PROJECT WORK ON COTTON INDUSTRES

PREPARED BY- LITENDRA KUMAR JENA

YEAR- 2023

INSTITUTE NAME: INSTITUTE OF FIRE AND SAFETY MANAGEMENT,

KUHI, NAGPUR
 CONTENTS

1. INTRODUCTION TO COMPANY ................................................... 05

1.1 INTRODUCTION… ....................................................... 05

1.2 SALIENT FEATURES OF ARVIND LTD… ................ 07

1.3 PROCESS FLOW DIAGRAM… ................................................... 08

1.4 BRIEF DESCRIPTION OF PLANT PROCESS ....................... 09

2 SAFETY ORGANISATION

2.1 INTORDUCTION ........................................................................... 13

2.2 SAFETY AND HEALTH POLICY… ............................................. 14

2.3 PROMOTIONAL ACTIVITY............................................................15

2.4 FIRST – AID PERSONNEL AND FACILITY… ................................ 15

2.4.1. FIRST- AID TRANING .................................................................. 17

2.5 ACCIDENT REPORTING & INVESTIGATION… ........................... 18

3 MATERIAL HANDLING

3.1 INTRODUCTION ................................................................................. 22

3.2 MANUAL MATERIAL HANDLING .................................................. 24

3.2.1. MAXIMUM LIFTABLE LOADS MANUAL HANDLING .......... 26

3.3 SOME COMMON EXAMPLE OF MANUAL HANDLING HAZARDS &

SOLUATION 27
 3.4 CONTROL MEASURE FOR MANUAL MATERIAL HANDLING RISK…33

3.5. MECHANICAL MATERIAL HANDLING… ................................................ 39

3.5.1. LIFTING EQUIPMENTS ........................................................................... 40

3.5.2. TRANSPORT EQUIPMENTS ................................................................ 45

3.5.3 SAFETY WHILE OPERATION OF FORKLIFT… ................................. 45

4. HANDLING OF HAZARDOUS CHEMICALS

4.1 SAFETY WHILE HANDLING OF SULFURIC ACID… ....................... 50

4.2 GOOD HOUSEKEEPING.......................................................................51

4.3. SAFETY WHILE HANDLING OF SODIUM HYPOCHORITE…………52..

4.4 SAFETY WHILE HANDLING OF HYDROCHLORIC ACID ..................... 54

4.5 SAFETY WHILE HANDLING ACITIC ACID .............................................. 57

5. CORRECTIVE ACTIONS AND SUGGESTION

5.1 GOOD HOUSEKEEPING .................................................................................60

5.2 FIRE PREVENTION ....................................................................................... 61

5.3 TRAINING PROGRAM .................................................................................. 62

5.4 USES AND CARE OF HAND TOOLS ........................................................ 63

5.5 DISPLAYED BOAR ........................................................................................ 64

5.6 GENARAL SAFETY ....................................................................................... 64

5.7 COMPETATION ............................................................................................... 64

 ACKNOWLEDGEMENT

Primarily I would like to thank god for being able to complete the project with successfully.
Than I would like to thank full of my teachers Mr. A.N Tripathi, whose valuable gaudiness has
been the once that help me patched this project andmake it full proof success of his instruction
of his served as the major contribute towards the completion of project

Then I would like to thank my parents and friends who have helped me theirvaluable
suggestion and guidance has been helpful in various phases of the completion of my
project work.

Last but not the least I would like to thank my classmate who has helped me a lot.

LITENDRA KUMAR JENA

 CHAPTER – 1

INTRODTION TO THE COMPANY

1.1) INTRODUCTION:

The Arvind Limited was set up with the pioneering effort of the Lalbhai Brothers in
1931, with the best of technology and business acumen, Arvind has become a true Indian
multinational, having chosen to invest strategically, where demand has been high and quality
required has been superlative. Today, the Arvind Limited is the flagship company of Rs. 20
Billion (US $ 500 million) Lalbhai Group.

An Arvind Limited has set the pace for changing global customer demands for textiles
and has focused its attention on select core products. Such a focus has enabled the company to
play a dominant role in the global textile arena. With its presence across the textile value chain,
the company endeavors to be a one- stop shop for leading garment brands.

Fore vision and technology has brought Arvind to be one of the top three producers of
denim in the world, and on its way becoming the global textile conglomerate. Arvind is already
making its presence felt in shirting‘ s, knits and khakis fabrics apart from being all set to create
ripples in the ready to wear garments world over.
 The late 1980‘s saw Arvind pioneer the manufacture of denim in India. Today with an
installed capacity of over 110 million meters per annul, Arvind is a leading producer of denim
worldwide. Design, Innovations and Sustainability have been our core competency and have
played a key role in our success. The use of sophisticated ultramodern technology under the
guidance of world-renowned designers has enabled Arvind to deliver many firsts in the
international markets. All our products are designed and modeled on the basis of expert design
inputs coming from our designers based out of India, Japan, Italy and the United States. All
Arvind Denim products come with the hallmark of distinctiveness and quality.

Some Examples:

· Shuttle looms for Selvedge denim

· Name selvedge and Stretch selvedge

· Unique Fibers like Excel, Jute, Silk and Linen

· Natural Indigo and Vegetable dyes

· Unique concept products like Indigo voiles & Handspun denim

· Organic, BCI & Sustainable denim

The denim facility at Arvind is accredited with ISO 9001, ISO 14001, OEKOTEX 100, GOTS,
and Organic exchange standard. Our labs are certified by NABL (ISO 17025 certification) and
customers like Levi‘s, Lee, H & M and Wrangler etc.
1.2) SALIENT FEATURES OF ARVIND LTD.:

The textile division of Arvind Ltd. Continuous to maintain technologies edge through all these
years & continuous to enjoy the status as one the most modern, state of the art textile plants in
the country.

One of India‘s largest textiles facilities, fully integrated at one complex

• Environmental friendly technologies

• All pervasive quality control

• Talented & skilled work force

• Largest retail network

• Widest range in the most number of categories

 SAFETY WHILE MATERIAL HANDLING

1.3) PROCESS FLOW DIAGRAM :

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 SAFETY WHILE MATERIAL HANDLING

1.4) BRIEF DESCRIPTION OF PLANT PROCESS :

DENIM MANUFACTURING PROCESS

The term "denim" has originated from the city of Nimes in France where "serge de Nimes" was
manufactured. Denim is made from a vat dye, the indigo dye, which is applied to cotton fabric in
loosely held form in layers. As far as manufacturing process of denim is concerned, it is similar
to -that of grey fabric up to the process of weaving with the only difference that in case of denim
fabric, it is dyed at the stage of sizing where as in case of Grey fabric, the decision regarding
dyeing stage depends upon the finished product.

SPINNING

The initial processes of denim manufacturing consist of the regular activities of opening and
blending of cotton fibers. Carding is done to remove any foreign matter and the sho fibers so that
cotton takes the form of a web which is then converted into a rope like from the silver. Then
drawing process produces a single, uniform sliver from a number (carded slivers. Yam is then
spun through open-end spinning or ring spinning. Roving also carried on, if the spinning has to
be done through ring spinning. Generally,' denim fabric are 3/l warp-faced' twill fabric' made
from a yam dyed warp and an un dyed we yarn. Normally dyed and gray ring or open-end yarns
are used In warp and we respectively. Traditionally speaking, the warp yarn is indigo dyed.

