Lecture 1 Health and Safety

6/24/2020
By
Dr. Asim Zaheer
A little about me:
Dr. Asim Zaheer
• Ph.D. in Mechanical Engineering from University of Sheffield, UK (2018)
• Masters in Engineering Management from Wichita State University, KS, USA
(2005)
• BE in Mechanical Engineering from NEDUET (2000)
Working Experience:
• As a Quality Assurance Manager in Super Tech Auto Parts (O.E.M), Karachi,
Pakistan.
• As a Management Trainee engineer Derby Cellular Products Derby
Connecticut, USA.
• 2007 till date, NED University Of Engineering and Technology as a Assistant
Professor in Industrial & Manufacturing Department.
Health, Safety and Environment by
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•
List of Papers
Zaheer, A., Yoxall, A., & Rowson, J. (2018). Ergonomics Approach to Assess The Risk Associated with the
Performance of Domestic Tasks–Part “B”. International Journal of Public Health and Clinical Sciences
(IJPHCS), 6(2), 132.
• Zaheer, A., Yoxall, A., & Rowson, J. (2018). Ergonomics Approach to Assess The Risk Associated with the
Performance of Domestic Tasks–Part “A”. International Journal of Public Health and Clinical Sciences
(IJPHCS), 5(4), 228‐245.
• Zaheer, A., A. Yoxall, and J. Rowson, Experimental trials and Predictive Validity of Task Assessment Tool for
Ease and Risk (TAER). Design for Health, 2018.
• Zaheer, A., A. Yoxall, and J. Rowson, Evaluation of Ergonomics Risk Factors and Physical Strain Within Home
Environment. Design for Health, 2018.
• Zaheer, A., M. Carre, A. Yoxall, and J. Rowson. Evaluation of adopted postures and the hardest part of the
domestic laundry task. in Design4health. 2015. Sheffield, UK: Proceedings of the Third European
Conference on Design4Health 2015.
• Zaheer, A. and R. Khalid, Ergonomics: A Work Place Realities in Pakistan. International Poster Journal of
Science & Technology 2012. 2(1): p. 1‐11.
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Books Used
• Industrial safety by Roland P. Blake
• Industrial Safety handbook by William Handley
• Industrial Safety and Health management (5th edition) by C. Ray Asfahl.
• Safety & Health for Engineers by Roger L. Braker
• System Safety Engineering and Risk Assessment, Second Edition Nicholas
J.Bahr CRC Press Taylor & Francis Group
• Introduction to Health and Safety at Work by Phil Hughes MBE and Ed
Ferrett, 8the Edition.
• Internet resources
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MARKS BREAKUP
Assessment/Deliverables Marks
Class Performance 5
Article Presentation/Case Study 20
Mid‐Term Exam Paper 15
Final Exam Paper 60
Total 100
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Analyze the Scenario …

Two companies pleaded guilty to charges of breaching the
Health Safety at Work (HSW) Act 1974 following the drowning
of a 9‐year‐old girl, who was playing with other children in the
company car park when they strayed onto nearby reservoirs. At
the time of the accident, in 2004, the main gates to the factory
were off their hinges because work was being carried out on the
site and a second gate, which led to the reservoir, was only
secured with a nylon rope.
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Analyze the Scenario…

In a separate case, a construction company has been found
guilty of failing to prevent unauthorized persons, including
children, from gaining access to an area where
construction material and equipment were stored. A child
was seriously injured by falling paving stones while playing
on a partly built housing estate where materials were
being stored during construction work.
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What is Safety?
• Safety is the state of being safe from Risk and Hazard.
• A condition which gives you freedom from hazard, risk,
accident which may cause injury, damage and loss to material
or property damage and even death.
• Safety is the state of being "safe", the condition of being
protected from harm or other non‐desirable outcomes.
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Avoiding Accidents!
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Key Concepts
Accident
An accident can be described as an
unplanned event or action that results in
undesired consequences, e.g. injury, ill health,
damage to the environment, damage to or loss of
property, plant and materials.
Incident
An incident is the sequence of events or
actions that produces that accident. All accidents
are incidents. However the definition of an
incident is wider in that it also includes
dangerous occurrences and near misses.
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Key Concepts
Near Miss
Is an unplanned event that did not result in injury, illness, or damage
but had the potential to do so. Only a fortunate break in the chain of
events prevented an injury, fatality or damage.
Hazard
The meaning of the word hazard can be confusing. Often dictionaries
do not give specific definitions or combine it with the term "risk". For
example, one dictionary defines hazard as "a danger or risk" which
helps explain why many people use the terms interchangeably.
A hazard is any source of potential damage, harm or adverse health
effects on something or someone under certain conditions at work.
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Key Concepts
Risk
Risk is the chance or probability that a person will be
harmed or experience an adverse health effect if exposed to
a hazard. It may also apply to situations with property or
equipment loss.
Risk (consequence/time) = Frequency (events/time) × magnitude (consequence/event)
Dangerous Occurrence
This is a ‘near miss’ which could have led to serious injury
or loss of life.
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Key Concepts
Adverse health effects include:
 Bodily injury
 Disease
 Decrease in life span,
 Change in mental condition resulting from stress,
traumatic Experiences, exposure to solvents, and so on.
 Effects on the ability to accommodate additional stress.
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Health and Safety Goal…
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Inviting Accidents !
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WHAT IS SAFETY ANALYSIS?
 Safety analysis is a generic term for study of the system, identification of

