• Industrial safety is primarily a management Terminology 1. The personal injury (final domino) occurs only as ❖Embrace consistency.
(final domino) occurs only as ❖Embrace consistency. Be consistent in all areas
activity which is concerned with
reducing, controlling and eliminating hazards from
the industries or industrial units.
• The danger of life of human being is increasing
with advancement of scientific development in
different fields. • The importance of industrial
safety was realized because every millions of
industrial accidents occur which result in
✓ death
✓ temporary or permanent disablement of
employees
✓ large amount of losses resulting from danger to
property and wasted man hours.
Need for Safety
1. Social Need
• The accident causes social loss in great
magnitude in form of suffering, loss of
earning capacity and cost due to disturbance to
economic efficiency. The economic costs are more
tangible.
2. Management Need
• Management bear huge loss due to accident.
Cost of accident is of two typeDirect & Indirect
cost. Indirect cost is several times more than
Direct Cost. Direct cost include medical expenses,
compensation to the injured or their
families.
3. Legal Need
• As per The Building & other construction Act
1996, Factories Act 1948 and
several other related Acts & rules the general duty
of the employer is to
ensure Health & Safety of his employee & protect
the Environment.
4. Humanitarian Need
• The Humanitarian reason for prevention of
accidents is based on notion that it
is duty of every person to ensure safety of his
fellow men
Safety and productivity
• In the world of manufacturing and construction,
there are mainly
three pillars
1. Safety 2. Quality 3. Productivity
• These three are interlinked with each other.
1. Safety improves quality and productivity.
• When operations are unsafe, they aren’t well-
managed.
• Employees will not be motivated nor mindful.
• Quality and productivity both suffer when
employees are under stress, unsatisfied, or
unable to complete their mission.
• But when businesses are safe, it frees up
employees to focus on their quality and
their productivity.
• The safer the organization is, the less frequently
the organization will experience
large scale disruption.
2. Quality improves safety and productivity.
• Safety is a measure of conscientiousness and
proactiveness.
• High quality work means better results and
better products.
• The higher quality the work, the fewer reworks
are needed, and the
greater overall productivity is.
• When quality is high for a business, it can be
assumed that standards
for the business are generally high, including
safety equipment, safety
software, and safety processes.
3. Productivity improves safety and quality.
• Carelessness is often what results in safety
issues.
• With the appropriate (and productive) safety
processes, safety can be
improved, and quality can be improved as well.
• The more productive employees are, the less
likely they are to cut
corners on things like safety processes.
• The more productive they are, the more likely
they are to put extra
attention into the quality of their work.
• Safety: Control over hazards or Freedom from
unacceptable risk of harm.
• Accident: Undesirable event that arises to injury,
fatality, ill health, property damage or
combination of these.
• Hazard: Source, situation, or act with a potential
for harm in terms of human injury or ill health or
property damage or a combination of these all.
• Reportable injury: If a person sustained injury &
unable to resume his duty within 48 hours.
Terminology…
• Risk: Combination of Probability & severity of
specific hazardous event occurring.
• Non Conformance: Any deviation from work
standards, practices, procedure, Regulations,
Management System requirements etc, that could
be either directly or indirectly lead to injury or
illness, damage or loss to property or combination
of these.
• Dangerous occurrence: Any occurrence of
serious nature which could have caused injury/
death to person but did not, is called Dangerous
occurrence.
• Near Miss: A narrow escape of injury or any
harm
Unsafe Act
• Committing mistake by person or Any act that
may lead to accident is
known as unsafe act.
Following are example of unsafe act:
1. Working without wearing safety helmet &
safety shoes
2. Working at height without wearing full body
harness.
3. Taking rest in working areas
4. Working or taking rest below Hanging Load
5. Over speeding
Unsafe Act…
6. Operating equipment without qualification or
authorization.
7. Lack of/or improper use of PPE
8. Operating equipment at unsafe speeds
9. Failure to warn
10. Bypass or removal of safety devices
11. Using defective equipment
Unsafe condition
• Any sources or situation or condition that have
potential to create accident
is known as unsafe condition.
Following are example of unsafe condition:
1. Damage welding cable
2. Mechanical guard not provided on rotating
parts
3. Defective sling or lifting equipment.
4. Defective work platform
5. Floor or platform opening, pits etc.
6. Poor housekeeping
7. Defective tools, equipment or supplies
8. Inadequate supports or guards
9. Congestion in the workplace
10. Inadequate warning systems
11. Hazardous atmospheric conditions etc
1. Domino Theory…
• Heinrich related these five stages to five
dominoes standing on edge in a line
next to each other, so that when the first domino
falls it automatically knocks
down its neighbour which in turn knocks down its
neighbour and so on. • Removal of any one of the
first four will break the sequence and so prevent
the injury.
• Heinrich suggested that accident prevention
should aim to remove or eliminate
the middle or third domino, representing the
unsafe act, mechanical or physical
hazard, thus preventing the accident.
• The five factors or stages in the sequence of
events are:
1. Ancestry and social environment, leading to
noble
2. Fault of person, constituting the proximate
reason for
3. An unsafe act and/or mechanical hazard, which
results in
4. The accident, which leads to
5. The injury
a result of accident.
2. An accident occurs only a result of a
personal/mechanical hazard.
3. Personal/mechanical hazard exist only through
the fault of careless persons or poorly
designed or improperly maintained equipment.
