MCN401- INDUSTRIAL SAFETY

ENGINEERING
Module I

Shilpa P
Assistant Professor
College of Engineering Vadakara
CONTENTS
SAFETY
• As per OSHA 18001-2007 standards, safety is defined as,

"a tool or device designed to prevent accidents,

incidents and injuries".
NEED FOR SAFETY
• The danger of life of human being is increasing with
advancement of scientific development in different fields.

• Millions of industrial accidents are occurring every year

• These accidents causes temporary disablement of the

employees, involve large amount of loss resulting from damage
to property and wasted man hours and machine hours.
• It is important to reduce the rate and severity of accidents
because health and safety are basic desire and instinct.

• “Industrial safety is primarily a management activity which is

concerned with reducing, controlling and eliminating hazards
from the industries or industrial units.”

• The benefits of accident prevention have been well-understood

and accepted by industries throughout the world.
DEVELOPMENT OF SAFETY MOVEMENT IN INDIA
• An organized safety movement in India was started in Bombay in
1922 which is the first safety association of India.

• In 1955 the council of industrial safety was started at Bombay by the

Mill owners association.

• In 1965 The National Safety Council was formed by representatives

of government, management and trade unions.
• The council is a voluntary nonprofit making body

• It has been setup to educate and influence society to adopt

appropriate policies and procedures for preventing and
reducing human suffering and economic loss arising from all
type of accidents

• National safety day is celebrated on March 4th because on this

day NSC (National Safety Council) of India was established
• The importance of industrial safety in any organization may be
concluded by following facilitation:
1. Treatment: industrial safety management provides treatment
for injuries and illness at the work place.
2. Medical Examination: it carries out medical examination of
staff joining the organization or returning to work after
sickness or accident.
3. Hazards identification.
4. Provision of protective devices.

5. Consultancy: it provides medical advised on other condition

potentially affecting health e.g. works canteen etc.

6. Education: it provides safety and health training

OBJECTIVES OF INDUSTRIAL SAFETY
1. To prevent accidents in the plant by reducing the hazard to
minimum.

2. To eliminate accident caused work stoppage and lost production.

3. To achieve lower workmen’s compensation, insurance rates and

reduce all other direct and indirect costs of accidents.

4. To prevent loss of life, permanent disability and the loss of income

of worker by eliminating causes of accidents.
5. To evaluate employee’s morale by promoting safe work place
and good working condition.

6. To educate all members of the organization in continuous

state of safety mind and to make supervision competent and
intensely safety minded.
AIM OF INDUSTRIAL SAFETY
• Provide workers with a safe work environment.
• Conduct routine/regular workplace inspections.
• Provide Personal Protective Equipment.
• Develop and implement safe work procedures and rules.
• Provide on-going safety training
• Enforce safety rules and appropriate discipline.
• Provide on-going property conservation practices.
SAFTEY AND PRODUCTIVITY
• Healthy and safe working environment has the potential to
increase labour productivity and in turn increase company profits.

• Safety culture is the product of individual and group values,

attitudes, perceptions, competencies, and patterns of behaviour
that determine the commitment to and organization’s health and
safety management.

• It varies from one country to another.

• Employees may behave differently due to their background
differences in race, nation, religion, and community.

• To achieve a positive safety culture, employee involvement

and satisfaction must be considered, as it drives continuous
improvement, which may lead to better productivity.
• Productivity construct is composed of eight items, including:

1. Good working environment: A good safe behaviour results in a

good working environment.

2. Material damage: The improvement of safety culture will

reduce the material damage

3. Quality of product: Quality improvement is influenced by a

positive health and safety implementation
4. Compensation cost: A positive safety culture leads to the
reduction of costs of accidents borne by the organization, such
as compensation cost and plant damage.
5. Reputation: High rates of severe injuries in organizations can
have harmful effects on the reputation as well as performance
of an organization.
6. Increased working speed: Enhancement of safety culture leads
to increased working speed.
7. Customer perception: A global concern for safety is related to
an ever-increasing consumer expectation of service excellence.