dangerous aspects of the system, and correction of them.
 System safety is the formal name for a comprehensive and systematic

examination of an engineering design or mature operation and control of any
particular hazards that could injure people or damage equipment.
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WHAT IS SAFETY ANALYSIS?
System safety engineering is a compilation of engineering analyses and

management practices that control dangerous situations, specifically
Identify the hazards in a system:
 Determine the underlying causes of those hazards
 Develop engineering or management controls to either eliminate the hazards
or mitigate their consequences
 Verify that the controls are adequate and in place
 Monitor the system after it has been changed and modify further as needed
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BRIEF HISTORY OF SAFETY

In the United Kingdom, in the early 1960s, Imperial Chemical Industries started
developing the concept of the HAZOP (Hazard & Operability Analysis) study (a
chemical industry safety analysis).
In 1974, it was presented at an American Institute of Chemical Engineers

conference on loss prevention.
Also in the early 1960s, Pillsbury Company, United States, collaborated with the U.S.
Army to produce food for astronauts on NASA missions and created the Hazard
Analysis and Critical Control Point (HACCP) methodology.
It is a systematic approach to food and pharmaceutical safety that identifies physical,

chemical, and biological hazards during the entire supply chain—especially during
production—that can cause the product to be unsafe for humans.
In 1993, it became a regulation for all Europe community countries and, in 2005, was
incorporated into the ISO 22000, Food safety management system-requirements
for any organization in the food chain.
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BRIEF HISTORY OF SAFETY
A key development in system safety is the ALARP principle that states that the
residual risk of a system shall be as low as reasonably practicable (ALARP
principle) and was codified through the UK Health and Safety at Work Act of 1974.
The concept emphasizes that safety-critical systems and operations should be safe
as far as reasonably practicable without risks to health and safety .
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‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
Major Disasters
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
WHY DO WE NEED SAFETY

ENGINEERING?
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Dec. 1984: Bhopal, India
 Leakage of over 25 tones of

Methyl Isocyanides from a
pesticide plant in 1984.
 Over 2259 people killed at
the spot, 16,000 were died
later with the effects of
leakage.
 Compelled others like ICI to
improve their standards
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April 1986: Chernobyl, Russia
 The Chernobyl disaster was the worst

nuclear power plant accident in
history in terms of cost and casualties.
($18 billion)
 Escaping of several tones of fuel &
Fission products due to overheated
water‐cooled Nuclear Reactor.
 45 people killed at the spot, 100,000
evacuated, 3940 were killed with
effects of radiation.
 About 41,000 people were ill due to
different types of cancer.
 Loss of public confidence in nuclear
industry.
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July 1988: Piper Alpha, North Sea
 Explosion followed by massive

oil gas fire.
 Loss of about $3.4 billion. Killed

167 men, many by the inhalation
of CO gas.
 New regulations for the offshore

oil & gas industry.
 Mandatory requirement of
offshore risk assessment.
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Friday 11 March 2011: Pacific coast of Tōhoku
BLACK SAWN EVENT
 A magnitude 9.0 earthquake and
resulting tsunami in 2011 triggered a
series of fires and explosions at a
commercial nuclear power plant in
Japan(Fukushima nuclear accident ).
 resulting in three of the six reactors
melting down.
 over 100,000 residents permanently
evacuated.
 The latest report from the Japanese
National Police Agency report
confirms 15,894 deaths, 6,156
injured, and 2,546 people missing.
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Sept. 2012: Baldia, Karachi
 The death toll was 258, including;

men, women and children.
 1,500 workers present in the
three‐story,2,000‐sq‐yard factory
located on Hub River Road when
the fire broke.
 At least 22 fire vehicles were at the
site.
 Most casualties were happened
due to the inaccessibility towards
exit (locked doors).
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September 2007, Sher Shah Bridge
• Sher Shah Bridge is a flyover in
karachi, Pakistan. Bridge was
collapsed in September 2007, five
men were crushed in that incident.
• The newly constructed Northern

