INDUSTRIAL SAFETY AND

PREVENTIVE CONTROL
CONTENTS
 INTRODUCTION
 SAFETY IN INDUSTRY
 NEED FOR SAFETY
 ORGANIZATION FOR SAFETY
 SAFETY COMMITTEE
 SAFETY PROGRAMME
 SAFETY TRAINING AND INSTRUCTIONS
 ACCIDENTS
 CAUSES OF ACCIDENTS
 TYPES OF ACCIDENTS
 ACCIDENT PREVENTION
INTRODUCTION
 INDUSTRIAL SAFETY
Measures or techniques implemented to reduce the risk of
injury, loss and danger to persons, property or the environment
in any facility or place involving the manufacturing, producing
and processing of goods or merchandise.

 PREVENTIVE CONTROL
An internal control that is used to prevent undesirable
events, errors and other occurrences than an organization has
determined could have a negative material effect on a process or
end product.
SAFETY IN INDUSTRY
 The modern safety
movement started
around 1912 with the
First Cooperative
Safety Congress and
the organization of
National Safety Council
in U.S.A.
 From 1912 to the present time, remarkable advances have been
made in reducing the rate and severity of accidents.

 The importance of industrial safety was realized because every year

millions of industrial accidents occur which result in either death or
permanent disablement of the employees.

 Loss of lives and accidents costs gradually led to the formation of

Factories act, Office, Shops and railway Premises Act etc.

 Safety begins on the drawing board when in the original design of

tool or workplace layout, accident hazards may be built in or
eliminated.
 SAFETY results

1. from safe plant, processes and operation

2. by educating and training workers and supervisors regarding safe
practices on the shop floor.

 In an industry, safety may be considered

1. From mechanical side ( equipments, tools, etc.)

2. From the workmen’s compensation side
3. As a matter of training in and motivation towards safe work
practices for workers
NEED FOR SAFETY
i. Increasing rate of production
ii. Reducing production cost
iii. Reducing damage to equipment and machinery
iv. Preventing premature death of talented workers who
are an asses to the society
v. Preventing needless pain and suffering to its
employees.
ORGANIZATION FOR SAFETY
 In a small concern each shop supervisor may be responsible for safety in
his shop.

 Each shop supervisor may report to top executives as regards safety

matters.

 Since the shop supervisor has it main job to turn out production, he may
treat safety as a secondary aspect.

 For this reason sometimes safety function is taken care of by personnel

officer or general foreman.

 With the growth in the size of the industry, a full fledged safety department
may be created with the safety Director/Manager as its chief executive and
a number of persons under him at different levels.
SAFETY COMMITTEE
 It may consist of
executives,
supervisors and shop
floor workers.

 It aids in developing
safety consciousness
as well as it is a policy
making body on such
safety matters that
come before it.
 To get a maximum out of a safety committee

1. It should be assigned specific problems and duties

such as planning safety rules, publicizing them etc.
2. Its members should be asked to go on the shop floor
and watch what is being done about the safety.
3. It should be asked to report periodically and what
improvements have been made and what more can be
done.
SAFETY PROGRAMMES
 It tends to discover when, where and why accidents occur.

 It aims at reducing accidents and losses associated with them.

 It begins with the assumption that the most work-connected

accidents can be prevented.

 It does not have an end, rather it is a continuous process to achieve

adequate safety.

 It involves providing safety equipments and special training to the

employees.
 Elements of a safety programme

i. Support by top management

ii. Appointing a safety director
iii. Engineering a safe plant, processes and operations
iv. Educating all employees to work safely
v. Studying and analyzing the accidents to prevent their
occurrence in future
vi. Holding safety contests, safety weeks etc.
vii. Enforcing safety rules
A safety programme includes mainly four E’s
1. Engineering

2. Education

3. Enlistment

4. Enforcement
SAFETY INSTRUCTIONS AND
TRAINING

Safety training involves

a) Induction and orientation of new recruits to safety rules
and practices.
b) Explaining safety function, during, on job training
c) Efforts made by the first level supervisors
d) Formulating employees safety committees
e) Holding special employees safety meetings
f) Displaying charts, posters, films etc., to emphasize the
need to act safely.
Educating employees to develop safety
consciousness

