Quality Circle Forum of India

Environment Health and

Safety Improvements
Success Story. TEAM MEMBERS:-
1) Shreyas Kulkarni
2) Dhananjay Chaudhari
3) Ajinkya Gaikwad
4) Manish Vishwakarma
5) Bhausaheb Kasbe 1
 INDEX

Sr. No. Content Page No.

1.0 History 3
2.0 Introduction 4
3.0 Case- 1 Problem Description 5
4.0 Case- 1 Problem Solution 6
5.0 Case- 2 Problem Description 7
6.0 Case- 2 Problem Solution 8
7.0 Case- 3 Problem Description & Solution 9
8.0 Case- 4 Problem Description & Solution 10
9.0 Case- 5 Problem Description & Solution 11
10.0 Case- 6 Problem Description & Solution 12
11.0 Cost Of Construction / Cost of Construction / Cost per person -1 13
12.0 Cost Of Construction / Cost of Construction / Cost per person -2 14

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 1.0 History-

• This study aim towards the safety enhancement done in design of ready made
safety equipment (Case 1) i.e. Roof Life Line System

• Construction and installation of safety equipment for maintaining the building

structural (Case 2) i.e. For the cleaning & maintaining building roof.

• Systematic strategy towards the protection of environment (Case 3, Case 4, Case

5 & Case 6) i.e. To reduce / prevent emission of harmful gases to environment by
reduce, reuse and recycle mind-set.

• Improvement action taken towards health hazards during gate entry (Case 7,
Case 8 & Case 9) i.e. For containment of spreading harmful microbial from one
person to another.
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2.0 Introduction :-
• The safety enhancement of “Roof Life Line System” of SSD building terrace roof

• Construction and installation of safety equipment to Facility building roof cleaning activity.

• Used batteries scraping and disposal problem.

• Non moving production inventory packing Square tubes packing frames scraping issue.

• Incomprehensible use of Ac in offices during winter which results in waste of electricity.

• At company main gate people come in close contact which results in spreading of harmful
microbial causing health hazards.

• The security person come in contact with the outsider while taking their body temperature, this
may lead spreading of contagious disease causing health hazard.

• Enclosed office of IP bay 1, members feel suffocated & unwell due to stale air.

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 Improvements in Safety :
1.0 Case-1Problem Statement
• “Roof Life Line System” of SSD building terrace roof need additional
safety while crossing over to reach another side, due the substantial
height of the roof
Time period consumed for implementation-90-100 days
Hazard Type- Physical Hazard.
Consequence:-
1. Body stress.
2. Lack of confidence, Fear, dizziness, Acrophobia
Risk level Score of previous procedure:- Probability x
Consequences.
Risk level Score:- 2x4= 8
Tool / Technic Used To Solve The Problem:- Brainstorming
Steps:- 1) Gather all the team members of department in circle. Brainstorming
2) Titled the problem on the display board and asked each one member to write their ideas on
board below the title.
3) Repeat the turn of members until all have given-up & maximum idea are recorded on board,
now sort the idea with similarities & discuss the pros and cons of top similar ideas.
4) Thus finally the solution is obtained with most pros and least cons idea. 5
 Improvements in Safety :
Top ideas obtained in brainstorm were as follows:-
1) Restriction to specific manpower
2) Use cherry picker instead of life line system to reach other side
3) Use big ladder from ground floor to terrace
4) Providing safety rope rail to roof safety life line system
3.0 Case-1 Solution Of Problem:-
Constructed Enhanced safety Rope Rail above SSD
terrace for roof crossover to reach another side of roof
Cost Sheet Of Safety Rope Rail
Sr. No. Material Description Rate QTY Total
1 Wire Rope 25 / m 100 m 2500
2 Turn buckle Hook & Eye, Thimble (Kit) 1000 /Kit 16 Kit 16000
3 Vertical Support - Square Tubes 35 / feet 16 feet 630
4 Welding Consumables 350 / pack 1 pack 350
2 Person Deployed for 4 Days 8000
Safety Rope Rail Cost Of Construction RS 27480 /- Approx.

Advantages:-
1) Improved safety
2) Improved confidence
3) Hazard minimized

Risk level Score after improvement:- 2 x 2 = 4 i.e. 50 % reduced Enhanced Safety Rope Rail to Roof Life Line
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 Improvements in
Safety :
2.0 Case-2 Problem Statement
• No provision for house keeping person to clean the
facility building roof from bottom side.
Time period consumed for implementation-90-100
days

Hazard Type- Physical Hazard.

Consequence:-
30 feet
1. Body stress.
height
2. Poor work quality.
Tool / Technic Used To Solve
The Problem:- Brainstorming

Previous Roof Cleaning

Procedure :-
The house keeping person used to climb on two step ladder and
clean with mop stick, but this was unsafe as if the ladder would
imbalance it could case sever accident due to the substantial
Riskneeded
height, so one extra person level Score:- 2x5=
to avoid this happen. 10 Facility Building Roof Height
7
 Improvements in Safety :
3.0 Case-2 Solution Of Problem:-
Constructed and installed safety Elevator for monthly
roof cleaning activity of facility building roof from
bottom side.
Cost Sheet Of Safety Elevator
Sr. No. Material Description Rate QTY Total
1 Guide Rail 250 / m 25 m 6250
2 Guide Wheel 300 / piece 2 nos 600
3 Vertical Support - Square Tubes 20 / feet 16 feet 320
4 Welding Consumables 350 / pack 1 pack 350
2 Person Deployed for 8 Days 16000
Safety Rope Rail Cost Of Construction RS 23520 /- Approx.
Roof Cleaning Procedure after installing Safety Elevator:-
Now the house keeping person aboard in the elevator, with proper
PPEs, safety harness and with height work permit raised.
Advantages:-
1) Improved safety
2) Improved confidence
3) Hazard minimized
4) Improved work quality
5) Easy for maintenance thus increased life.
Risk level Score after improvement:- 2 x 2 = 4 i.e. 50 % reduced
Safety Elevator 8
 Improvements towards Environmental Protection :
3.0 Case-3 Problem Statement:-
Energy Conservation, Reduce emission of harmful
gases and carbon foot print, Reduce-Reuse & Recycle.

