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SAFETY INDUCTION FOR EMPLOYEE
WHY NEED ATTENTION ON SAFETY
1. Over 7700 people die each day from work-related accidents
or diseases – that’s nearly 2.78 million every year
2. Every 15 sec, a worker dies from a work related accident or
disease, and 153 people experience a work related injury.
These represent an enormous burden for organizations and
society as a whole, costing over 2.78 million deaths a year,
not to mention the more than 374 million non-fatal
accidents.
3. The burden of occupational injuries and diseases is
significant, both for employers and the wider economy,
resulting in losses from early retirements, staff absence and
rising insurance premium (3.94% global GDP or 2.99
trillion USD indirect and direct costs – failing to invest in
safety and health is nearly equal to the combined GDP of the
130 POOREST COUNTRIES IN THE WORLD)
4. Source: WWW.ISO.ORG
FUNDAMENTALS OF SAFETY
AND
ACCIDENT PREVENTION
Three essential ingredients in any
Organization
Man,
Machine
Material
MANAGEMENT
MACHIN
E
MATERIA
L
A Machine can be programmed, Material flow can
be controlled but Man can not be programmed or
controlled in democracy like us.
A quality or condition of being safe from
“danger, Injury, damage, loss,
accidents”
INDUSTRIAL SAFETY MEANS
Industrial safety refers to the
management of all operations and events
within an industry in order to protect its
employees and assets by minimizing
hazards, risks, accidents, and near
misses.
SIGNIFICANCE OF INDUSTRIAL SAFETY
Industrial accident causes a great loss to both the
Employer and Employee.
Cost of compensation
Cost of medical-aid
Cost of training a new worker
Cost of the lost time
Cost of Investigation
Cost of supervision &
inspections
Cost of the Govt. in terms of Factories Inspector & other
statutory authority
Cost of spoilage of materials Cost
of the damage of machinery
Cost of wages payable during injury
Cost of loss of morale
Cost of loss to the worker and his
OBJECTIVES OF INDUSTRIAL SAFETY
To prevent accidents in the plant by reducing the hazard to
minimum
To eliminate accident caused work stoppage and lost
production
To achieve lower workmen’s compensation and reduce all
other direct and indirect costs of accidents
To evaluate employees morale by promoting safe work
place and good working condition
To educate all members of the organization in continuous
state of safety mindless and to make supervision competent
and intensely safety minded.
GENERAL DEFINITIONS
Occ. Health: The protection of bodies and
mind of people from illness resulting from the
materials, processes or procedures used in the
work place Occ. Welfare facilities: Facilities
to maintain the health and well being of the
workers at the work place i.e. washing,
sanitation, resting area, drinking water,
lighting, café etc
Near miss: Incidents that could resulted
in an accident Stats – appx. 10 near
misses a minor accident
Dangerous occurrence: Near miss that could
lead to major accident – serious injury or death
Ex. Collapse of scaffolding or embankment
General Definitions
Unsafe Act: Act of people(s)that may
potentially cause harm to something
Unsafe Condition: Condition or circumstance
that may potentially cause harm to something
Reportable Accident:
Non-Reportable Accident:
“To expose to danger ,risk, chance of
accidents, loss
- A hazard is any source of potential
damage, harm or adverse health effects
on something or someone under
certain conditions at work.
-"Condition, event, or circumstance that
could lead to or contribute to
an unplanned or undesirable
event."
Overview of Hazards
What’s going on in your
workplace?
Images by: Diamond Rubber Products' photostream
CHEMICAL & DUST
HAZARDS
(cleaning products,
pesticides, asbestos, etc.)
BIOLOGICAL
HAZARDS
(mold, insects/pests,
communicable diseases, etc.)
ERGONOMIC
HAZARDS
(repetition, lifting,
awkward
postures, etc.)
WORK
ORGANIZATIO
N HAZARDS
Things that cause
STRESS!
OTHERS HAZARDS
(slips, trips and falls, faulty
equipment, etc.)
PHYSICAL HAZARDS
(noise, temperature
extremes, radiation, etc.)
“A possibility of danger or
harm”
What is risk?
Risk is the likelihood that a person may be
harmed or suffers adverse health effects if
exposed to a hazard.’
Difference between Risk &
Hazard
"hazard". A
The
term
is
often
confuse
d
wit
h
"risk
"
hig
h
voltag
e
power supply,
a
sample of radioactive material, or a toxic
chemical may present a hazard, meaning
that they present the potential for harm.
Risk indicates probabilit
y
of hazard causing
the harm.
Fundamentals of safety and accident prevention -final (1).pptx
INCIDEN
T
An event that could or does
result in unintended harm to
people and /or damage to
property and/or environment.
Incidents are divided into two
categories.
Fundamentals of safety and accident prevention -final (1).pptx
Fundamentals of safety and accident prevention -final (1).pptx
WHAT IS ACCIDENT
AN UNINTENDED, UNPLANNED
EVENT WHICH HAS THE POTENTIAL
TO CAUSE HARM OR INJURY.