13
 SAFETY WHILE MATERIAL HANDLING

WARP PREPARATION- DYEING AND SIZING PROCESSES

Warp yarns are indigo dyed and sized with the help of two methods.

(i) Threads from several back beams are combined to form a warp sheet and dyed and sized on
the same machine.

(ii) Threads, about 350-400 in number are formed into ropes. 12-14 ropes run adjacent to each
other through the continuous dyeing unit. After dyeing, the ropes are dried on drying cylinders
and then collected in a can. -After that, a worker's beam is prepared. Sizing is then done in the
conventional manner.

There are various dyeing and sizing processes, which can be classified-into four categories.

(1) Continuous Indigo-Rope dyeing and sizing

(2) Continuous Indigo dyeing and sizing

(3) Indigo-back beam dyeing and sizing

(4) Continuous dyeing and sizing

The yarn coming out from the ring frames is wound into cheeses or cones and then placed on the
ball warped on which 350-400 threads are formed into a rope and are cross wound to a ball in
accordance with the length of warp beam. During this process, lease bands are inserted at
particular intervals as they are required for further processing on Long Chain Beamer. Based on
the size of the rope dyeing plant, 12-24 ropes, at a time, are dyed, oxidized, dried and placed in
large containers. These ropes .are then opened on the Long Chain Beamer through tension roll

14
 SAFETY WHILE MATERIAL HANDLING

and expansion comb and wound on to a back beam. Back beams are then sized and the sized
warp is then woven. This system is commonly used in the US.

Continuous indigo dyeing and sizing:

In this process, back beams are processed on the dyeing/ sizing machine instead of ropes. The
warp is dyed, oxidized, dried and sized at a one go. Although this process is less cumbersome,
the risk of individual thread breakage is greater than dyeing in rope form. This method is
commonly used in the European countries.

Indigo-back beam dyeing and sizing

Dyeing and sizing is done in two stages method. In the first stage, back beams are dyed,
oxidized, dried arid wound on a batch roll. The batch roll is then sized, dried and wound on a
weaver's beam.

Continuous dyeing and sizing

Although glass is hard and rigid yet it can be transformed into fine, translucent and flexible Glass
Fiber, commonly known as fiberglass. It is very glossy in appearance and feels like silk. There
are two methods for glass fiber manufacturing, Continuous Filament Process and Staple Fiber
Process. Apart from being glossy and flexible, glass fiber is also heat resistant. Due to its many
qualities, this fiber is widely used for home furnishings, apparels and many other industrial
purposes. It's really very interesting to know about the whole process of Glass Fiber
Manufacturing.

WEAVING

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 SAFETY WHILE MATERIAL HANDLING

The weaving process interlaces the warp, which are the length-wise indigo dyed yarn and the
filling, which are the natural-colored cross-wise yarn. The warp thread is in the form of sheet.
The weft thread is inserted between two layers of warp sheets by means of a suitable carrier,
such as Shuttle, Projectile, Rapier, Air current, Water current, etc. The selection of carrier
depends upon the type of weaving machinery used. The two different technologies available for
weaving machines are - Conventional Shuttle Weaving System which is done by Ordinary
Looms or Automatic Looms; and the Shuttle less Weaving System which is done by Air jet,
Water jet, Rapier, or a Projectile weaving machine. The Conventional Shuttle loom results in
lesser production due to slow speed and excessive wear and tear of machinery. As such, now
denim is generally

FINISHING

The final woven fabric, wound on a cloth roll, is taken out from weaving machines at particular
intervals and checked on inspection machines so that any possible weaving fault can be detected.
In this quality control exercise, wherever any fault is seen, corrective measures are taken then
and there only. The woven Denim Fabrics then goes through various finishing processes, such as
brushing, singeing, washing, impregnation for dressing and drying. Brushing and singeing
eliminate impurities and help to even the surface of denim fabric. Dressing regulates the hand
and rigidity of the fabric while compressive shrinking manages its dimensional stability. The
standard width denim fabrics are then sent for making up. In this process, the fabric is cut into
the

Desired width according to the size required. The made- up denim fabric is then thoroughly
checked for defects such as weaving defects, uneven dyeing, bleaching and dyeing defects, oil
stains, or patches. After inspection, the final product is categorized quality-wise. The fault less
fabric is sent to the packaging department while the defective ones are sent for further correction.

16
 SAFETY WHILE MATERIAL HANDLING

CHAPTER – 2

SAFETY ORGANIZATION

2.1) INTRODUCTION

In Arvind Limited, Naroda department named Fire & Safety Department is looking after
the Fire & safety inside the plant where 1 Group Head Fire & Safety, 1 Sr. Safety Manager, 1
Safety Manager and 18 Fire man are working. The department is full all the facilities in case of
emergencies and having emergency telephones (Ext. 1001 & 8200), B.A Sets, Emergency
Torches, Fire hoses & Nozzles. It fulfills the basic definition of Fire & safety organization.

Safety organization is defined as a definite planned and organized set up whose purpose
is to enlist and maintain the combined efforts of the entire personnel of an establishment of
undertaking in the work of accident prevention.

The overall objective and safety organization is to remove unsafe physical condition &
substitute safety practices. The top executive in charge of safety provides the load & the
direction to the organization.Safety Department carries out various works.

⚫ Work Permit

⚫ Safety Inspections

⚫ Accident reporting and investigation

⚫ Education and training

⚫ Promotional actives

⚫ Fire fighting Equipments maintenance and availability

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 SAFETY WHILE MATERIAL HANDLING

2.2) SAFETY AND HEALTH POLICY

―Safety of a person overrides all the production targets‖ is the Safety, Health
and Environment policy of Arvind Limited.

Arvind Limited believes that all injuries, occupational illness as well as

safety and environmental incidents are preventable.

Arvind Ltd. is committed for safe and healthy working environment through
total elimination of accidents and the resultant injuries and losses in all the
sphere of activities.

We shall therefore strive to:--

* Comply with all statutory requirements concerning Health, Safety and

Environment.

* Ensure that all equipments and systems are designed, installed and maintain
in conformity with Safety, Health and Environmental regulations.

* Conduct all its activities in such a manner as to avoid harm to employees,

contractors and community.

* Create a culture of learning and practicing Safety, Health and Environment

systems, procedures and practices among all its employees and contractors.

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 SAFETY WHILE MATERIAL HANDLING

* Sustainable development by continuously improving its environmental

practices and performance.
* Utilize energy resources in resources in a responsible and efficient manner
so as to reduce emissions and generation of effluent and waste products.

Jayesh Shah,
Director Place: Ahmedabad
Occupier Date: 24th March, 2014

SAFETY TRAINING

Objective: - To ensure that employees have the necessary training education and skills to
reduce the level of risks as much as possible. This will also enable employees to
identify potential losses and assist in the creation of health and safety culture.

