Two day national seminar on industrial safety

GITAM university 26-27 March 2014

Safety- A question of mind set
Dr. Y. Manohar Former Director, RINL/ Vizag Steel Plant & Sr Professor, HBS-GITAM University

What is mindset

Fixed mental attitude

General Safety Rules
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Certain facts

• An avg. of 200-250 No.s of Accidents / Yr. • Includes both Work place and Road Accidents • Fatal, Reportable, Non–reportable.

• For both Regular and Contractor employees
• Many more Near misses
8

Hazards in VSP
 Fire  Explosion  Gas poisoning  Slips, trips & falls  Electrical shock  Electrical flash over  Fall from heights  Hot metal burns  Burns due to other hot objects
9

Hazards in VSP
 Body part caught in moving machinery  Material handling hazard  Level crossing hazards  Cold burns (frostbite)  Noise  Dust  Radiation  Confined spaces  Working with chemicals  Transportation  Snake bites
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Hazards – Accidents – Causes
• If hazards are not put under control, Accidents will takes place. • Any Accident can only be caused by either/both of the following two reasons.. -

Unsafe acts
Unsafe conditions
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Accident ?
Any event that is
Unplanned Undesired Unexpected which results Or has potential to cause Death Bodily injury Ill health Loss of property Damage to equipment Damage to environment
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Unsafe Acts
X Standing below a hanging load. X Welding / Gas cutting without eye protection. X Jumping over a running conveyor. X Operating crane without permission. X Using compressed air for cleaning body. X Using oxygen for cooling. X Height work without safety belt.
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X Using welding rod holder without proper insulation. X Using damaged sling for X lifting loads. X Entering gas prone areas without permission. X Throwing down material from top without caution. X Running a loco at high speed X Carrying out elect S/D job without caution tag (Men-atwork) at panels.

Causes of Accidents-1 Unsafe Acts
• • • • • • • • • Ignorance Negligence Over confidence Shortcut methods Hurry & worry Horse play No concentration Communication gap Poor co - ordination • • • • • • • • •
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Not trained in the job Unauthorized person Violation of SOP/SMP Using Defective tools No PPEs Poor health conditions No P – T - W system Giving wrong / No signals Fatigue

Causes of Accidents-2
Unsafe Conditions
• • • • • • • • • • • • • Unguarded m/c Floor openings No hand rails Slippery floor Loose elect. Cables No body earth Working in gas areas Working at heights Obstructions on the path Absence of interlock Poor illumination Jungle growth Water / Oil leakage and stagnation • Poor operating condition of the equipment
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Safety ?
• State in which the risk of harm to persons or damage to property is limited to a tolerable level.

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Statutory Acts Applicable
• • • • • • • • Indian Factories Act-1948 AP Factories rules-1950 Indian Electricity Rules-1956 Gas Cylinders Rules-2004 Indian Explosives Act-1884 Indian Boilers Act-1923 Calcium Carbide Rules-1987 Workmen’s compsn Act - 1923 • • • • • • Indian Motor Vehicle Act-1988 Central MV Rules-1989 Petroleum Act1934, Rules 1976 Noise pollution Act - 2000 Chemical Accident Rules- 1996 The Static and Mobile Pressure Vessels Rules-1981 • The Environment( Protn.) Act - 1986

Many More …….
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Indian Factories Act 1948
Contains XI chapters and 120 Sections
Chapter III (sec 11-20) Chapter IV (sec 21-41) Chapter IVA (sec 41A-H) Chapter V (sec 42 -50) Chapter VI (sec 51-66) Chapter X (sec 92-106) Health Safety Hazardous processes Welfare Working hours Penalties for Offenses

Section 7A – Duties of Occupier Section 101 – Exemption of Occupier from liability
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Salient features of Indian Factories Act
• • • • • • • • • • Sec 21 – Fencing of Machinery 22 - work on/near M/c in motion 23 – Employing young persons 28 – Hoists / Lifts 29 – Lifting M/cs, ropes, chains.. 31 – pressure plant 33 – pits, sumps, floor openings 35 – Eye protection 36 – portable elet. Light cautions 37 – Explosve/Inflamable gases
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• 41A – Site appraisal Comittee • 41B – Disclosure of Info must • 41C – Occupier responsibility in relation to Haz. Processes • 41D – Power of Central Govt. • 41E – Emergency Standards • 41F – permissible Exposure limits of chemical substances • 41G – Workers participation in safety management • 41H – Rt of worker to warn about an imminent danger

Complying with the statutory provisions
• • • • • • • • • • • Appointing “Occupier” & “Manager” Accident Reporting and Investigation. Reporting of Electrical accidents to REA, Chennai Safety audits - Internal and External agencies Onsite and Offsite Emergency plans Material Safety Data Sheets (MSDS) SOP / SMPs and HIRA / Control measures Protocols - Hazardous Jobs Fire Fighting facilities Health Checkups – Eye, Ear.. Safety Trg. – Regular and Contractor Employees 21

COMPLYING WITH THE STATUTORY PROVISIONS

• • • • • • • • • •

Testing of all Pressure vessels, tools, tackles, Safety Belts …. Emergency Management Team. Mock Drills. “Permit To Work” System. DSC and CSC Meetings. Providing adequate Illumination. Supply of PPEs Interlocks Statutory Records update. Corrective and Preventive actions
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Safety promotional activities
• • • • • • • • • National Safety on 4th of March every year. Fire Safety Day on 14th of April every year. Suggestion scheme on safety. Shop floor safety talks. Safety skits, poster, slogan, Housekeeping… competitions. Quality circles for improving safety standards. Weekly review of safety activities of VSP by ED (W). Implementations of OHSAS – 18001. Nominating employees to National seminars, Workshops, symposiums, competitions, Trg. programs on safety.
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Accident prevention
• Ultimate aim of all these endeavours is to achieve.. The goal

Zero accidents

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Mindset

Correction Techniques
Union leaders  Supervisors and managers  Total worker population Continuous R&D Experience sharing Quality of PPE Modern Technology (eg:-CCTV)

Counseling

Coaching
Mentoring

Motivation
+ve Reinforcement

Total safety culture
PDCA RTR Walk the talk MWA I-I-I

‘she is owning it’: GM chief steps up to handle safety questions
(Business standard 20-03-14)

Past 10 years Faulty Ignition switch 12 Fatal 1.6 m cars recalled
Mary T Barra ,CEO-GM

Toyota to pay 1.2b $ over safety issues
(Business standard 20-03-14)

Disclosure by Toyota
Since 2009 10m cars recalled US-Toyota settlement

Thank You

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