AN INCIDENT WHICH CAUSES HARM
OR HAS POTENTIAL TO DO SO.
Industrial Accidents:
“Industrial Accidents are caused
by chemical, mechanical, civil,
electrical, or other process failures
due to accident, negligence or
incompetence, in an industrial plant
which may spill over to the areas
outside the plant causing damage to
life and property.”
Hazards/
Danger
Observable or predicted from knowledge

Risk
Not directly observable - probability of harm to system elements
being realised from exposure to hazards and danger.

Harm
Damage to system elements - long or short term

Accidents

Injuries Ill-Health Damage
Defects in
the
system
Existence of
Hazard
Employees to
error
Associate
d Risk
Accidents
occur
How do accidents occur
??
ACCIDENTS
CAUSATION
CAUSES OF ACCIDENTS
ACCIDENT CAUSES
INDIRECT CAUSE
DIRECT CAUSE
PHYSIOLOGICAL
UNSUITABILITIE
S
PHSYCOLOGICAL
UNSUITABILITIES
LACK OF
KNOWLEDGE
& SKILL
UNSAFE
ACT
UNSAFE
CONDITION
Causes of Accident
Direct Indirect
Unsafe Act
Unguarded or inadequately
guarded machines /
equipments
Defective conditions of
m/c’s, equipments, tools etc.
Unsafe methods of storing, piling
etc. Inadequate or incorrect
illumination Inadequate
Ventilation
Improper House Keeping-- things
not at their proper
places
Unsafe design or construction
of machines and
equipment etc.
Operating without
authority Bypassing safety
devices Operating at
unsafe speed
Using wrong tool /
equipment Unsafe Placing
Unsafe Loading
Taking unsafe position or
posture
Working on dangerous or
moving equipment
Not using PPE
Horse playing at work place
Causes
Unsafe Condition
Causes of Accident
Physiological
Unsuitability
’s
Indirect Causes
Poor eye sight
Hard to hearing
Intoxicated
Physiological disabled
Psychological
Unsuitability's
Negative
attitude
towards safety
Ignorance of safety
rules and
procedures
Frustration &
Conflict
Morale
Individual
differences
Acclimatization
Lack of Knowledge &
Skill`
Fire
Explosion
Toxic
release
Poisoning
Combinatio
ns of the
above
Major Threats
Major Consequences
 Loss of life / injuries
 Impact on livestock
 Damage to Flora/fauna
 Environmental Impact (air,
soil,water)
 Financial losses to industry.
Bhopal Gas Tragedy
Worst industrial disaster in history
2,000 people died on immediate
aftermath Another 13,000 died in next
fifteen years 10-15 persons dying
every month
520,000 diagnosed chemicals in
blood causing different health
complications 120,000 people still
suffering from
Cancer
Tuberculosis
Partial or complete blindness,
Post traumatic stress disorders,
Menstrual irregularities
Rise in spontaneous
abortion and stillbirth
IOC JAIPUR - 2009
slide 32 Uran
IOC JAIPUR - 2009
slide 33 Uran
IOC JAIPUR -
2009
ENVIRONMENT !!!
COST OF ACCIDENT
DIRECT COST –
Insurance Claims
Loss of Production or reduced
output
Product loss or damage
Damage (plant, materials,
premises)
Sickness cover/ sick pay
Medical treatment
Repairs to plant & equipment
Replacement of equipments

INDIRECT
COST
 Business interruption
 Product liability
 Loss of orders
 Legal
fees/fines/penalties
 Delay in production
 Start up cost
 Increased insurance
renewal costs
 Training replacement
 Cancellation of
orders
 Reduced
 Lossof profit
 Loss of corporate
image
 Cost of time spent on
–
 Investigations
 Supervisors assisting
victim
 Workers stopping to
discuss the incident
 Preparation of
reports
 Attendance on
court
The Cost of
Accidents
“Iceberg” analogy of costs Direct Cost
• Compensation
• Medical Expenses
• Equipment
damage
Indirect Cost
• Cost of Lost
time
• Production loss
• Over head &
administrativ
e expenses
etc.
HEINRICH THEORY OF ACCIDENT
CAUSATION
INJURY IS THE RESULT OF COMPLETION OF 5 DOMINOS
1. Social Environment.
2. Fault of the person
3. Unsafe Action / Unsafe
Condition
4. Accident
5. Injury
Domino no-3 i.e. Unsafe Acts & Unsafe
conditions are the main contributory
factor for accident causation.
Unsafe Acts – 88%
Unsafe Conditions –
10% Others – 2%
It indicates that 98% of accidents
can be prevented.
What is Unsafe Act, Condition & Near miss
8
3
Theories of Accident Causation
600 Near Miss / Unsafe conditions
300
No
Injuries
300
No
injury
29 Minor Injuries
LT
I
1
Major/
Fatal
Theories of Accident
Causation
1
Fatality
10
Minor Injuries
30
Property Damages
600
Near Miss / Unsafe conditions
Reporting and investigation of “NoIinjury accidents”, “Near misses”
can
improve the safety performance of a unit
Frank Bird analyzed 1.75 million accidents
in 1969
PRINCIPLE OF SAFETY MANAGEMENT
“Unsafe action / Unsafe condition & accidents
are only the symptoms of some thing wrong
in the safety management systems”.