Some Safety training programs are:

• Training to workers for specialized works like Acetic acid

spillage Drill, Sludge spillagedrill etc.

• Training to workers & staff of Fire fighting.

• Training to workers of First – Aid

• Safe operating instructions in Gujarati Language.

• Training on the usage of PPEs.

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 SAFETY WHILE MATERIAL HANDLING

2.3) PROMOTIONAL ACTIVITY

Arvind Limited safety officers not only do regular inspections , investigation and follow-up of
rules and regulation but also they do promotional activities for safety. They celebrate safety
week every year with full of competition and quiz and various awards to employee. They are
having safety committee beside that they have safety suggestion scheme and they are
encouraging for the same.

2.4) FIRST – AID PERSONNEL AND FACILITY.

Objective: - To ensure that adequate arrangement are in place and maintained in accordance
with the nature and scale of the organization's OH & S risks.

• Adequate first aid facilities been under taken and reviewed.

• First aid facilities easily accessible to workers.

• Guidance sheet provided with each first aid box.

• First aid train personnel identify easily

• Adequate First aid personnel – plant wise / shift wise in section.

• List available with first aid box

• Records available & maintained

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2.4.1. . FIRST AID TRAINING

Objective: - To ensure that employees are competent to perform tasks associated with first aid.

All first aid personnel trained to approve standard.

First aid training by qualified doctor from St. John Ambulance.

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 2.5) ACCIDENT REPORTING & INVESTIGATION

Accident reporting and investigation is necessary in any industry. We know that

accident reporting is statutory requirement and the organization has to carry out reporting in one
or the other way. And it has to inform the chief inspector of factory and factory inspector in case
of fatal accidents.

Following are the some accidents reported on the last 100 accidents in the
company as per the types of accidents. No fatal and serious accident occurred from last few
years. By analysis of the data it looks that most of the accident occurred by slipping / Tripping /
Falling from Same level , Collision with the object , Falling object , contact with machinery tools
or objects and manual handling which indicate the bad housekeeping in the work place area.

SR.
No. Types of Accident No. Of Accidents Percentage of Accident

1 Animal 1 1

2 Burn 3 2

3 Collision with object 21 16

4 Contact with Chemicals 2 1

5 Contact with machinery / Tools 20 15

6 Fall From Height 5 4

7 Falling Object 20 15

8 Manual Handling 17 13

9 Slips / Trips/ Fall on Same Level 34 25

10 Trapping / Crushing under or between object 9 7

11 Vehicle 2 1

Total 134 100

1
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ACCIDENT INVESTIGATION

The person who is familiar with the accident sources and causes, the worker processes and
equipment and machines where these maybe involved. Generally the supervisor or the head of
department makes investigation firstly than safety officer and if necessary the factory inspector
or chief inspector of factories investigates the accident. During accident investigation principles
which should be followed.

• Common sense and clear thinking

• Each clue should be investigated fully

• In most of accident – unsafe act or unsafe condition is involved, so both should be

investigated fully.

• Every accident should be considered serious, whether it is serious or not.

Appropriate action should be taken to remove unsafe condition immediately. Then other
departments also informed that this type of accident could occur so the proper steps to be taken

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 ACCIDENT INVESTIGATION

No Guard on Pulley Belt SM # 1,2 Colour Install Guard on Pulley Belt

Kitchen

ACCIDENT INVESTIGATION

3010064 Ghadage Lala Rope 16/09/201 While he was attending his job, he was
Laxman Finishing 1 working on ODR machine, at that time
SEVENDAY RDP 06:00:00 accidentally his Left Hand came in J-Scray
RELIER Finishing AM Nip(pressure roll) and his Wrist got bluntly
injured.

Nip Guard Missing at J Scray at ODR M/C Nip Guard Installed at J Scray at ODR M/C

24
SAFETY WHILE
MATERIAL
HANDLING IN
TEXTILE
INDUSTRY

25
CHAPTER – 3

MATERIAL HANDLING

3.1) INTRODUCTION

Material handling which accounts for about 23 % of accidents, consists of 6 basic tasks

1. Lifting

2. Lowering

3. Pushing

4. Pulling

5. Carrying

6. Walking

Common unsafe working habits:

1. Unsafe gripping

2. Lifting excessive load

3. Lifting improperly

4. Failure to wear shoes or gloves where necessary.

Makeshift handling creates disorderly field conditions, work interruptions, and damage.
Unnecessary confusion and distraction, which usually accompany inefficient handling methods,
interfere with job operations and result in lower quality.

26
The three fundamental principles of good material handling procedures are:

➢ Continuous flow without back – tracking

➢ Uninterrupted work schedule

➢ Adequate storage facilities

In our plant majority of accidents are caused while handling the material and hence great care
has to be exercised to do this work safely. The person in-charge should select the method of
handling goods having regard to the following factors:

⚫ weight

⚫ Physical characteristics

⚫ Size

⚫ Shape

⚫ Rate of handling

⚫ Distance to be moved

⚫ Purpose of moving

⚫ Obstacles if any, on the path of movement of materials

⚫ Horizontal, vertical, inclined movements.

The methods of handling goods or materials can be divided into

2. Manual Handling

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 3. Material Handling with Equipments (Mechanical Handling)

3.2) MANUAL MATERIAL HANDLING:

Manual handling covers a wide range of activities including lifting, pushing, pulling. Holding,
throwing and carrying. It includes repetitive tasks such as packing, typing, assembling, cleaning
and sorting, using hand tools and operating machinery and equipment. Because most jobs
involve some type of manual handling, most workers are at risk of manual handling injury. Of
course, not all manual handling tasks are hazardous. But it is significant that around 25% of all
workplace injuries are caused by manual handling.

1. Manual Handling Risk factors

Risk factors (also known as ―ergonomic hazards‖) are conditions that may adversely affect a
person‘s wellbeing and could influence an individual‘s ability to safely perform an manual
handling task. As with most musculoskeletal disorders, chronic low back pain usually results
from some combination of risk factors acting together over time. It should be noted, though, that
there is no established dose/response relationship. In other words, it is impossible to say how
many times, or over what period of time, an activity, posture, force, or other risk factor can be
performed before resulting in a low back musculoskeletal disorder. (1)

2. Personal Risk Factors

A variety of personal qualities and traits, which the worker may bring to a manual materials
handling job, have been identified as potential risk factors in the development of low back pain.
These include a prior history of back injury, poor personal fitness levels, second jobs,
recreational activities, hobbies, and smoking, the aging process, gender, obesity, physical stature,

28
and psychosocial issues (including family, financial or other personal difficulties, job or
management dissatisfaction, a lack of job control, and work-related stress among other factors).

3. Environmental Risk Factors

Confined or limited workspaces may be considered a risk factor for low back pain. Work in
spaces that constrain an individual‘s posture should be eliminated where possible, especially
when it affects headroom or horizontal reaches. Reaching over obstacles and into containers at a
distance from the torso places undue strain on the back. Work areas should be unobstructed and
allow the handler freedom of choice as to how the object is appraised, approached, and handled.
Foot and legroom should be sufficient to allow the handler to bend the legs and knees when
getting close to the object. Floors should be free of debris or materials that might pose a slip, trip,
or fall hazard. Many materials handling jobs are performed while standing.