4. Fault of persons are inherited or acquired as a
result of their social environment or
acquired by ancestry.
5. Environment is where and how a person was
raised and educated.
• On safety audits and inspections, when the risk
of an accident has been identified,
possible event chain should be investigated and
action taken to remove potential cause.
• Domino Theory – Corrective Action Sequence
(The three “E”s)
1. Engineering
• Control hazards through product design or
process change
2. Education
• Train workers regarding all facets of safety –
Impose on management that attention to
safety pays off
3. Enforcement
• Insure that internal and external rules,
regulations, and standard operating procedures
are followed by workers as well as management.
2. Human Factors Theory
• Heinrich posed his model in terms of a single
domino leading to an accident. The premise
here is that human errors cause accidents. These
errors are categorized broadly as:
❖Overload –
• The work task is beyond the capability of the
worker
• Includes physical and psychological factors
• Influenced by environmental factors, internal
factors, and situational factors
❖Inappropriate Worker Response –
• To hazards and safety measures (worker’s fault)
• To incompatible work station (management,
environment faults)
❖Inappropriate Activities
• Lack of training and misjudgement of risk.
3. Accident/Incident Theory
• Extension of human factors theory.
• Here the following new elements are
introduced:
• Ergonomic traps – component of the design
contributes to an accident.
✓These are incompatible work stations, tools or
expectations (management failure)
• Decision to err – Unconscious or conscious
(personal failure)
• Systems failure – Management failure (policy,
training, etc.)
Common Responsibilities of the Safety Team
Following are seven common responsibilities of
the safety team
❖Focus on learning. There should be a
continuous, conscious effort to learn and
improve. We learn from four distinct areas:
1. Failure: This is one of the most common ways
we learn because when something goes wrong,
we must fix it.
2. Near misses: A near miss can be defined as an
unexpected event that occurred outside the
identified hazards and planned work procedure,
but during which no one was injured and no
property was damaged.
3. Positive work experiences: These occur when
employees work within the established and known
safety expectations, getting the job done without
incident.
4. Observations: During observations, attention is
paid to work habits and management abilities,
including attitude and behaviour.
Common Responsibilities of the Safety Team…
❖Be committed. Each member of the safety team
must be committed to being the leader they are
expected to be, which includes consistently
demonstrating a good attitude and appropriate
behaviour as well as being transparent and
accountable.
❖Communicate. Effective communication leads to
learning, understanding and improvement by all
parties.
of your responsibilities as consistency leads to
sustainable habits regardless of your role.
Common Responsibilities of the Safety Team…
❖Be understanding and tolerant. People will make
mistakes. An error can be an opportunity to
identify safety gaps and improve working
behaviours.
❖Have patience. Even attitude and behaviour
changes require patience. Change takes time.
❖Follow through. If you say you are going to do
something, do it; that proves you mean what you
say and helps build trust
Common Responsibilities of Executive and
Operations Management
1.Respond to failure.
• Put in the work to determine the causes of a
failure, no matter the severity or consequence.
• You may identify gaps that could lead to
improved working conditions and/or management
abilities.
2.Lead with the appropriate demeanour.
• As a manager, how you respond to safety
requirements – whether verbally or physically
through facial
expressions and body language – communicates
your interest in safety to those you lead.
• It also gives those you lead permission to
respond in a like manner. Choose your demeanour
wisely.
3.Celebrate victories of all sizes.
• Doing so encourages and inspires those you lead
to continue the effort to meet safety expectations.
• Always keep an eye out for opportunities to
applaud employee efforts.
Executive Management Responsibilities
1.Care
• Before anything else, you must care about those
who work for and with you. There is a
difference between an employee and a person.
• When you consider someone an employee, the
implication is that they are replaceable, like a
tool or machine.
• When you consider someone a person, you are
more likely to see them as an individual who
has value and meaning.
• Humans are not replaceable, and they deserve a
safe working environment – which an
employer, by law, is required to provide.
2.Culture.
• Setting the organization’s cultural expectations
means establishing the overall expectations
for safety within the organization, and then
providing the means for maintaining those
expectations.
Operations Management Responsibilities
1.Evaluate.
• Keep production, quality and safety in mind
when planning a job or task.
• Observe the people you lead to make sure they
understand their jobs and can perform them
effectively. • Confirm they have the appropriate
training before any work begins.
2.Ensure.
• Make sure the people you supervise understand
the hazards associated with the work to be
performed, the safety requirements that apply,
the proper procedures to be followed and the
appropriate equipment needed to safely
perform the work.
Operations Management Responsibilities…
3. Engage.
• Communicate effectively and consistently so
that the people you lead fully understand
what is expected of them.
• Create an environment in which everyone is
empowered to ask questions, make
recommendations and respectfully remind other
employees, including managers, when a safety
correction needs to be made.
4. Enforce.
• It means making sure the people you lead are
following all safety expectations.
• If they are not, it is your obligation to work with
them to make the necessary corrections.
Worker Responsibilities
1.Determine.
• They must be sure that they fully understand
their tasks before starting, especially any
associated hazards.
2.Decide.
• They must decide if they have the training,
knowledge, tools, PPE, equipment and time to
complete their tasks safely.
3.Do.
• They must use the right tools and equipment
and follow the appropriate safety procedures to
complete their tasks.
• Workers are obligated to communicate when
necessities for safety are not available, when
they have ideas for improvement and when they
identify opportunities for correction.