“Safety should be managed like any other
company function.
“The key to effective line safety performance
is
management procedures that
fix
ACCOUNTABILITY”.
Hierarchy of Controls
Requires a physical
change to the
workplace
Requires
worker to
wear
something
Elimination/Substitution
Requires worker or
employer to do
something
Most Effective
Least Effective
Reasons for Accident Prevention
Accident
Preventio
n
1
Humanitaria
n
4
Lega
l
3
Socia
l
2
Economi
c
What could have prevented these
losses?
RISK CONTROL
MEASURES
Physical Protection
Procedural
Protection
Educational
Protection
•Strict & Rigorous approach in
following the Relevant Standards ,
Codes & Practices
•Built in Safety Devices and Safety
System
•Field Monitors for Different Toxic
Gases
Physical Protection
•Provision of Wind Cones
•PPE
•Passive Protection System
•Active Protection system
•Automatic Protection system
PROCEDURAL PROTECTION
•Fire Emergency Procedure
•Disaster Preparedness Plan
•Mutual Aid Scheme
•No Smoking Policy
•Investigation of All Accidents
•Hazard Identification through Safety
Committee, House Keeping Committee, Safety
audit Committee
•Conducting Plant Survey, safety survey
•Work Permit System
Contd.
• Safety promotional activities
•Information notes on unsafe
conditions
• MSDS – Material Safety
Data Sheet
•Annual Medical Check up of
Employees
•Safe Start up & Shut Down
Procedure
• Regular and Preventive
Maintenance
•Periodic testing of Fire Fighting
EDUCATIONAL
PROTECTION
•Periodic Training Program on Safety,
Fire Safety and Hazardous properties of
materials
•Mock Fire Drill
•Safety Manuals
•Health & Safety News Bulletins,
leaflets
•Safety Motivation schemes
•Plant Operating Manual
•Educating the Public Living nearby
SAFETY SYSTEM AT WORKPLACE
Safety Policy: To establish a safety policy as per
sub section 3 of section 7A (General duties of
Occupier) as per Factories Act 1948 &
M.P.Factories Rules 1962.
Purpose:
1. To eliminate the incidence of work related
injuries, diseases, fatalities, disaster and loss
of assets
2. Ensuring achievement of high level of
occupational safety, health and environment
performance through proactive approaches.
3. To enhance the well-being of the employee
Safety Organization
The Occupier shall employ such number of Safety officer as per
Section 40B of Factories Act 1948.
In every factory,
a. Wherein 1000 or more workers are ordinarily employed or
b. Wherein, in the opinion of the state Govt, any
manufacturing process or operating is carried on, which
process or operation involves any risk of bodily injury,
poisoning or disease, or any other hazards to health, to the
persons employed in the factory.
Conditions of service:
1. Where the number of safety to be appointed in a factory, one
of them shall be designated as a Chief Safety officer.
2. Safety officer shall work directly under the control of Chief
Executive of the Factory.
Roles and Responsibilities of Officers &
Supervisors
1. He/ She shall responsible for ensuring the health and safety
of their respective section
2. He/ She shall have to arrange to provide or made available
for required PPEs
3. He / She shall have to ensure the effective functioning of all
the emergency switches, trip switch, control mechanism or
any other mechanism provided for the purpose of worker
safety.
4. He/ She shall have to report all kind of accident to
immediate officer, Fire wing, Dispensary, safety department,
Factory Manager & Occupier
5. He / She Shall have to conduct accident investigation
6. He / She shall have to fill IOD form
7. He shall have to organize on the job training program
8. He shall have to follow work permit system
9. He shall have to display SOPs at designated location.
10. He shall have to depute their employees for safety training
Workers Responsibilities
1. The worker shall have to follow safety rules and regulation
2. To obey or follow the safety instruction by supervisor /
officer
3. To wear all PPE
4. To report near miss, minor & major accident to concerned
person
5. To identify unsafe condition and unsafe act
6. To cooperate with emergency rescue team at the time of
emergency
7. To all safety training program.
Employees participation
1. Safety committee meeting
2. Statutory function like National Safety week celebration
- Industrial Safety Day
3. Involvement in Accident prevention method
ACCIDENT/INCIDENT
MINOR ACCIDENT/
INCIDENT
MAJOR ACCIDENT/
INCIDENT
Responsibility of shift
supervisors / shift officers
Sectional In-charge
1.To inform safety department
and higher authority.
2.Implement the corrective
action to avoid similar kind
of accident in future
CONCERNED
SUPERVISOR/OFFICER
Accident reporting system chart
Reportable/Major accident: As per Section 88 of the Factories Act, 1948 if an accident occurs in any factory which causes death, or bodily injury by reason
of which the person injured is prevented from working for a period of 48 hours or more.