4. Workplace Risk Factors

The workplace risk factors typically associated with low back pain include handling heavy loads,
task repetitiveness, extreme postures of the back (twisting, bending, stretching, and reaching),
static postures, whole body vibration, prolonged sitting, direct trauma to the back (striking or
being struck by an object), slips, trips and falls, and work-related stress. People performing
heavy work, working near their personal strength and endurance limits, are more likely to
develop back problems than those who need to use only a small fraction of their strength
capacity. Therefore, the more an object weighs, the greater the chance of musculoskeletal injury.

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3

3.2.1) MAXIMUM LIFTABLE LOADS BY MANUAL HANDLING

As per Gujarat Factories Rules, 1963 Rules No. 62 maximum permissible load to be carries out
while manual handling is:

Person Permissible Maximum Weight in Kg

Adult Male 50

Adult Female 29

Adolescent Male 29

Adolescent Female 20.4

Male Child 15

Female Child 13

Two adult workers working together for

500
carrying load by Hand – cart

30
3.3) Some common example of manual handling hazards and
solutions:

1 HANDLING BALES

Usually in used delivery and storage areas for transferring bales.

Risk Factors

Bales are generally too heavy to be handled without mechanical help. The manual movement
of bales can present a serious risk of injury and even the use of hand trucks should be kept to a
minimum.

Risk Controls

An individual can be reduced by having more than one worker doing the job, particularly
when getting the bale onto a truck. All the workers are using hand hooks to grip the bale. Also
consider using lift and clamp trucks more widely, providing roller conveyors, using
appropriate hand trucks for the bales being moved, and maintaining floor surfaces to reduce
risks.

2. LOADING YARN PACKAGE ONTO A PALLET

Many workplaces hand stack yarn packages onto pallets on the floor. Sometimes the yarn
packages are large, heavy and awkward in size.

Risk factors

Sustained or repetitive

• Bending the back forwards and twisting more than 20 degrees

31
 • Reaching forwards or sideways more than 30cm from the body

• Lifting or lowering

• Exerting force while in an awkward posture

Long duration

High force

• Using a finger-grip or an open-handed grip to handle a heavy or large load

• Two or more people need to be assigned to handle a heavy or bulky load (Figure 1).

• Stronger employees are assigned to do the task

• Exerting high force while in an awkward posture

Risk controls

Altering the workplace

• Extending a conveyor or use an extension roller surface to reduce carrying distances.

• Placing the pallet on a stand to raise the working height to between mid thigh and
shoulder height and allow access to all sides of the pallet to reduce forward reaching and
forward back bending

3. HANDLING LONG ROLLS OF FABRIC

Rolls of fabric or carpet are often awkward shapes to handle in the workplace. Frequently,
handling involves team lifting
32
Risk factors

Sustained or repetitive

• Bending the back forwards more than 20 degrees

• Reaching forwards or sideways more than 30cm from the body

• Lifting or lowering

• Gripping with the fingers held wide apart

• Exerting force while in an awkward posture

Long duration

High force

• Lifting, lowering or carrying heavy loads

• Two or more people need to be assigned to handle a heavy or bulky load.

• Stronger employees are assigned to do the task

• Exerting high force while in an awkward posture

Altering the workplace

• Ensuring that workstations are at a suitable height so that employees do not have to
bend to reach rolls

33
Using mechanical aids

• Using roller conveyors to connect workstations and move rolls on boards. This will
eliminate the need to lift rolls and enable employees to push/pull them easily between
workstations

• Using an overhead crane to eliminate lifting.

• Installing hydraulic lifting arms on machines to handle rolls

• Using a tilting roll trolley or a long handle lever trolley which slides under a roll, to
move rolls between workstations

• Using a forklift with drum grabber appropriate for the load .

• Using a probe lifter to move the roll supporting it through the core. This reduces the
application of force in an awkward posture and enables the task to be performed by one
employee.

4. HANDLING HEAVY ROLLS OF FABRIC

Handling heavy rolls of fabric or carpet involves high force, often with awkward postures.

Risk factors

High force

• Lifting, lowering or carrying heavy loads

• Two or more people need to be assigned to handle a heavy or large load.

• Stronger employees are assigned to do the task

• Exerting high force while in an awkward posture

Changing the objects used in the task

34
 • Installing a roll barrier onto a pallet to allow the forklift to transport rolls on the pallet.
(Example: This pallet has been modified with a roll barrier to prevent contact with grease
from the forklift mast. Previously rolls were handled manually to keep them clean. )

Using mechanical aids

• Using automated push off systems to move the rolls

• Using an overhead crane to move rolls

• Using a tilting roll trolley or a long handle lever trolley which slides under a roll, to
move rolls between workstations

• Using a forklift with drum grabber appropriate for the load.

• Using a probe lifter to move the roll supporting it through the core .

5. INSPECTING

Inspection tasks involve long periods of time looking down at fabric and sometimes involve
throwing pieces of material onto a table.

Risk factors

Repetitive or sustained

• Bending the back forwards or sideways more than 20 degrees

• Bending the neck forwards more than 20 degrees

• Reaching forwards or sideways more than 30cm from the body

• Working with one or both hands above shoulder height Long duration

High force

• Applying fast or jerky forces during lifting

• Throwing or catching.

35
Altering the workplace

• Providing options for sitting or standing or adjustable sit/stand seating to reduce

forward reaching and forward bending of the neck and back. Ant fatigue matting or foot
rests for prolonged standing work can improve working postures.

Providing mechanical aids

• Providing an adjustable angle table like a drafting board, to support items being
inspected to reduce bending of the back and neck and reduce work at or above
shoulder height. Providing a clamp so that the item remains stable when he table is tilted
will also reduce the need for throwing the item on the table and the application of fast or
jerky forces.

Altering the environmental conditions

• Providing an alternative lighting colour or lamp design to highlight faults inthe thread
or material and to reduce glare from the light source, or investigate whether
lighting from underneath would make fault detection easier. This will assist in reducing
sustained forward neck bending

Altering systems of work

• Introducing job rotation in combination with other risk controls to provide postural
variety and reduce exposure to sustained postures, especially forward bending of the neck
and back.

6. HANDLING LOOSELY FOLDED CLOTH

Common to a number of intermediate stages of the production process, for example, moving
cloth to or from machines, inspection and quality control areas including lifting to or from
weighing scales.

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Risk Factors

Risks arise from the weight of the cloth, its unstable nature (ie a tendency to sag), the
difficulties of ensuring a firm grasp on the load and the problems often associated with the
tendency for folded cloth to sag when held at each end. This often results in more effort when
lifting onto raised surfaces because the arms must be raised so much higher than the work
surface. This is demonstrated by the woman on the right who must raise her arms well above
the work surface, even though it is close to waist height.