3.0 Case-3 Solution Of Problem:-

1. Use of rechargeable batteries in place of ordinary batteries.
• 98% of batteries bought in the India are not recycled and end up in landfills. When taken to landfills,
most batteries release harmful metals such as mercury, lead and cadmium into the environment
causing soil contamination and water pollution.

• We have started using re-chargeable batteries for temperature guns and

Medicare equipment’s this has reduced environmental impact by using only
10 rechargeable batteries instead of 120 ordinary ones. Batteries Disposal

2. Reuse of metal square tubes for fabrication projects.

• We re-used Metal squares from Non moving production inventory
packing Square tubes packing frames for many fabrication projects.

1. Door enclosures for piston valve area racks

2. Pre-setter machines enclosure

3) Beds for people staying In Premises during lockdown.

4) Small modifications to workstations and cupboards, guards for machines

etc..
Metal square tube fabricated projects 9
 Improvements towards Environmental Protection :
4.0 Case- 4 Problem Statement:-
Energy Conservation, Reduce emission of harmful gases and carbon foot print, Reduce-Reuse & Recycle.
4.0 Case- 4 Solution Of Problem:-
3. Use of wall fans to reduce AC consumption during winter.
• During winters AC temperature maintained at 28 degree Celsius to
avoid suffocation
• We installed 10 wall fans; resulting into lesser consumption of power by
500-600 units/month keeping circulation intact with open windows.

• 0.8 kg CO2 per unit of energy generated i.e. 510 kg

per month CO2 emission saved. Use of wall fans to reduce AC consumption during winter.
5. Use of VFD and Cut off through PID controller to
save power.
• Use of VFD to run at optimal operating frequency i.e 25-28 hz
which was earlier 50 Hz(full speed).
• In addition cut off added for DO level above 3 ppm which was
earlier 4ppm.
• This has impacted in more than 50 percent savings in
electricity.
• i.e. 2000 units * 0.8 M.F = 1600 kg of CO2 emissions saved
per month.

VFD to Cut off through PID controller to save power.

10
 Improvements in Health Hazards :
5.0 Case- 5 Problem Statement:-
Maintaining social distancing at main gate entry to
avoid the spreading of harmful microbial in the
current COVID-19 pandemic

1. Case-5 Solution Of Problem:-

1. We installed safe distance alert system at entry main
gate with collaboration of industry college & with help of
VIT Pune.
Safe distance alert system
2. Use of automatic temperature sensor at entry main gate
to reduce cross contamination
• Safety Improved of security person taking the readings.

• Beep alerts for overshooting temperatures.

Benefits / Advantages:-
• Increase accuracy in temperature Screening.
• Man Hours Saved i.e. 30 Min / shift = 1.5 hrs / day x No. of
days from installation i.e. 180 days, Therefore total Man-hours
is 270 Hrs
• Prevented the Spreading Of hazards Microbial
Before After 11
 Improvements in Health Hazards :

6.0 Case-6 Problem Statement:-

• Enclosed office of IP bay 1, members feel
suffocated & unwell due stale air.

1. Case-6 Solution Of Problem:-

3. Introduced Fresh air supply system to mask to

eliminate stale air

• Members sitting in closed spaces for longer duration, were

susceptible to recirculated air of the room which was a
hazard in these corona times.

• We introduced a system wherein they would get direct fresh

air to the masks.

Fresh air supply system to mask

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 Cost Of Construction / Cost of Construction / Cost per person :
• Though safety should not be counted in cost, but cost of construction and cost saving figures gives us
an value estimate to replicate the same ideas.

50+ RS RS
Users 27480 550
1) Enhanced Safety Rope Rail to Roof Life Line
Cost of Construction Cost to per person
No. Of Users

50+ RS RS
Users 23520 470
2) Safety Elevator For Building Roof Cleaning
No. Of Users Cost of Construction Cost to per person

3) Use of rechargeable batteries in place of use and throw 500+ RS RS 8

batteries Users 3600

No. Of Users Cost saved per person

Cost Saving
4) Reuse of metal square tubes for fabrication projects.
50+ RS RS
Users 87000 1740

No. Of Users Cost Saving Cost saved per person

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 Cost Of Construction / Cost of Construction / Cost per person :

100+ RS RS
5) Use of wall fans to reduce AC consumption during winter. Users 6340 64

No. Of Users Cost Saving Cost saved per person

6) Use of VFD and Cut off through PID controller to save power. 500+ RS RS
User 12000 24

Cost Saving Cost saved per person

No. Of Users

7) Safe distance alert system 500+ RS RS 6

Users 3000

No. Of Users Cost of Construction Cost to per person

8) Automatic temperature Sensors 500+ RS RS

Users 22500
45
Cost saved per person
No. Of Users Cost Saving

9) Fresh air supply system to mask 50+ RS RS

Users 6000 120

No. Of Users Cost of Construction Cost to per person

14
THANK YOU

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