Non-Reportable / Minor accident: If any small injuries by reason of which the person injured is prevented from working for a period of less than 48 hours or
less is called as Non-Reportable accident.
Sectional In-Charge
1. To sign IOD form I & II and
send to concerned authority.
2. Implement the
corrective
action to avoid similar
kind of accident in future.
1.To inform respective section in
charge & Safety
2.To inform Factory Manager &
Occupier
3. To inform Ambulance in
case of injury & Fire
4.To inform CISF-Fire in case of fire
or requirement evacuation.
5. To fill IOD form –I&II
6.To arrange to send injured
person to dispensary/
Local hospital
7.To send accident observation
report along with duly filled &
Signed IOD forms I&II to safety
department.
1.To inform respective
sectional in charge & Safety.
2.To inform Factory
Manager & Occupier
3.To inform CISF-Fire in
case of fire.
4. To inform Ambulance
5. To fill IOD form –I
6.To arrange to send inju red
person to dispensary/
local hospital
7.To investigate the incident
5
9
Permit To
Work
A safe work permit is document that identifies the work to be done,
the hazards involved, and the precautions to be taken. It ensures
that all hazards and precautions have been considered before work
begins.
Safe work permits should always be used when work is performed
by an outside agency or employer.
SCOPE OF PERMIT TO WORK (PTW)
The work permit should be filled for all the jobs where hazards and
probability of accidents are more.
Permit is requiredfor the following jobs :
 Major & Minor Maintenance work (Cold Job).
 Entry into confined space.
 Work at Height
 Excavation.
 Electrical job at height
 Electrical maintenance
 Hot work (Cutting, welding and grinding work)
 Section 7A : General duties of occupier Sub section (d)
 Section 36 : Protection against dangerous fumes gases
etc.
6
3
 Section 36A: Precautions regarding use of portable
light
 SCHEDULE XI] CHEMICALWORKS PART -I
(State Factories Rules
TYPES OF PERMIT
 Hot Work
 Electrical Shutdown
 EOT Crane/ EOT Crane Gantry Work
 Work At Height
 Confined Space
Safe work permit should be prepared in triplicate:
 First copy to Permit tee.
 Second copy for safety department
 Third copy as book copy.
6
4
Issue of Safety Work
Permit
24
Understand the
task
Site visit /
Identify
hazards
Identify precautions to be
taken & PPE to be
used
Fill up the permit clearly stating jobs,
agency concerned, date and validity
period, hazards & precautions (Cross
Reference)
Ensure all precaution are
taken
e.g. electrical isolation
Sign the permit authorizing the
person concerned to carry out
the task
Explain the details to
person
carrying out the job
After job completion the person signs the
permit
- ensure all safety fittings are in place
Authorise electrical
for
energisation if
isolated
Permit
acceptance
Permit
closure
6
5
Hot Work
A process in which spark and heat is generate.
Ex. : Welding, Cutting etc.
6
6
ARC WELDING
 Use welder suit, welding screen/shield, leather hand gloves, and
tight shoes.
 Remove combustible materials from the vicinity of welding or
cutting operations.
 Keep tight connections of cables to avoid overheating of welding cables.
 Use suitable screen for out-door jobs.
 Always memories the location of fire extinguishers.
 Do not use electrode holders with defective jaws.
 Do not attempt to repair welding machine. Always take help of
electric department.
 Do not use wet hand gloves and shoes while welding.
 Switch off the welding machine when not in use.
GENERAL PRECAUTION FOR WELDING &
CUTTING JO B
 Welding and cutting jobs are to be carried out in areas away from
inflammable or combustible substances.
 Don’t carry out any welding jobs in confined spaces without
adequate ventilation.
 Don’t pick up hot objects.
 Don’t look at on electric arc with naked eye.
 Don’t use cracked welding shields.
 Don’t attempt to repair equipment’s.
 Don’t do any chipping without suitable goggles.
 Don’t drop or abuse cylinders and do not roll.
 Never tamper with cylinder safety devices.
 Always protect hose/welding cable from being trampled on or run over.
 Protect the hose and cylinders from flying sparks, hot slag, hot
objects, and open flame.
 Don’t use match stick for lighting torch, hand burns may result.
Use
friction lighters, stationery pilot flame or some other suitable source
of ignition.
 When the welding or cutting is to be stopped for long time or taken
down,
close the cylinder valves and then release all gas pressure from the
regulators and hoses.
 Hose pipes of oxygen and acetylene use are to be tested to make
sure
that the same are free from any leakage. Damaged/leaked hose
pipes should never be used.
Confined
Space
Confined Space refers to any place, including any vessel, tank,
container, pit, bund, chamber, cellar or any other similar space
which, by virtue of its enclosed nature, creates conditions that give
rise to a likelihood of an accident, harm or injury of such a nature as
to require emergency action due to the presence or reasonable
foreseeable presence of lack of oxygen :
These conditions can be present in a confined space:
- flammable or explosive atmospheres
- harmful gas, fume or vapour
- free flowing solid or an increasing level of liquid
- excess of oxygen
- excessively high temperature
6
7
Height Work
85
 Any work to be performed at a height of 1.8 m./
2m. from ground level where a person is standing is
defined as work at height.