8. Accident rate: The frequency of accident occurrences may be

reduced with good safety program.
ACCIDENT
• Accident can be defined as "an unplanned event that results in
personal injury or property damage.”

INJURY
• An occupational injury is defined as “any personal injury,
disease or death resulting from an occupational accident.”
UNSAFE ACT
“Performance of a task or other activity that is conducted in a
manner that may threaten the health and/or safety of
workers.”

UNSAFE CONDITION
“A condition in the work place that is likely to cause property
damage or injury.”
ACCIDENT

• Basically accidents constitute a behavioral problem signifying

disintegration in the equilibrium of the individual in relation to
the work situation.

• The forces that make for the disequilibrium are mainly drawn
from the stress of the work situation and the psycho- social
character of the individual involved.
• The American 'National Safety Council' has defined accident as

“that occurrence in a sequence of events which usually

produces unintended injury, death or the property damage”.

• Accidents are also defined as "unforeseen, sudden, unintended

or unconscious deviations in work, activity tending to end or to

an injury".
THEORY OF ACCIDENT OCCURENCE
BASIC PHILOSOPHY OF ACCIDENT
PREVENTION/CONTROL
• Accident prevention is the short-term, approach to
controlling workers, materials, tools and equipment, and the
workplace for the purpose of reducing or preventing the
occurrence of accidents.

• A good accident prevention process is an orderly approach

very similar to the methods engineering program shown in
figure below.
• The first step in the accident prevention process is the identification of the
problem in a clear and logical form

• Once the problem is identified, the safety engineer needs to collect data

• Then analyze them so as to understand the causation of the accident

• Identify possible remedies to prevent it or, if not completely prevent it, at

least to reduce the effects or severity of the accident.

• In many cases, there may be several solutions, and the safety engineer will
need to select one of these solutions.
• Then the remedy will have to be implemented and monitored
to ensure that it is truly effective.

• If it is not effective, the engineer may need to repeat this

process and attempt another, perhaps better remedy. This
monitoring effectively closes the feedback cycle and ensures a
continuous improvement process for accident prevention.
ACCIDENT CAUSES
• It is established that the accidents are caused, they do not happen out
of nothing. The causes of accidents may be classified into two categories:

1. Technical causes – Unsafe conditions

(a) Mechanical factors

(b) Environmental factors

2. Human factors

(a) Unsafe Act

(b) Unsafe personal factors

Mechanical factors

• 1. Continued use of old, poorly maintained or unsafe equipment, this is

generally accompanied by failure to have regular plant safety and
preventive inspection of all production facilities in accordance with a
properly designed time schedule. For example: If crane elevator cables
are not regularly inspected and promptly replaced when dangerously
worn.

• 2. Unguarded or improper guarded machines or equipment, guards of

improper height, strength, mesh etc.
• 3. Unsafe process, mechanical, chemical, electrical etc.

• 4. Improper material handling system

• 5. Improper plant layout

• 6. Violation of prescribes safety practices

• 7. Unsafely clothed, no goggles, gloves and masks, smoking in no smoking

areas, wearing high heal shoes etc.
Environmental factors
• 1. Temperature and humidity: Low temperature causes shivering. Too
high temperature causes head-ache and sweating, this causes fatigue to
the operator.

• 2. Defective and inadequate illumination: It causes glares, shadows, eye

strain etc.

• 3. Presence of dust, fumes and smoke.

• 4. Harsh or dominating behavior of management or supervisors towards

worker.
• 5. Overly fatigued worker: Excess fatigue may arise out of work
assignment that may tax the worker’s physical and mental powers

• 6. Excessively long duration of work, shift duty.