Risk Control

the use of a lightweight ‗stretcher-board‘ which not only reduces the distance through which
the load is lifted, but also improves its stability and provides for a more even distribution of
weight between the two lifters. The board also has suitably designed hand-holds which
improve grip and the ability to apply the necessary force during the lift.

The most effective way to prevent handling injuries is to avoid the need for handling
altogether. a weighing scale mounted into the floor close to the workstation. Rather than
transferring cloth onto weighing scales and then putting it onto storage trolleys, the loaded
trolley can be wheeled onto the scale for the cloth to be weighed, removing the need to lift the
cloth.

3.4) CONTROL MEASURES FOR MANUAL MATERIAL

HANDLING RISK

The best control measure is to eliminate the need for workers to perform manual handling tasks.
Since this is not always possible, design manual handling tasks so that they are within the

37
workers‘ capabilities. Considerations include the load itself, the design of the workstation and
work practices. Providing mechanical handling devices or aids can often eliminate the task itself
or ease the demands on the worker.

Task Design

The Load

Reduce the weight of the load by decreasing the:

• size of the object (specify size to suppliers)

• weight of the container (e.g., plastic is

• lighter than steel)

• capacity of containers

• load in the container

Conversely, consider increasing the weight of the load so that it may only be handled
mechanically. This can be done by the use of:

• palletized loads, and

• larger bins or containers

Decrease the load on the worker by:

• Limiting the number of objects he/she is required to handle during the day

• Designating heavier loads as team lifts (i.e., two or more persons)

• changing the size and shape of the load so that the worker can get closer to the load‘s
centre of gravity

Work Station Design

38
Reduce the distance over which the load has to be moved by relocating production and storage
areas. Design work stations so that workers:

• can store and handle all material between knuckle and shoulder height; waist height is
most desirable can begin and end handling material at the same height

• can face the load and handle materials as close to the body as possible

• do not have to handle loads using awkward postures or an extended reach, and

• do not handle loads in confined spaces that prevent them from using good body
mechanics

Facilitate access to material by:

• providing workbenches and other work stations with toe cut-outs, so that workers can get
closer to the load

• supplying bins and totes with removable sides removing obstructions, such as
unnecessary railings on bins

Work Practices

Lifting and Lowering

• Eliminate the need to lift or lower manually by providing and ensuring proper use of:

• lift trucks, cranes, hoists, scissor lifts, drum and barrel dumpers, stackers, work
dispensers, elevating conveyors, articulating arms and other mechanical devices gravity
dumps and chutes , power lift tail gates on trucks, and hand trucks to ensure easy transfer
of material from the truck to ground level, portable ramps or conveyors to lift and lower
loads on to work stations

Pushing and Pulling

Eliminate pushing or pulling by ensuring the use of:

39
 • powered conveyors, powered trucks, slides, chutes, monorails, air tables and similar
mechanical aids

Make loads easier to push or pull by ensuring the use of:

• carts, hand trucks and dollies with large diameter casters and good bearings, and grips or
handles on loads or mechanical aids, placed to provide optimal push force and prevent
awkward postures

Instruct employees to:

• push rather than pull

• avoid overloading – limit the load pushed or pulled at one time

• ensure the load does not block vision

• never push one load and pull another at the same time

Carrying and Holding

Reduce carrying and holding forces by:

• evaluating the work flow – determine if heavy loads can be moved mechanically over any
distance

• converting the operation into a pushing or pulling task providing carts, slings or trolleys

• providing portable containers in which to place awkward loads

• providing grips or handles on loads

• limiting the distance over which the load is moved

Environmental Factors

Maintain an optimum environment by ensuring that:

• the temperature of the work area is at an acceptable level

40
 • in a hot environment –– workers take frequent breaks away from the heat –– workers
drink frequently from liquids provided near the work site

• in a cold environment, –– workers wear good insulating clothing –– loads are easy to
handle when gloves and heavy clothing are worn

• humidity is at an acceptable level

• lifting instructions can be heard in a noisy environment

• lighting levels are adequate for the work place

• the layout of the work area provides better access to the load

• the aisles are clear of obstacles

• signs are posted where there are gradients in the slope of the floor; whenever possible,
limit such slopes to 10 degrees

Storage

Provide proper storage facilities such as:

• storage boxes and containers that can be

• lifted mechanically rather than requiring manual handling

• avoid deep shelving that make retrieving or placing a load difficult

• racks or shelf trucks to store material, thus eliminating the need for lifting the containers

• storage bins and containers with fold down sides for easier access to loads

When storing loads, employees should:

• store loads in easy to access locations

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 • store loads between knuckle and shoulder height

Personal Factors

Clothing

• Wear appropriate clothing and safe, comfortable shoes:

• clothes that are comfortable around the hips, knees and shoulders, and that do not have
exposed buttons or loose flaps, and

• Non-slip shoes with broad based low heels. Safety footwear is essential when handling
heavy loads on a regular basis

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3.5) MECHANICAL MATERIAL HANDLING

Mechanical material handling done by two types of Equipments

1) Lifting Equipments

2) Transport equipments

1) Lifting Equipments

Following equipments are used for Lifting

1.1) Lifting tools and tackles

1.2) Hoisting Equipments

2) Transport Equipments

2.1) Trucks / Tractors / Tanker

2.2) Forklifts

1) Lifting Equipments

1.1) Lifting Tools and Tackles

Lifting tools and tackles equipments are like Hooks, Pulley, Slings (Fiber rope, wire rope and
chain), Sheaves, Clamps, etc used for lifting the objects.

As per rules no. 60 prescribed by G.F.R 1963 and section 29 of Indian Factories Act 1948
following conditions should be fulfilled

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Lifting machines, chains, and ropes and lifting tackles.

In any factory the following provisions shall be complied with in respect of every lifting machine
(other than a hoist and lift) and every chain, rope and lifting tackle for the purpose of raising or
lowering persons, goods or materials:-

(a) All parts, including the working gear, whether fixed or movable, of every lifting machine and
every chain, rope or lifting tackle shall be--

(i) Of good construction, sound material and adequate strength and free from defects;

(ii) Properly maintained; and

(iii) Thoroughly examined by a competent person at least once in every period of twelve
months, or at such intervals as the Chief Inspector may specify in writing; and a register shall
be kept containing the prescribed particulars of every such examination;

(b) no lifting machine and no chain, rope or lifting tackle shall, except for the purpose of test, be
loaded beyond the safe working load which shall be plainly marked thereon together with an
identification mark and duly entered in the prescribed register; and where this is not practicable,
a table showing the safe working loads of every kind and size of lifting machine or chain, rope or
lifting tackle in use shall be displayed in prominent positions on the premises;

(c) All lifting machines, chains, ropes and lifting tackle except a fiber rope or fiber sling,
which have been lengthened, altered or repaired by welding or otherwise, shall not be used
again, unless it is adequately tested and examined by a competent person and certified in writing
by him to be in order.

(d) A register in Form 10 containing the particulars, the register shall be readily available for
inspection.

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LIFTING TOOLS AND TACKLES

45
1.2) Hoisting Equipments

• Never lift a load in excess of the safe working load marked on Hoist.