Or above
 Height where there is no permanent platform, the job require a
permit to work along with a work at height checklist.
WORK ON ROOF TOP AND WORKING IN HEIGHT
 Authorized PERMIT TO WORK is a must.
 Use safe work ladder and safety belt.
 Use safety helmet.
 Job must be carried out under strict supervision.
 People under work zone should be warned/ evacuated and area may be cordoned, if
necessary.
 Working platform/stir used for working must be of sufficiently strong in
construction.
 Single person should not be allowed to work on a height.
Gate Entry
(With propel COVID-19 Precaution)
Security Check up
Personnel Department
(Check all required Documents & Legal Formalities Eg. ESI,
Insurance, Competency Certificates, Medical Certificate by Civil
Hospital)
Safety Department
(Document check, Safety Induction)
Site visit by
User + Safety
Department
(For Safety Concern)
Method Of Statement
(With all work procedure, Rolls
& Responsibility, Tools and
Tackles)
Tool Box Talk
(Daily Basis before start the work , in the presence
of Workers, Vendor Supervisor & Site Supervisor)
Work Start
(With all precaution and arrangement as per Method Of Statement)
Vendor Selection
(By Purchase Department As per Guideline Given By Safety Department)
OHC
(For Thermal Scanning &
Check-up Regarding
COVID -19)
Permit To Work
(Work above 2m. Required PTW for Height Work)
Procedure For Height
Work
Horizontal
Lifeline
Safety
Net
Safety
Harness
Fall
Arrester
Height Work Arrangements
Fundamentals of safety and accident prevention -final (1).pptx
MACHINERY OPERATION
 Employees should not operate a machine without knowing the correct
operating and stopping procedures.
 Before starting a machine, be sure the guards of moving parts of
the machine and other safety devices are in proper place and in
order. If you find any irregularities with the safety devices, report it
immediately for rectification.
 Do not wear loose clothing’s/ chappals around moving machineries.
Use tight fitting clothing’s and covered shoes.
 Do not leave running machinery, unattended.
 Detected electrical irregularities are to be attended immediately
Machine guarding is a safety feature on or around manufacturing or other
engineering equipment consisting of a shield or device covering hazardous
areas of a machine to prevent contact with body parts or to control hazards
like chips or sparks from exiting the machine.
Nip Point
Nip Point
Ni
p
Point
Nip
Point Ni p Point
6
9
Types of Guards
7
0
 Fixed :- Provide secure barrier.
 Interlocked :- Cuts off power when guard opened or removed.
 Adjustable :- Barrier manually moved to accommodate
stock or operation .
 Self-adjusting :- Barrier automatically moves to accommodate
operation.
Fixed Guards
 Advantages
– Maximum protection
– Variety of applications
– In-house fabrication
– Low cost & maintenance
 Disadvantages
– Poor visibility
– Must remove for repairs
requiring LOTO
7
1
Interlocked
Guards
Switch that when opened stops power.
 Advantage : 
Disadvantage :
 Maximum protection
 Portion of guard
easily removed for
access
Can be overridden by
employee
High cost
Maintenance required
7
2
Adjustable
Guards
 Advantage
– Flexibility
– In-house fabrication
 Disadvantage
– Not maximum protection
– Rely on worker to
properly position
– May prohibit easy access
Bandsaw
adjustabl
blade
e
guard
7
3
Self-adjusting
Guards
• Advantage
– Employee not involved
in positioning
– Readily available
• Disadvantage
– Not maximum
protection
– May need frequent fine
tuning
7
4
Cranes
A crane is a type of machine, generally equipped with
a hoist rope, wire ropes or chains, and sheaves, that can be
used both to lift and lower materials and to move them
horizontally. It is mainly used for lifting heavy things and
transporting them to other places.
7
6
CRANES, HOISTS, LIFTS
 Make sure that the load does not get over the maximum allowable load.
 Never walk or stand under a suspended load.
 Check cranes, hoists, limit switches, operating switches, chains and
slings for any defects before using them. Do not use defective slings or
chains.
 Use caution boards while attending any maintenance jobs in cranes,
hoists, lifts.
 Every lift-way shall be sufficiently protected by an enclosure fitted with
gates and the lift and every such enclosure shall be constructed as to
prevent any person or thing from being trapped between any part of the
lift and any fixed structure or moving part.
 The cage gates and floor landing gates (lift-way gates) shall be fitted with
interlocking or other efficient device to secure that the gates is at the
landing and the cage cannot be moved unless the gate is closed.
 The maximum safe working load shall be plainly marked and no load
greater than such load shall be carried thereon.
 Thoroughly examined by a competent authority at least once in twelve
months.
LIFTING MACHINES, CHAINS, ROPES,
SLINGS & LIFTING TACKLES
All lifting appliances must be of good mechanical construction,
sound materials, and adequate strength and free from all
defects.