Bypass Bridge was caved in Saturday
at 01:20 pm when the track leading
to Gulbai and Shershah collapsed,
taking with it a number of vehicles,
including two trailers and a police
mobile. The vehicles were buried
under the rubble.
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October 2019: Pakistan Railway Tezgam
• Pakistan, Railway Tezgam passenger train caught
fire while traveling from Karachi to Rawalpindi,
resulting in at least 75 passenger deaths.
• The train accident was the deadliest in Pakistan
since 2005, when the Ghotki rail crash killed
more than 100 people. Preliminary evidence
suggested the explosion of a portable stove
occurred because some passengers illegally
cooked food aboard the train.
• Such use of gas stoves is common on Pakistan's
railways; train authorities often turn a blind eye
to the dangerous practice.
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HOW SAFE IS SAFE ENOUGH?
The insurance industry functions by answering the question “How safe is safe
enough?” One question you must answer is “How much am I willing to spend to
protect myself from accidents (including lawsuits and lost business revenue)?”
After the 2010 BP Deepwater Horizon offshore oil platform explosion, BP has
budgeted around $40 billion for paying out of claims and other compensation.
The total cost (home, workplace, motor vehicle, etc.) to the U.S. economy of
injuries and accidents in 2011 was $753 billion (U.S. National Safety Council,
2013)
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The UK Health and Safety at Work Act 1974 defined the concept of as low as
reasonable practicable (ALARP). The ALARP principle is based on reasonable
practicability, which simply means that hazard controls are implemented to
reduce residual risk to a reasonable level of practicality. For a risk to be
considered ALARP, it must be demonstrated that the cost in reducing the residual
risk further would be grossly disproportionate to the benefit gained.
Therefore, a risk assessment is conducted, and a cost–benefit analysis performed to

determine how far to carry the hazard control.
Unfortunately, there is no standard method to demonstrate that the hazard control

trade-off will meet ALARP.
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Accident Categories
Cost Incurred by Accidents
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Occurrence of Accidents
Four parts of the structure of an accident
 Contributing causes
 Immediate causes
 Accident
 Results of an accident
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1. Contributing Causes
a) Supervisory Safety Program
i. Safety instructions inadequate
ii. Safety rules nor enforced
iii. Safety not planed as part of job
iv. Hazard not corrected
v. Safety devices not provided
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b. Mental Condition of Person
i. Lack of safety awareness
ii. Lack of coordination
iii. Improper attitude
iv. Temperamental
v. nervous
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c. Physical Condition of Person
i. Extreme fatigue
ii. Deaf
iii. Poor eyesight
iv. Physically inadequate for job
v. Heart condition
vi. Crippled
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2. Immediate Causes
a. Unsafe Act
i. PPEs provide but not used
ii. Hazardous method of handling
iii. (wrong lifting, loose grip etc.)
iv. Improper tool used although proper tools available
v. Hazardous movement (running, jumping, stepping up,
throwing etc.)
vi. Horseplay
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2. Immediate Causes
b. Unsafe Conditions
i. Ineffective safety devices
ii. No safety device used
iii. Hazardous housekeeping (material on floor, congested
aisles etc)
iv. Defective equipment, tools, machines
v. Improper dress or apparel
vi. Improper illumination or ventilation etc.
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Incident Ratio Model‐Heinrich’s theory
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What is an Unsafe Act?

• Unsafe act is any act that deviates from a generally recognized
safe way or specified method of doing a job and which increases
the probabilities for an accident.
• “The unsafe act is a violation of an accepted safe procedure which
could permit the occurrence of an accident.”
• The performance of a task or other activity that is conducted in a
manner that may threaten the health and / or safety of workers.
• It must contain an element of unsatisfactory behavior
immediately before an accident that was significant in initiating
the event.
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What Causes Unsafe Acts?