• Always lift load vertically.

• Never lift with the point of hook.

• Never run the wire rope out too far.

• Apply grease to the wire rope periodically.

• Before use of hoist, examine the wire rope to ensure that there is no twist.

• Do not lubricate any point of contactors.

• Inspect the wire rope for wear and tear regularly.

• Under no circumstances should the hoist be operated when Limit Switch is not operating
properly.

• Ensure that the rope drum is perfectly horizontal when Hoist is used as a fixed suspension
unit.

• Examine the supply provided and connections are made accordingly.

• Examine brake operation periodically and set the brake adjustment.

• Periodically examine the bolts and nuts. If required tighten them.

• Load should not be allowed to swing during operation.

• Operator should use helmet.

• Never open any electrical contact when supply is ON.

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 • Hoist should be examined, inspected & tested by an impartial & competent authority
once in a year for its wear and safe working as certified as Factories Act 1948.

• Always use lubricant for gears as recommended by Hoist Manufacturer.

• Periodically examine that no foreign particles accumulate on Beam on which Trolley is

moving.

• Care should taken that Electric hoist block fitted on Beam should be properly ground if it
welded.

• Do not leave load suspended in the air for long time.

• It is always recommended to use Hoist as per class Designed.

• Electrical parts shall be protected, if application is out door.

AFTER A PROLONGED STOP OR WHEN MAKING A ROUTINE EXAMINATION

• CHECK operation of brakes.

• CHECK operation of limit switches.

• CHECK for damaged hooks, ropes or cables.

• KEEP rope clean and well lubricated.

• CHECK the wire rope for improper seating, twisting, kinking, wear or other defects
before operating the hoist.

• CHECK that suspending cables of the Control Box are not broken or loosen. If the cable
is damaged, change it.

WHEN IN USE

• HOLD the load in a balanced way, securing it by using appropriate equipment (sling…).

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• MAKE SURE the load clears vicinity, stock piles, machinery, or other obstructions when
raising, lowering or moving the load.

• CENTER hoist directly above the load before operating, never pull from the side.

• MAKE SURE that the load is high enough to see and avoid any obstacle lying on the
ground.

• AVOID swinging the load or hook block when traveling.

• MAKE SURE that the load is correctly held in the hook.

• CHECK that the rope reeving is correctly tight (slackness not desirable).

• KNOW AND USE the hand signals for hoisting and traveling.

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2.0 SAFETY WHILE OPERATION OF FORKLIFT

Pre-use inspection

The forklift must be checked for defects daily — usually by the operator before beginning a
shift. Even if you operate a forklift safely, a defect can cause or contribute to a serious accident.
Some things to look for are:

• Is the horn working? Sound the horn at intersections and wherever vision is obstructed.

• Are there hydraulic leaks in the mast or elsewhere? These could cause slipping hazards or
lead to hydraulic failure.

• Are fuel connections tight and battery terminals covered? Dropping a piece of metal
across battery terminals can cause an explosion.

• Is there a lot of lint, grease, oil or other material on the forklift that could catch on fire?

• Do sparks or flames come out from the exhaust system?

• Does the engine show signs of overheating?

• Are tires at proper pressure and free of damage? A tire with low pressure or a tire failure
can cause a forklift to tip or fall when a load is high.

• Do all controls such as lift, lower, and tilt work smoothly? Are they labeled?

• Is there any deformation or cracks in the forks, mast, overhead guard, or backrest?

• Are lights operating if used at night or in dark locations?

• Is steering responsive? A lot of play or hard steering will reduce your control.

• Do brakes stop smoothly and reliably? Sudden stops can cause tipping.

• Does the parking brake hold the forklift on an incline?

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 • Are seat belts (if equipped) working and accessible?

• Is the load capacity plate readable?

Loading and unloading the forklift

Check the load before you pick it up.

• Is it stable or will parts slide or fall during transit? Secure it as necessary. The
illustrations below show some common pallet stacking patterns.

• Do the dimensions and weight of the load fall within the capacity rating of the forklift at
the highest elevation and extension you will handle the load? If not, can you break the
load into smaller parts?

When pick up the load:

• Move squarely into position in front of the load.

• Position the forks wide apart to keep the load balanced.

• Drive the forks fully under the load.

• Tilt the mast backward slightly to stabilize the load and lift.

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Check the destination before place the load.

• Is the destination flat and stable — or, will the load rock, tilt or lean?

• Never place heavy loads on top of light loads.

• Observe maximum stacking quantities and orientation if printed on cartons.

• Do you know the load bearing capacity of your rack or storage loft destination?

• Are rack legs or support members bent or disconnected? The load bearing capacity of a
damaged rack is unknown! Wait until the damaged component has been replaced before
loading.

• Are racks arranged back to back with a stock behind where you will place the load?
Someone may need to be in the next aisle to control access while you place the load.

• Are wooden stringers or decking laid between front and rear rack beams in good
condition?

• If you are stacking, are other pallets in the stack in good condition and capable of
supporting the load in addition to what they are already supporting?

When place the load at its destination:

• Move squarely into position in front of the rack or stack where the load will be placed.

• When ready to place the load, tilt the mast to level. Only tilt forward when the load is
over the spot where it will be placed.

• Lower the forks and back away.

• Visually verify that the load is stable.

Fueling/charging

When refueling or charging batteries, observe the following precautions:

51
• Do not smoke or allow any open flames or spark /arc generating equipment in the
refueling / charging area.

• Make sure there is adequate ventilation to disburse fumes.

• Make sure there is a fire extinguisher nearby.

Forklift

Failure of Forklift
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CHAPTER - 4

HANDLING OF HAZARDOUS CHEMICALS

In Arvind Ltd, Naroda following Hazardous chemicals are used:

1 Sulfuric Acid - pH neutralize in ETP

2 Caustic lye - in mercerize for finishing products.

3 Sodium Hypochlorite as sizing material

4 Hydrochloric Acid for softening of water in DM Plant.

5 Acetitic Acid – Finishing Agent

4.1 Safety While Handling of Sulfuric Acid:

• Use only minimum concentrated necessarily for the process.

• Never pour water in to acid while diluting, always acid into water stirring constantly

• whenever individual contains are to be transported only experienced persons should be

allowed to undertake the work and the appropriate equipments should be explained as

(a) Hand truck or power truck should transport large container

(b) Small contains such as bottles should be carried in safety bottle, carders which
provides protection against impact and retain acid in the event of damage.

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 • Decantation should be done by means f special siphons, transfer pump, drum or carboy
tilting, cradles etc.

• Where acid is mixed with other chemical, workers must be made fully aware of any
violent or dangerous reaction.

• Where the process acid mist or vapors generated, exhaust ventilation should be installed.

Handling thorough Pipe-lines

• All valves on acid lines must be provided with a hood made out of lead sheet, which will
prevent spraying of acid from leaky valve glands.

• Flanges joints on acid lines are to be covered with loose cover of lead sheet, which will
prevent acid from spraying around In case of leaky joint.