Measures to be adopted to increase the awareness of a need for

safety in the environment of work are as follows :
i. Display of safety posters and films to remind workers of particular
accidents.
ii. Providing simple and convenient safety devices.
iii. Providing allowances to the worker for setting, removing and
replacing any necessary safety devices.
iv. Ask the employee from the first day he starts work to adopt safety
measures.
v. Hold safety competitions and award prizes to the winners.
vi. Create in employees a feeling of pride in safe work.
vii. Elaborate on safety theme.
Contd…

viii. Hold regular safety meetings.

ix. Lay out work areas to reflect safety considerations.
x. Mail information and literature pertaining to safety at
the homes of the employees.
xi. Report safety activities to all employees.
xii. Welcome all safety suggestions.
xiii. Cross-mark all accident areas.
xiv. Conduct safety training lectures periodically.
ACCIDENTS
 An industrial accident may
be defined as an event,
detrimental to the health
of man, suddenly
occurring and originating
from external sources,
and which is associated
with the performance of a
paid job, accompanied by
an injury, followed by
disability or even death.
 Economic aspects (cost) of accidents
o An accident can be very costly to the injured employee
as well as to the employer of the concern.
o There are some definite costs associated with the
accidents :

1. DIRECT COSTS
i. Compensation insurance, including payment and
overhead costs.
ii. Uncompensated wage losses to the injured employee.
iii. Cost of medical care and hospitalization
2. INDIRECT COSTS
i. Costs of damage to equipment, materials and plant.
ii. Costs of wages paid for time lost by workers not
injured.
iii. Costs of wages paid to the injured worker.
iv. Cost of safety engineers, supervisors and staff in
investigating, recording and reporting of accidents and
its causes.
v. Costs of replacing the injured employee.
vi. Cost of lowered production by the substitute worker.
vii. Cost of delays in production due to accident.
viii. Cost of reduction in efficiency of the injured worker
when he joins the concern after getting recovered.
CAUSES OF ACCIDENTS
 An accident is an unplanned incident and for
each such incident there is usually a specific
cause or causes if one could but discover them.

Causes of accidents

Technical causes Human causes

Mechanical factors Environmental factors Personal factors

 TECHNICAL CAUSES:

MECHANICAL FACTORS:

1. Unsafe mechanical design or construction

2. Hazardous arrangement
3. Improper machine guarding
4. Unsafe apparel
5. Detective agencies or devices
6. Improper material handling
7. Broken safety guards
8. Protruding nails
9. Leaking acid valve
10. Untested boilers or pressure vessels
 ENVIRONMENTAL FACTORS
1. Too low a temperature to cause shivering
2. Too high a humidity to cause uncomfort, fatigue and
drowsiness.
3. Defective and inadequate illumination causing eyestrain,
glares, shadows etc.
4. Presence of dust, fumes and smokes and lack of proper
ventilation.
5. High speed of work because of huge workload.
6. Too high a temperature to cause sweating and headache.
7. Inadequate rest pauses or breaks between working hours.
8. Noise, bad odour and flash coming from the nearby machinery,
equipment or processes.
9. Poor housekeeping.
 HUMAN CAUSES

PERSONAL FACTORS

1. Age
2. Health
3. Number of dependents
4. Financial position
5. Home environment
6. Lack of knowledge and skill
7. Improper attitude towards work
8. Incorrect machine habits
9. Carelessness and recklessness
10. Day dreaming and inattentiveness
11. Fatigue
12. Emotional stability
13. High anxiety levels
14. Mental worriness
15. Unnecessary exposures to risk
16. Non-use of safety devices
17. Working at unsafe speeds
18. Improper use of tools
TYPES OF ACCIDENTS
1. Near accident
2. Trivial
3. Minor
4. Serious
5. Fatal
ACCIDENT PREVENTION
 Prevention of accidents is a true humanitarian
concern
 Accident prevention is highly essential in an
industry in order to
1. Prevent injury to and premature death of
employees
2. Reduce operating and production costs
3. Have a good employer-employee relationship
4. High up the morale of employees.
 Accident prevention does not occur by itself; there
should be a consistent implementation of safety
measures and safety programmes emphasizing the
need for

1. Safe workplace layout and working conditions.

2. Safe material handling.
3. Personal protective devices.
4. Safety activities in the organization.
PERSONAL PROTECTIVE EQUIPMENTS
AND PROTECTIVE CLOTHING