• 7. The type of leader ship adopted by the management in the

organization
Human causes: Unsafe act

• 1. Operating without authority

• 2. Operating or working at unsafe speed

• 3. Making safety devices unoperative

• 4. Taking unsafe position or posture

• 5. Failure to use personal protective devices

• 6. Improper use of tools

The unsafe personal factors

• The unsafe personal factors are the mental or bodily characteristics

which promote unsafe acts.

• 1. Improper attitude (disregard of instructions, failure to understand

instructions, nervousness, excitability)

• 2. Ignorance, forgetfulness, carelessness, day dreaming etc.

• 3. Lack of knowledge and skill (unaware of safe practices, unskilled)

• 4. Home environment

• 5. Mental worries
• 6. Bodily defects (defective eye sight or hearing, weak heart etc.)

• 7. Feeling of job in security among workers.

• 8. Accident Proneness (It is a continuing tendency of a person to have

more accidents as a result of his persisting/inherent characteristics.)
SAFETY ORGANIZATIONS
• The accident prevention is a continuing process and hence
continuous systematic efforts are necessary.

• A safety organization consists of a systematic procedure by

means of which interest is created and maintained and all
safety activities are co-related and directed.
• The organization setup depends upon the size and
complexities of the industries.

• In small industry foreman or supervisor may be responsible

for achievement of all the objectives of safety.

• Whereas in large industries the number of positions may be

involved in the organization set up
Objectives Of Safety Organization

(i) Creating and maintaining interest.

(ii) Fact finding through periodical inspections and surveys of

structures, machines, tools, equipments, processes and employee
procedures, accident investigation and analysis.

(iii) Selection of remedies and corrective action with regard to unsafe

acts and conditions based upon the found facts.
• A typical organization structure for a manufacturing g concern employing 1000
workers is shown in the figure.
The Organization set up consists of:

1. Executive safety committee.

2. Operations safety committee.

EXECUTIVE SAFETY COMMITTEE
• The executive safety committee consists of presidents'
representative, the General Manager, the plant superintendent
and the sales manager.

• The chief function of the executive safety committee is to

determine the policy and set the standards or plan at which the
safety work is to be conducted.
• Specific responsibilities and activities of the executive safety committee
shall include:

1. Review and action on the reports and recommendations of the

operations safety committee.

2. Periodical considerations of trends and progress in the control of

accident frequency and severity.

3. Approval for abnormal expenditures for accident prevention.

4. Approval for major changes in safety organization and of activities

effecting matters of policy.
OPERATIONS SAFETY COMMITTEE
• The function of the operations safety committee is to execute
the policies set up by the executive safety committee regarding
all the phases of accident prevention.

• Membership shall consist of executive safety committee, the

plant safety inspector, sales supervisors and plant
superintendents.
• Specific responsibilities and activities of the committee include:

1. Study and discuss the principal accident producing conditions

and circumstances and to take and recommend practical
effective corrective action

2. Review of and action on the reports and recommendations

received from the service engineering

3. Review of and action on the reports of the plan safety inspector.

4. Review of and action on accident investigation reports
submitted by supervisors.

5.Periodical check of all authorized safety procedure and their

proper functioning.

6. Approval of proposed new construction and installation of

equipment, changes in procedures and processes etc. from the
safety viewpoint.
• Steps taken by safety organization to control accidents In order to
control the accident the following steps must be taken by safety
organization:

A. Supervisory Safety Performance:

(1) Job safety analysis.

(2) Proper job placement.

(3) Development of safe working conditions.

(4) Enforcement of Safety Rules.

B. Mental Condition of Person:

(i) Adequate induction and job training.

(ii) Safety training, safety awareness, safety

promotion/publicity.

(iii) Regular safety contacts by supervisor.

(iv) Involvement/participation.

(v) Adequate communication concerning the employee.

C. Physical Conditions of Person:

(i) Pre-employment medical examination.

(ii) Periodical medical checkup.

(iii) Proper job placement.

(iv) Adequate medical facilities.

(v) Recognition of physical limitations of workers who are new

on job.