Professional Documents
Culture Documents
UNIT-5
Today, advanced technology plays a vital role in the field of textile industry. Any
manufacturing unit employees five M’s that is Men, Machine, Material, Management
and of course Money. To get organizational success, managers need to focus on
synchronizing all these factors and developing synergies within and outside
organizational operation. In short, many textile companies are leveraging the
technological power to adding value to their business.
Risk management in a textile industry is attempting to identify and then manage threats
that could severely impact or bring down the organization. Generally, this involves
reviewing operations of the organization, identifying potential threats to the
organization and the likelihood of their occurrence and then taking appropriate actions
to address the most likely threats.
It has therefore become mandatory for the listed Industries to prepare a comprehensive
framework of accident risk management for assessment of risks and determine the
responses to these risks so as to minimize their adverse impact on the organization.
Goals/Targets of Safety:
Accident prevention
Accident control
Protection of human health/life
Protection of material and property
Protection of environment
All workmen as well as staff of the factory should be committed to safe work
environment and hence they should follow the basic principle of ‘safety first’.
The safety department of the factory is responsible for creating safe environment at
workplace. They are also responsible for creating and maintaining awareness on safety
aspects at factory premises. This is achieved by regular training programmes, display
of posters and notices at strategic locations, arranging documentary film shows related
to safety, on job training, daily safety round, recommendation for corrective action,
etc.
The Department should have formulated safety procedures and rules, depending upon
the nature of work carried out at respective location. These procedures allow the safety
personnel to periodically inspect equipments such as safety guards, cranes, lifting
tackles, etc.
Timely inspection should be there for the certificates of fitness of the equipment.
However, the factory has well laid procedure for accidents, which is as follows.
Managing Director
Safety Officer
Government Authorities
Multiplying any number by zero results in a product of zero, which means that an
extremely hazardous substance can be present with little risk of adverse effect, if
handled safely under proper conditions then the ‘exposure’ component of the risk
equation is driven towards zero. Similarly, the hazard component can be reduced to
zero even if there is a high probability of exposure, by changing the process design,
substituting less hazardous commodity, using a lesser amount of a chemical, etc. and
the recognition of vulnerability as a key element in the risk equation has also been
accompanied by a growing interest in linking the positive capacities of people to cope,
withstand and recover from the impact of hazards.
It conveys a sense of the potential for managerial and operational capabilities to reduce
the extent of hazards and the degree of vulnerability, which derives the total equation
of risk towards zero.
Risk assessment is concerned with determining those factors which are especially
dangerous and determining the likelihood of unacceptable toxic exposure. Risk should
be assessed against defined limits of exposure, established on the basis of tests under
appropriate conditions.
Risk Management – a decision-making process to select the optimal steps for reducing
a risk to an acceptable level. In the industrial context, it consists of 3 steps:
a. Risk assessment (evaluation),
b. Emission and Exposure control, and
c. Risk monitoring.
a. Mechanical Hazard
It mainly involves properties of machine parts or work pieces, such as:
a. Faulty design (Shape): It may cause injury to workman
b. Relative location: Confined location during repairs & maintenance
c. Mass and stability: May cause physical injury
d. Inadequacy of mechanical strength
e. Accumulation of energy inside the equipment: steam/ air /water pressure cause
injury to workman
f. During commissioning, operation, maintenance and decommissioning of Co-
generation plant following hazards are anticipated:
Crushing hazard, shearing hazard, cutting or severing hazard, entangling hazard,
friction or abrasion hazard and high pressure fluid injection or ejection hazard.
b. Electrical Hazard
Probable incidences for electrical hazards, could be
a. Contact of persons with live parts (direct contact),
b. Contact of persons with parts which have become live under faulty conditions
(indirect contact)
c. Approach to live parts under high voltage
d. Electrostatic phenomena
e. Thermal radiation or other phenomena such as the projection of molten particles and
chemical
f. Effect of short circuits, overloads, etc identified during construction, production and
maintenance.
c. Thermal Hazard
Probable causes of thermal hazards are -
a. Burns, scalds and other injuries by a possible contact of persons with objects or
materials with an extremely high or low temperature, by flames or explosions and also
by radiation of heat sources
b. Damage to health by hot or cold working environment
c. Thermodynamic hazard such as overpressure, under pressure, over-temperature,
under temperature need to be avoided by providing system management
1 Minor Failure results in minor system damage but does not cause injury to
personnel,
allow any kind of exposure to operational or service personnel or allow any
release of chemicals into the environment
2 Major Failure results in a low level of exposure to personnel, or activates facility
alarm
system
3 Critical Failure results in minor injury to personnel exposure to harmful
chemicals or
radiation, or fire or a release of chemical to the environment
4 Catastrophic Failure results in major injury or death of personnel
Whereas, if, there is a probability number of any particular cause/incident is 5 and its
severity is catastrophic then,
Risk involved in the hazard is 5x4 = 20
Thus, the Risk of those hazards scoring 20 are defined and considered as ‘Non-
acceptable Risk’
Mitigation measures or operational control procedures required for
such hazards identified is given below in Table 5.3
PHYSICAL HAZARDS
1 Noise Simple gear, Sound levels cause Isolation of the machine and Silencer
Continuous trauma to the cochlear mustbe kept.
geartrain, structure inthe inner ear. Inverted drive control noise in ring
Chain drive, It will cause high blood frame.