Keep them in good order through proper inspection and
maintain relevant records.
Ropes, chains, slings, etc. used in erection or dismantling must
be of proper dimensions and properly connected to strong
attachment points.
Make sure that the load does not go over the maximum allowable
load.
Check chains, ropes, slings, etc. for any defects before using
them. Do not use defective chains, ropes, slings, etc.
Do not tie the load chain of pulley block with the load. Use
separate chain or sling with the load for lifting.
Avoid angular lifting of load by chain pulley block.
perpendicular lifting is always advisable.
Never walk or stand under a suspended load.
All these equipment’s should be thoroughly examined by a
competent authority at least once in every twelve months and
records of such test certificates should be maintained.
Hazards of Crane
7
8
 Over Loading
 Excessive Speeds
 No Standard hand signals.
 Inadequate Inspection and
Maintenance.
 Unguarded Crane rotating parts.
 Over Head Electrical Lines.
ELECTRICAL
I.E Rules must be followed for electrical installations and work system
.
Power supply from the mains must have the prior approvals of electrical
Manager/Engineer.
Proper insulated power tools to be used.
Hand lamps of 24 volts with proper earthing to be used in confined
space/damp locations.
Temporary/loose wirings are to be avoided at all costs.
Lock-out system is essential for any electrical jobs in addition to removal
of fuses, display of caution/warning notices.
Wire/cable should not be drawn on road/sharp objects/hot surface of
plant equipment’s.
All electrical equipment/machines including portable equipment are to
be tested by authorized competent person of electric Dept., before taking
the same in line/use.
Electrical
Use flame-proof electrical equipment’s and fittings in restricted
areas.
All electrical panel doors/distribution boards/starters/fuse boxes
are to be properly closed.
Irregularities detected in connection with earthing need to be
rectified immediately.
Only authorized electricians can work on electrical equipment
and /or circuitry.
Never touch loose or fallen electric wires. Consider them as live
and inform your supervisor immediately for early rectification.
Check electrical extension cords for any defects and cracks
before plugging them.
The electrical contractor’s employees must have necessary work
permits as prescribed for different jobs. They must strictly follow
the company’s standing safety rules/code of practices.
While working in confined space always use portable equipment
of 24 Volts supply.
SAFE CHEMICAL HANDLING
All employees should know the correct fire, health and safety
precautions to be taken while working at the chemical areas.
Use suitable types of PPE.
Avoid breathing, chemical dust, mist, gas and vapors
Wear correct PPE while handling toxic and hazardous
substances.
Never put chemicals into unmarked container or use chemicals
from unmarked containers.
Do not lift PVC drums, tied with rope by crane, hoist, etc.
Do not handle chemicals or containers, jars, etc. without labels.
Never add acid with water. For dilution add water with acid.
In case of inhalation of toxic gases, remove the victim to fresh
airy are and immediately take help of first aid facility.
Material Safety Data Sheets
MSDS
 A Material Safety Data Sheet (MSDS) is designed to provide
both workers and emergency personnel with the proper
procedures for handling or working with a particular
substance.
 MSDS's include information such as physical data (melting
point, boiling point, flash point etc.), toxicity, health effects,
first aid, reactivity, storage, disposal, protective equipment,
and spill/leak procedures. These are of particular use if a spill
or other accident occurs.
 MSDS's vary in length depending on their format, content, and
font size.
7
9
FIRST AID
 Take help of First Aid facility for immediate treatment.
 There are eye wash fountains and emergency showers. Know
where they are located in your plant and know how to use them
properly. These equipment’s must be kept cleaned and in order.
 If a corrosive chemical splashes on skin, eye or any part of
body, use safety shower or eye wash fountain for at least 15
minutes, or until the feeling of sickness disappears.
 For breathing trouble, if any, due to inhalation of chemicals,
gases, inform the safety department / HR department
immediately.
If the victim is conscious but has difficulty in breathing.
-Remove the victim to quite and fresh air, from affected areas.
-loosen his clothes immediately.
-Keep him warm using blanket.
-Lay him down with his legs raised.
If the victim is unconscious
- Place the patient in a comfortable position with head and trunk
elevated.
- Remove dentures.
- Immediately call for help of medical assistance.
Safety induction manual
FIRE SAFETY
8
8
What is Fire?
 The rapid oxidation of a fuel evolving heat, particulates,
gases and non-ionizing radiation
8
9
Fire is chemical reaction in which substance (fuel) combines with
oxygen making an exothermic reaction with the emission of
light, heat & smoke.
9
0
Classification of fire As per factory Rule
9
1
 Class A fire.—Fire due to combustible
materials such as wood, textiles, paper, rubbish
and the like.
 Class B fire—Fire in flammable liquids like
oil, petroleum products, solvents, grease,
paints etc.
 Class C fire—Fire arising out of
gaseous substances.
 Class D fire—Fire from reactive chemicals, active
metals and the like.
 Class E fire—Fire involving electrical
equipment
and machinery and the like.
Removal of heat.