• Pipe-lines should be properly supported.

4.2 Safety While Handling of Caustic lye or caustic solution:

Dry Form:

• Keep it dry. When combined with water, the reaction is exothermic, meaning it gives off
a great deal of heat which could burst the container or cause burns.

• Dry sodium hydroxide is very caustic when it makes contact with skin or eyes. Always
wear safety glasses and suitable gloves (neoprene, nitrile or natural rubber) when
working with it.

• Avoid inhaling sodium hydroxide dust if it becomes airborne.

Liquid Form:

54
 • The liquid form is more dangerous to work around than the dry form due to splash
hazards. It can cause severe chemical burns to the eyes and skin. Always wear safety
goggles, face shield, gloves and chemical apron when using the chemical.

• Sodium hydroxide solutions greater than 2% by weight should be labeled as corrosive.

• Do not let sodium hydroxide come in contact with aluminum. It reacts violently and
produces hydrogen gas, creating a fire and explosion hazard.

First aid:

• If either the dry or liquid form comes in contact with skin or eyes, flush with large
amounts of water for at least 15 minutes and seek medical help. Spills can be neutralized
with a weak acid such as vinegar.

4.3 Safety While Handling of Sodium Hypochlorite:

Precautions:

• Avoid contact with eyes, skin and clothing.

• A safety shower and eye wash fountain should be strategically located near the
production, loading, unloading and storage areas, or anywhere that sodium hypochlorite
solution is handled.

• PPE should be specific to the task, as a minimum, wear chemical splash goggles, face
shield, rubber gloves, and rubber boots when handling.

• Avoid breathing fumes.

• Insure adequate ventilation, or use an approved acid gas respirator in poorly ventilated
areas.

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 • Do not allow contact with organic materials such as rags, wood fibers, paper, debris or
with reducing chemicals except under controlled conditions.

• Care should be taken when disposing of sodium hypochlorite. Hazardous reactions could
result.

Storage Containers:

• Covered tanks are recommended to protect bleach from contamination. A venting

system must be in place to eliminate excessive pressure or vacuum when filling or
discharging contents.

• Sodium hypochlorite is usually discharged from an outlet a few inches off the tank
bottom.

• The tank should be equipped with a man away to permit internal inspection. Fiberglass
Reinforced Plastic (FRP) or poly tanks are usually the materials of construction to
minimize corrosion. Consideration should be given to a system for determining the
volume or level in the tank.

Valves:

• PVDF, PTFE, PVC non-metallic or lined valves are recommended for sodium
hypochlorite service. Precautions must be taken with cavity valves, particularly those
made of all plastic materials, such as ball or plug valves to prevent product leakage
and/or pipe/valve damage should there be any pressure build up in the closed cavity due
to the transition metal catalyzed decomposition hypochlorite solution

Pumps:

• A titanium or suitable non-metallic lined pump is recommended.

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 • When ordering pumps, the sodium hypochlorite concentration should be specified. Due
to the numerous individual components comprising a complete pump, special care
should be used when specifying this device

4.4 Safety While Handling of Hydrochloric Acid:

Transportation

(1) General precautions

• The shipping containers must be tightly sealed so that hydrochloric acid does not leak,
and must be handled with great care so as not to break them.

• Transport hydrochloric acid with great care, and be sure to wear protective goggles and
rubber gloves, and wear rubber boots or rubber clothing as required.

• In the case of consolidated transport, keep alkalis and metals away from hydrochloric
acid, and do not place the containers on top of other containers containing organic
chemicals.

(2) Transportation of hydrochloric acid in acid-resistant bottles

• When acid-resistant bottles containing hydrochloric acid are to be transported, check

them thoroughly beforehand for damage and condition of the seals of the bottles.

• When the acid-resistant bottles are to be moved, use a cart regardless of the presence or
absence of any contents. Do not use chain, hoists, pulleys, or makeshift lifts. Do not
carry the bottles by holding them by their caps or necks.

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(3) Transportation of hydrochloric acid by tank truck

• The laws require that each tank truck should be provided with a document describing the
name, components and grade of the contents, the first aid measures to be taken in case of
an accident, protective equipment, tools and so on. In the case of long periods of
transportation, a standby driver is required to ride in the truck.

• The driver must be certain to close the manholes or valves so that the liquid does not
leak.

Precautions for Storage

• Place containers containing hydrochloric acid outdoors. If they are placed indoors, it is
desirable that acid-resistant paints and acid-resistant mortar be used, and the floor should
be coated with asphalt, acid-resistant blocks, or sodium- silicate-treated concrete,
because the buildings will be corroded by hydrochloric acid mist, It is necessary for the
storage place to be equipped with a drainage, and any spilt hydrochloric acid should be
flushed away using a large quantity of water. For this, a water supply that can provide a
large quantity of water should be located near the drain. It is not recommended to store
hydrochloric acid in any basement area.

• To prevent health hazards caused by hydrochloric acid mist, and to avoid the danger that
the room will be filled with hydrogen generated by the corrosion of metals, the building
should be of an open structure and well ventilated.

• Use electrical facilities that are as airtight and corrosion resistant as possible. For the
wiring, use plastic-coated wire, or use airtight metal conduits protected by acid-resistant
paint or plastic conduits.

• Store hydrochloric acid apart from oxidants (in particular, nitric acid or chlorates) and
combustibles, as well as cyanides or sulfides.

• Avoid direct sunlight and close proximity to a heat source. In addition, avoid
passageways and places where there is a risk of something falling.

58
 • The containers must be mechanically strong and corrosion resistant, and should not
allow the contents to leak out.

• The containers must be tightly sealed, and an appropriate head space (5% by volume or
greater) must be left when the container is filled with hydrochloric acid.

• When hydrochloric acid is stored in a tank, always check the quantity of the remaining
hydrochloric acid to prevent any danger of its overflowing. Install a ventilation hole in
the tank and connect the hole to a hazard prevention facility.

General Precautions for Use of Hydrochloric Acid

• Since hydrochloric acid is highly corrosive, operators must always wear protective gear
when handling hydrochloric acid. Take a shower or bath after the operations, and wash
their face and hands, and gargle immediately before taking a meal.

• If the place where the hydrochloric acid mist is produced, and the place cannot be
naturally ventilated, discharge the contaminated air using an exhaust system.

• When a sealed acid-resistant bottle is opened, the slightly higher pressure in the bottle
than the ambient pressure may eject the contents; therefore, keeps the face or hands
away from the cap of the bottle.

• When hydrochloric acid is being taken out of an acid-resistant bottle, do not use air
pressure, but use a bottle holder that can be safely tilted, and a siphon.

• When hydrochloric acid is sampled by suction, use a safe pipette, vacuum pipe, or the
equivalent.

• If an operator needs to enter a storage tank, tank car, tanker, tank truck or equipment
using hydrochloric acid, fill the tank with water to clean it beforehand, and sufficiently
ventilate the tank after flushing. Disconnect any hydrochloric acid pipes connected to
the storage tank, or insert a blanking plate to prevent any hydrochloric acid from flowing
in, and the operator must enter the tank wearing a ventilation mask (air aspirator) and
safety rope and have an observer standing outside the tank.

