Guidance Document Machine & Chemical Safety

1. Employment practice
• Training on Accident Prevention and Warning signs, Hazard Communication
Labeling and , Material Safety Data Sheets (MSDSs), awareness, emergency
chemical spill procedures

• Training procedures must take into the OH&S risks and also account for differing
levels of responsibility (authorized vs. awareness training), educational level and
language skills.

2. Accident / First Aid Program - No Accident/Incident Log

• The company must establish and maintain systems to monitor and measure it's
Occupational Health and Safety performance on a regular basis. These systems
must provide for the measurement of: Number of occupational injuries and
illnesses cases reported with reference to chemical handling and spillage. There
must be an updated system to measure, monitor and record the number of
occupational Injuries and illness cases reported due to chemical spillage or use
of hazardous chemicals.

3. PPE / Chemical Safety –

No appropriate PPE Emergency Preparedness and Response procedure
• Emergency Preparedness and Response: The organization must identify and
evaluate its hazards in a written plan to determine the potential for serious
incidents or emergency situations and the appropriate response. Example: An
emergency situation could result if ammonia were to be released from a
neighboring industrial facility.
• The emergency response procedures must include methods for evaluating the
effectiveness of the program and revising the program based on the results of
an actual emergency.
 Other protective equipment not available to protect against chemical, thermal or other
physical hazards.
• Other protective equipment shall be provided for employee use to protect them
against chemical (i.e., gloves, aprons, boots, etc.), thermal (i.e. heat resistant
gloves, smocks, pants, hoods, etc.), or other physical hazards (i.e., hard hat,
bump caps, floor mats, steel-toed boots, electrical protective equipment, etc.)

4. Hazardous Liquids (e.g. Flammable and Acid-based Liquids) - Hazardous liquids not stored in
appropriate (durable and compatible) bulk, drum and container storage.
• Bulk storage tanks must be of durable construction, compatible with the
chemicals stored and designed in accordance with international standards
• Where highly flammable liquids (flashpoint less than 22.8°C 73°F) are stored in
large portable containers (e.g. IBC’s, cubitainers, etc), these containers must be
of metallic construction with metal valving. Valves must be self-closing. Where
material incompatibility prevents this then metal clad plastic lined units may be
used
No standard operating procedures (SOP) for handling of flammable liquids available at site.
• Flammables must be stored away from oxidizing agents and other combustibles.
• Adequate fire protection must be provided as per applicable national/local law.
• Formal standard operating procedures must be in place including the
supervision of unloading by a site employee
• Individual containers must be clearly marked to indicate their contents and the
degree of flammability.
• Appropriate warning signs must identify stores and areas containing significant
quantities of flammable or combustible substances.
• All process vessels used for flammable liquids must be metallic and bonded to
earth and static control measure must be implemented including anti-static
flooring; anti-static clothing and static dissipative (SD) footwear.
• Areas where more than 50 liters of flammable liquids are handled or used must
be subject to a hazardous area classification exercise and appropriate control of
ignition sources implemented

No list of Hazardous (Flammable and Acid base) liquids being used at site is available.

• Factory should maintain a list of hazardous liquids (Flammable and Acid base)
being used at site.
 No training record for the employees involved in handling of Flammable liquids available.

• Adequate training and knowledge of the properties of flammable liquids are

essential for their safe storage and handling. This training must be provided by
management to all staff who will come into contact with stored flammable
liquids.

No preventative maintenance programme put in place for flammable liquid systems and
equipment installed in hazardous (classified) locations
• A preventative maintenance programme must be put in place for flammable
liquid systems and equipment installed in hazardous (classified) locations.
Hazardous (classified) locations are defined as those areas "where fire or
explosion hazards may exist due to flammable gases or vapors, flammable
liquids, combustible dust, or ignitable fibers or flyings.

5. Equipment Safety –
No Maintenance Records (Safe Machine operation, Lock Out Tag Out (LOTO) Systems,
Cleaning Lubrication Tightening and Inspection (CLTI) check list, Machine Maintenance record,
Root Cause Analysis (RCA) of frequent incident/accidents.)
• Safe Machine operation, Lock Out Tag Out (LOTO) Systems, Cleaning Lubrication
Tightening and Inspection (CLTI) check list, Machine Maintenance record, Root
Cause Analysis (RCA) of frequent incident/accidents. Factory should maintain
maintenance records along with maintenance schedule of all the machinery.
Factory should maintain CLTI checklist and monitor most frequent breakdowns
and also keep records of occupational health injuries occurred due to unsafe
machine operation along with Root Cause Analysis (RCA).

No Safety Guards (Rotating parts, dangerous cutting areas not guarded or protected.)
• Rotating parts, dangerous cutting areas not guarded or protected. All
production equipment and machinery at factories shall be routinely maintained,
equipped with guards or other protective devices and safely operated. All
production equipment and machinery at factories shall be routinely maintained,
equipped with guards or other protective devices and safely operated.

6. Electrical Safety - Poor Wiring/Circuit Box Condition (Inappropriately enclosed electrical

boxes.)
• Electrical panels and boxes as well as connections must be always covered and
have good insulation. They also need to be isolated from worker movements
and the floor area around well marked to ensure it is kept free of obstruction.
7. Material Handling –
Improper usage of equipment (Cranes, derricks, or other material handling equipment used
beyond rated loads or for other than designed purposes.)
• Cranes, derricks, or other material handling equipment used beyond rated loads
or for other than designed purposes. Material handling methods shall be
employed to prevent injuries.
The equipment shall be used following technical specification and must not
exceeding rated loads or be used for other than the designed purposes.
Equipment Requirements
- Posted load ratings
- Available fire extinguisher
- Adequate Clearance
- Current inspection
- Warning signs
Using Instructions must be available to the designated employees.

Improper usage of equipment (Forklifts, cranes, derricks or other material handling equipment
not inspected before use.)
• Forklifts, cranes, derricks or other material handling equipment not inspected
before use. Material handling methods shall be employed to prevent injuries.

8. Health and Safety Risk Assessment -Risk assessments relating to significant occupational
health & safety risks must be documented and then kept under periodic review.
• Occupational health and safety risk assessments must be undertaken, which
take into account previous operational experience plus the routine and non-
routine activities of all individuals working for, and the facilities and equipment
provided by the organization. Risk assessments relating to significant
occupational health & safety risks and proposed corrective and preventive
actions must be documented and then kept under periodic review.

9. Machine Safety Training - No appropriate trainings for safe machine operation, interlocking
and automatic shutdowns of machines, pasting of machine safety instructions in local
language.
• Training for safe Machine operation is mandatory. Factories shall provide
adequate safe Machine operation training and ensure that all production and
manufacturing processes are carried out in conditions that have proper and
adequate operations of Machines for the health and safety of those involved.
Wal-Mart will not do business with any supplier that provides an unhealthy or
hazardous work environment or utilize mental or physical disciplinary practices.
10. Machine Safety Committee - No Machine Safety committee.
• Factory should have machine safety committee, constituted of management,
worker representatives and maintenance team to address concerns related to
machine safety.

11. Material Handling Equipment - Inadequate safety of material handling equipment.

• Factory should have conducted Material handling equipments (like forklifts,
elevators, etc.) maintenance, obtained operating license / permit, provided
Safety alarms.

12. Pressurized/Compressed Equipment (Boilers, Compressors. Gas Cylinders etc.) - Inadequate

pressure vessel.
• Factory should have pressure vessel (Like air compressors, boilers, etc.) with
legal certificate (license or registration) to operate, regular inspection and
maintenance schedule and records.