(Best cooling media is
water)
Reducing % of oxygen.
Cutting off the supply
of oxygen. (Blanketing,
Use foam)
Removal of fuel or
removal of combustible
material
9
2
* Keep your back to
a clear escape route,
*Stand back 6 to 8 feet
from the fire,
* PASS
Using a Fire Extinguisher
P.A.S.S.
PULLRemember the PASS
word :
AIM
SQUEEZE
SWEEP
9
4
FIRE SAFETY
COMMON CAUSE OF INDUSTRIAL FIRE:
Leak/spillage of inflammable/combustible materials.
Electrical short circuiting/overloading.
Welding, gas cutting, soldering and other hot jobs.
Smoking in prohibited areas.
Chemical reaction.
Spontaneous combustion.
Mechanical/Frictional heat/spark.
Naked flames.
Molten substances.
Spontaneous ignition.
Static sparks/lightning.
Safety induction manual
BASIC PREVENTION MEASURES
 Know the place of your work, the fire hazards present and the location
of firefighting equipment’s.
 Keep firefighting equipment’s well maintained and easily accessible.
 Know how to operate and use proper type of extinguisher.
 Keep emergency telephone numbers handy.
 Ensure good housekeeping standard.
 Do not smoke in plant premises.
USE OF FIRE EXTINGUISHERS
9
1
CLASS OF FIRES A B C D
TYPE OF EXTINGUISHERS
Water Type S NS NS NS
Foam Type S S NS NS
DCP Type S S NS S
CO2 NS S S S
NS: Not suitable
S: Suitable
ESTINGUISHERS CHART (SUITABILITY)
WATER (CLASS -A): WOOD, RUBBER, PAPER, PLASTICS
MECH. FOAM (CLASS – A&B) RUBBER, PLASTICS, OIL, PAINT
DCP (CLASS- B, C &D) OIL, PAINT, GAS, METAL, Electrical
CO2 (CLASS- B, C &D) GAS, CHEMICALS, ELECTRICAL
DO NOT USE WATER IN ELECTRICAL FIRE
GENERAL SAFETY RULES
 You are responsible for your own safety. Make sure you know these rules,
any special safety rule and where equipment’s are located in your plant and
also try to know the proper and correct use of safety equipment’s.
 The Supervisor of the department must enforce safety rules with all
employees in his department.
 Be sure you understand your job completely. If not, ask the supervisor or
officer.
 Pay close attention to your work and avoid unsafe acts and practices. Do
not take chances or risk or shortcuts.
 Read and follow warning signs and operation procedures of your machines/
equipment’s.
 Clean your work area before commencement and at the end of duty.
 Any unsafe condition detected should to be informed to the supervisor for
necessary rectification at an early time.
 Eating is allowed in designated areas only.
 Consumption of alcoholic beverages and/ or drugs, and smoking is strictly
forbidden anywhere in the unit premises.
 Use of audio / camera mobile phone instrument by individuals are
prohibited.
 Work on powered equipment shall not proceed until it is assured that
the said equipment has been disconnected.
 Opening pipe lines that may contain hazardous materials or under
pressure shall not proceed unless authorized by company safety
representative.
 When walking in the plant, always watch out for trip hazards.
 When climbing stairs use hand-rails. Do not run up or down or take
two stairs/steps at a time.
 Never use compressed air to dust off your clothes or parts of your body.
 No horseplay allow in plant.
 Always use- tight-fitting clothing and covered shoes.
 All outside contractors and their laborers must obey the company safety
rules.
 Plant visitors must obey the plant safety rules.
 Walkways/passage ways should never be obstructed/ blocked.
 Use of mobile phones is strictly restricted in inside the mill area.
 In the event of fire, inform control room/ security dept. /safety officer
and Department heads.
 Keep all the firefighting appliances clear from obstructions.
 Oil soaked cotton wastes are to be kept in covered containers and
emptied regularly.
 Segregate inflammable substances from source of ignition.
 Promptly eliminate oil/gas leaks and clean spillages of inflammable
substances.
 All storage vessel and pipelines carrying inflammable substances
should be properly grounded, bonded and marked.
 Strictly adhere to WORK PERMIT instructions for welding, gas cutting
and other hot jobs in areas where inflammables are present.
 Store incompatible chemicals separately.
 Use fuses and circuit breakers of correct capacity.
 Avoid multi-socket connections.
 Do not use damaged electric cord and avoid temporary/extension
connections.
 Lubricate, maintain and align all machines/equipment’s to prevent
generation of heat.
 Use only non-ferrous tools while opening the
cans/drums/containers containing highly inflammable substances.
SAFETY INSTRUCTIONS- Do’s & Don’ts
DO’S
 Do ensure machine safety mechanisms are in order before start.
 Do ensure machine safety guards are in position and properly
fixed.
 Do keep the machine/equipment and surroundings clean, free
of oil/ service leakages.
 Do follow sequences of operation of machine/equipment
and avoid shortcuts.
 Be alert when you are working.
 Ensure availability of water and suitable types of portable
firefighting appliance before start of gas cutting/electric
welding/other hot process jobs.