59
 • Care must be taken so that the hydrochloric acid to be used does not mix and react with
an oxide (especially nitric acid and chlorate), cyanide, or sulfide which generates toxic
gases

4.5 Safety While Handling Acetic Acid:

STORAGE REQUIREMENTS

• Store in approved flammable liquid storage area.

• No smoking, naked lights/ignition sources.

• Keep containers securely sealed.

• Store at room temperature.

• Store away from incompatible materials in a cool, dry, well-ventilated area.

• Protect containers against physical damage and check regularly for leaks.

• Storage areas should be clearly identified, well illuminated, clear of obstruction and
accessible only to trained and authorized personnel - adequate security must be provided
so that unauthorized personnel do not have access.

• Store in grounded, properly designed and approved vessels and away from incompatible
materials

• Store according to applicable regulations for flammable materials for storage tanks,
containers, piping, buildings, rooms, cabinets, allowable quantities and minimum
storage distances.

• Use non-sparking ventilation systems, approved explosion proof equipment and

intrinsically safe electrical systems.

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 • Have appropriate extinguishing capability in storage area (e.g. portable fire
extinguishers - dry chemical, foam or carbon dioxide) and flammable gas detectors.

• Keep adsorbents for leaks and spills readily available

• For bulk storages, consider use of floating roof or nitrogen blanketed vessels; where
venting to atmosphere is possible, equip storage tank vents with flame arrestors; inspect
tank vents during winter conditions for vapour / ice build-up; storage tanks should be
above ground and diked to hold entire contents

• Observe manufacturer's storing and handling recommendations.

PROCEDURE FOR HANDLING

• DO NOT allow clothing wet with material to stay in contact with skin.

• WARNING: Contact with water generates heat.

• Avoid all personal contact, including inhalation.

• Wear protective clothing when risk of exposure occurs.

• Containers, even those that have been emptied, may contain explosive vapours.

• Do NOT cut, drill, grind, weld or perform similar operations on or near containers.

Spillage Control

MINOR SPILLS

• Remove all ignition sources.

• Clean up all spills immediately.

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 • Drains for storage or use areas should have retention basins for pH adjustments and
dilution of spills before discharge or disposal of material.

• Check regularly for spills and leaks.

MAJOR SPILLS

• DO NOT touch the spill material.

• Clear area of personnel and move upwind.

• Alert Emergency Responders and tell them location and nature of hazard.

CHAPTER – 5

CORRECTIVE ACTIONS AND SUGGESTION

5.1 GOOD HOUSEKEEPING

In industry ‗Housekeeping‘ is not just a push bloom effort means much more than that. It
is practical method of increasing production, reducing and including employee morale. The
concept of a good housekeeping keeping is emerged from the result of a bad housekeeping which
is directly cause may accidents, poorly maintained plants and equipment‘s, improperly stored
materials tools & tackles, irregular or inadequate plant inspection, unsafe environment and
persons not conscious of all these are a potential of cause of many accidents. Majority of cause
viz. Stepping over or striking against objects handling goods articles use of hand tools falling on
the flat, pair etc. hot or corrosive substance are because of poor or bed housekeeping only. These
causes of accidents can be removed by good housekeeping occasional grand clean up setting in
order. To plan effectively typical attempts, which render a work place unsafe, must be
62
recognized.

1. Excessive material, waste in the work area

2. Congested aisles.

3. Overload waste container

4. Dirty walls, ceiling & windows

5. Disorder locker & wash rooms

6. Unclean machines.

7. Poor lighting

8. Electric wires, cables & air losses across to aisles

9. Spillage of oil, grease, acid etc. not proper marked IR knows the value of good
housekeeping.

It is necessary that workers should maintained good housekeeping.

Employees should be made to keep the area clean & arrange everything properly.

5.2 FIRE PREVENTION

The best way to fight with fire is to prevent them. Only one major fire accident is sufficient to
destroy every dream. The first aid fire protection appliances prevent fires from developing it to a
blaze if used properly at the appropriate stage.
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Depending on what material is n fire and how large the fire is one or more of these methods can
be adopted to put off the fire. In addition t necessary fire extinguisher, automatic fire, flame or
smoke detector and alarms, fire hydrants, monitors, sprinklers, sprays riser etc. should also use.
Fire fighting equipment‘s must be inspected and maintained regularly to keep it in good
conditions. Clear fire exit mark, fire escape stairs, fire warning, fire buckets and extinguished,
smoking notices should also provided.

Fire hydrant line should be painted in red color and drawing should be updated whenever it
modified, removed or installed.

5.3 TRAINING PROGRAM

Training deals with the development of skill in performance in industry it refers to the skilled
trades to the safety the training requirements in safety in the organization.

Level Needs Training

Helper Need for safety at work

Hazards connected with his ways

Guard operator Need for safety, safety requirements of his job

Supervisor and his Hazards on the operations supervised.

responsibility The technical skilled to identify and prevent them

Company‘s safety A broad knowledge of policy systems proceed and

responsibility for safety.

Techniques of supervisions.

Communication skill Human relation & responsibility for safety.

To meet the training needs it is necessary to plan and implement a comprehensive program for

64
training covering different levels.

On a minimize basis the training should include the following.

• As induction programs at on safety for new recruited at all levels (Employees transferred to
new job also)

• Safety appreciation programs at all levels.

• Training specified under status.

• Training program for specified groups identified as vulnerable (eg. Forklift truck drivers,
operators and supervisor in first aid and fire extinguishers.)

• Training program on specific topics.(eg notice)

5.4 USES AND CARE OF HAND TOOLS:

1. Select the right tool for the job.

2. Establish right work method.

3. Train the employee in the correct use.

4. Ensure that the supervision is alert and is not passive on safe working.

5. Introduce procedure for periodical inspection of all tools & replace defective tools.

6. Issue new tools liberty to replace defective once when reported by workrs.

7. Take simple precautions as dictated by common sense like keeping sharp tools in sheaths.

8. Give special attention to electrically & pneumatically operated tools.

9. Create & maintain a climate where safety in general & safety in the use of hand tools get
does respect.

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5.5 DISPLAY BOARD

The displays should be kept rotating in the company so the worker feel something new and get
tempted to read that different display board for different specific sharp is headed relating to the
hazards present in that shop so the worker can get clear ideas.

Display of injuries should be display day by day on the main gate to aware the worker of risk
related to his job.

5.6 GENERAL ASSEMBLY

General assembly is an effective practice to create awareness in the workers. In assembly

everybody‘s complains & suggestion for safety should take into consideration. Everybody should
have given the chance to represent their problems. If there as any accident the safety officer or
responsible person should bring it to the light how it is happened, why and when thus all can be
get aware of that accident & it would not be repeated.

5.7 COMPETITION

It is seen that competition is the best weapon to progress in every field. Safety can be motivated
by different contents like.

Safety Exhibition: this can prove a best idea to create awareness and safety amongst employees.

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When you gamble
with safety ...
You bet your life.

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