• Throwing materials
• Operating or working at unsafe speeds—either too fast
or too slow
• Making safety devices inoperative by removing,
• adjusting, or disconnecting them
• Using unsafe procedures in loading, placing,
• mixing, or combining
• Lifting improperly
• Distracting, teasing, abusing, startling, quarreling, and
horseplay.
• etc.. Dr. Asim Zaheer
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What is Unsafe conditions?
• Unsafe conditions are hazards that have the potential to

cause injury or death to an employee.
• “The unsafe condition is a hazardous physical condition or

circumstance which could directly permit the occurrence of an
accident.”
• Some of these hazards include flawed safety procedures,

malfunctioning equipment or tools, or failure to utilize
necessary safety equipment such as goggles and masks.
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What cause unsafe conditions?
• Defective tools, equipment or supplies.
• Inadequate supports or guards.
• Congestion in the workplace.
• Inadequate warning systems.
• Fire and explosion hazards.
• Poor housekeeping.
• Hazardous atmospheric conditions
• etc..
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3. Accidents
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4. Results of accident
i. Annoyance
ii. Production delays
iii. Reduced quality
iv. Spoilage
v. Minor injuries
vi. Disabling injuries
vii. Fatality
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Statistics of Occupational
Accident in UK
 An average of 250 employees and self‐employed people are killed
each year as a result of accidents in the workplace.
 A further 150 000 sustain major injuries or injuries that mean they
are absent from work for more than three days.
 Over 2.3 million cases of ill health are caused or made worse by
work.
 According to the Labour Force Survey, over 40 million working
days are lost through work‐related injuries and ill health, at a cost
to business of £2.5 billion.
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Human Factors Theory of

Accidents Causation
Overload
 Imbalance between person’s Capacity at any given time and
the load
 Person’s Capacity is the product of factors such as natural
ability, training, State of mind, fatigue, stress & Physical
Condition
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Human Factors Theory of

Accidents Causation
Added Burdens
 Environmental Factors (Noise, distraction etc)
 Internal Factors (Personal problem, emotional stress, worry)
 Situation Factors (level of risk, unclear restrictions)
Inappropriate Response
 Person detects hazardous condition but does nothing to
correct it
 Person removes safeguards from machine to increase
output.
Inappropriate Activities
 Person does not know to operate or perform certain activity
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Unsafe Act / Condition

1. Congestion or restricted 7. High or low temperature
action exposure
2. Defective tools, equipment 8. Horseplay
or materials 9. Improper lifting
3. Failing to use personal 10. Improper loading
protective equipment 11. Improper placement
properly 12. Improper position for task
4. Failure to warn
5. Fire and explosion hazards
6. Hazardous environmental
conditions; gases, dusts,
smokes, fumes, vapors
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Unsafe Act / Condition

13. Inadequate guards or
barriers 20. Operating at improper
14. Inadequate or excessive speed
illumination 21. Operating equipment
15. Inadequate or improper without authority
protective equipment 22. Poor housekeeping;
16. inadequate ventilation disorderly workplace
17. Inadequate warning 23. Radiation exposures
system 24. Removing safety devices
18. Making safety devices 25. Under influence of alcohol
inoperable and/or other drugs
19. Noise exposures
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For feedback and suggestions email at:
asimzaheer@neduet.edu.pk
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6/24/2020

Analyze the Scenario …

Analyze the Scenario…

Health and Safety Goal…

WHAT IS SAFETY ANALYSIS?

 Safety analysis is a generic term for study of the system, identification of

 System safety is the formal name for a comprehensive and systematic

WHAT IS SAFETY ANALYSIS?

System safety engineering is a compilation of engineering analyses and

BRIEF HISTORY OF SAFETY

In 1974, it was presented at an American Institute of Chemical Engineers

It is a systematic approach to food and pharmaceutical safety that identifies physical,

BRIEF HISTORY OF SAFETY

residual risk of a system shall be as low as reasonably practicable (ALARP

as far as reasonably practicable without risks to health and safety .

WHY DO WE NEED SAFETY

Dec. 1984: Bhopal, India

 Leakage of over 25 tones of

April 1986: Chernobyl, Russia

 The Chernobyl disaster was the worst

July 1988: Piper Alpha, North Sea

 Explosion followed by massive

 Loss of about $3.4 billion. Killed

 New regulations for the offshore

Sept. 2012: Baldia, Karachi

 The death toll was 258, including;

• The newly constructed Northern

Therefore, a risk assessment is conducted, and a cost–benefit analysis performed to

Unfortunately, there is no standard method to demonstrate that the hazard control

Cost Incurred by Accidents

Four parts of the structure of an accident

Incident Ratio Model‐Heinrich’s theory

What is an Unsafe Act?

What Causes Unsafe Acts?

What is Unsafe conditions?

• Unsafe conditions are hazards that have the potential to

• “The unsafe condition is a hazardous physical condition or

• Some of these hazards include flawed safety procedures,

What cause unsafe conditions?

Human Factors Theory of

Human Factors Theory of

Unsafe Act / Condition

Unsafe Act / Condition

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