem that is detected
during inspection or if reported by any packaging associate is attended
immediately.

In order to meet any kind of emergency situation, emergency situation for the
place of work has been identified.

2) Emergency situation for Rail SIding & CPDY area is –mentioned


emergency preparedness plan.

Emergency response plan has been made and communicated to our entire
employee through emergency preparedness training and mock drill that is
conducted by dept. as per their mock drill plan to know the exact response
time and preparedness towards emergency situation.

Site Safety audit is done to find out other unsafe act and condition that is
prevailing at site and corrective action is taken to close the issues.

For the Method statement each activity is analysed within taking care of
the work, environment , PPE, Safety, equipment and the instruction .
The main process are as follows-
1. Entry and Exit of wagon into yard
2. Strapping for wagon unitization
3. Welding of hooks and Klits for coil unitization
4. Coil loading in wagon

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Method statement format-

84
Industrial Packaging, lashing Unitization, Issue Date-02.02.2017
Packaging Tools and equipment’s supply
and technical service

85

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