Bevel drive, pressure. Proper maintenance lubricating
Worm and worm It affects sleep and work controlnoise.
wheel performance
Variable drive.
2 Dust Cotton Causes Dust collector,
Fiber particles respiratory problems and Proper Housekeeping
causes Byssinosis Necessary PPE should were by worker.
3 Lighting High beam and Eye strain Proper lightning condition
Low beam of light Glaring and Provide safety goggles for reduce
Irritation of eye eyestrain for improper lighting
condition.
FIRE HAZARDS
1 Welding Welding sparks Spark ignition is very Restrict unauthorized person to do
operation dangerous. welding
2 Electrical short Improper If no trip occurs its get ACB (Air circuit breaker), MCB
circuit happens earthingand sparks and get fire. (motorcircuit breaker).
Insulations
3 Smoking Easily ignitable Easily gets fire Safety signs & workers must aware of
materials notusing any ignition product
4 Flammable Dyes It may be easily ignited To store the dye stuffs in safe place.
dyestuffs To maintain properly.
ELECTRICAL HAZARDS
1 Improper Poor Trip occurs Electric Avoid improper earthing and
Earthing and housekeeping shock looseconnection,
Moisture Improper circuit All circuits to be enclosed in a proper
connections circuit.
Proper housekeeping.
2 Input power Using low quality Cable melting & switch Input wire must be more power
cable exceeds cables. becomes heat thanoutput wire.
More output
3 Looping in the Improper looping Electronics PCB Avoid looping
running line. system ECB board Check the connection
4 Electrical Imprope Easily get fire with the Needs preventive maintenance
Maintenance r friction of motors Grease the motor frequently.
electrical
Maintenance.
CHEMICAL HAZARDS
1 Bleaching Chlorine powders Exposed to dangerous Suitable PPE, including eye-protective
levels of chlorine, a skin equipment
and eye irritant Use personal protective equipment
Dangerous pulmonary
Tissue irritant causing
delayed lung oedema.
2 Corrosion Alkalis and acids Expose the workers to Protective clothing should be cleaned
the risk of burns and atregular intervals
scalds
ERGONOMICS HAZARDS
1 Uncomfortable Improper height Pain in hand and legs. Importance to ergonomics
work station Practicing shifts
and height. Provide height adjustable chairs so
individual operator can work at their
preferred work height
2 Repetitive Repeating of work Wrist, Neck, Shoulder, Proper working procedure
strain injuries Neck, Knee, Angle. Raised platforms to help operators
reachbadly located controls
Proper orientation of machine to
preventsquatting posture
PSYCHOLOGICAL HAZARDS
1 Not interested Physiological Trauma Give counseling.
to work problem Anxiety disorder
Bipolar and
Relateddisorder
Neurodevelopmen
tdisorder.
2 Production Stress to High blood pressure Set achievable Target.
target theworker Nervousness and tensions
Uncooperative attitude
Digestive problem
The following suggestions can be made to improve the safety and health
conditions in textile units:
The seats of the workers and the tables should be well aligned in
height so that there is no musculoskeletal strain.
There should be proper lighting at the place of work so that eye strain
can be avoided.
Machinery should be well maintained in order to reduce the
level of noise. If necessary, certain parts of machines can be
replaced.
In case the noise level cannot be controlled, workers should be
provided with earplugs so that exposure to noise can be reduced.
Workers can be rotated within jobs so that they are not faced with
continuous noise exposure for a long period of time.
Strategic Planning: This involves preparing for disaster threats from the long-term
perspective that is those, which are not to occur immediately, but could take place
in future.
Reporting: Each level in the organization reports to the next higher level. For
example in government, the top management reports to the political executive and
thereby to the Parliament.
There are certain types of materials which are required in large quantities during
disasters such as food grains, medicines etc. Use of inventory control techniques
such as ABC (Always Better Control) and VED (Vital, Essential and Desirable)
analysis can facilitate the task of inventory control. For example, items such as
chlorine tablets, band-aid and cotton are required in large quantities during
disasters. Similarly there are vital items such as milk powder, medicines and water.
ABC analysis helps in determining high consumption, medium consumption and
low consumption value items.
A disaster manager needs to catalogue, categorize and record the logistic
requirements for pre, during and post-disaster situations. This can include making
an inventory of:
The following aspects need to form part of a logistics management plan formulated
by the disaster manager:
Logistical requirements such as fuel, oil, tents, materials for cleaning and
sanitation and other supplies such as food, water, etc.
Procurement of supplies
Food security
Inventory of intended beneficiaries
Warehouse facilities
Modes of transport
Methods of distribution including dry ration and wet ration