 Do inform concerned person in case of any abnormality.
 Report all injuries to your supervisor / Department head
/Safety department / HR department
DON’TS
 Don’t leave machine, running unattended.
 Don’t use loose clothing and chappals.
 Don’t play with machines.
 Don’t undertake repair/maintenance of the machine/equipment’s
while running/in line.
 Don’t touch any bare electrical wire.
 Don’t pull/snap any electrical wire.
 Don’t touch any chemicals, till you know the same or hot objects
with bare hand. Always use suitable type hand gloves.
 Don’t put machine in ‘auto’ if you are working on manual’
mode.
Completely stop manual mode before switching machine on ‘auto’.
HOUSE KEEPING
Part of your job is to work neatly and keep your working area
clean. This includes stacking objects neatly and keeping of waste
materials neatly in proper locations/bins.
Clean up spills as soon as they happen or as soon as you find
them.
Keep pathway clear by storing everything away from the marking
lines.
When stacking objects, do not block doors, exits, firefighting
equipment’s, safety equipment’s or electrical accessories.
Inform your supervisor about leaky drums/ containers, storing
vessels,
tanks.
Inform your supervisor about the unguarded moving parts of
machineries and provide temporary arrangement, if possible.
Inform your supervisor about temporary/loose/un-safe electrical
installation.
Don’t leave any material/things around the work place that could
cause accident to anyone. Remove unwanted materials from high
places which could fall and hit somebody.
Use only those pallets that are in good condition.
PERSONAL PROTECTIVE EQUIPMENT
 Must wear tight-fitting clothes and covered shoes while on duty.
 Helmets are for protection against head injuries.
 Safety goggles and face shields are for the protection of eye and face
against chemical flash.
 Hand gloves, Aprons and Gum boots are for the protection of hand,
body, and foot respectively.
 Make sure you use the correct eye, face, body protection
equipment’s
when performing mechanical jobs.
 While working critical jobs where presences of toxic gases are there,
suitable type respirator must be used.
 The concerned department and their Supervisor must ensure
that
contractor’s men use proper and correct PPE.
 Safety belt need to be used when working at height.
 Loose clothes are not allowed while working in or near machines.
HAND TOOLS
 Learns the correct use of the tools and portable equipment’s and use
the right tools for the right job.
 Use only the tools that are in good shape and condition.
 Use non-sparking tools where fire hazard is there due to spark.
 Portable power tools are to be inspected and tested by authorized
Person/ department before use.
IN CASE OF EMERGENCY
 In case of emergency dial Fire, Safety & Security department and shout loudly Fire……
Fire … … . . Fire……..
 Act as per written emergency plan.
 If you are not involved in control of emergency go to nearest Assembly point and wait
for instructions.
 Ensure everything is safe before you leave your area.
 Do not start vehicles, unless it is safe to do so.
 Do not create panic, confusion and crowd at emergency site.
 Leave room and road for Fire Tender and Ambulance.
 Guide contract personnel and visitors to assemble at the nearest assembly point.
Safety induction manual
Fundamentals of safety and accident prevention -final (1).pptx
Don’t try to change the
people
Change the environment
i.e. method of working, training,
instructions, supervision,
inspection &
Safety
culture to
Fundamentals of safety and accident prevention -final (1).pptx

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Fundamentals of safety and accident prevention -final (1).pptx

  • 2. WHY NEED ATTENTION ON SAFETY 1. Over 7700 people die each day from work-related accidents or diseases – that’s nearly 2.78 million every year 2. Every 15 sec, a worker dies from a work related accident or disease, and 153 people experience a work related injury. These represent an enormous burden for organizations and society as a whole, costing over 2.78 million deaths a year, not to mention the more than 374 million non-fatal accidents. 3. The burden of occupational injuries and diseases is significant, both for employers and the wider economy, resulting in losses from early retirements, staff absence and rising insurance premium (3.94% global GDP or 2.99 trillion USD indirect and direct costs – failing to invest in safety and health is nearly equal to the combined GDP of the 130 POOREST COUNTRIES IN THE WORLD) 4. Source: WWW.ISO.ORG
  • 4. Three essential ingredients in any Organization Man, Machine Material MANAGEMENT MACHIN E MATERIA L A Machine can be programmed, Material flow can be controlled but Man can not be programmed or controlled in democracy like us.
  • 5. A quality or condition of being safe from “danger, Injury, damage, loss, accidents”
  • 6. INDUSTRIAL SAFETY MEANS Industrial safety refers to the management of all operations and events within an industry in order to protect its employees and assets by minimizing hazards, risks, accidents, and near misses.
  • 7. SIGNIFICANCE OF INDUSTRIAL SAFETY Industrial accident causes a great loss to both the Employer and Employee. Cost of compensation Cost of medical-aid Cost of training a new worker Cost of the lost time Cost of Investigation Cost of supervision & inspections Cost of the Govt. in terms of Factories Inspector & other statutory authority Cost of spoilage of materials Cost of the damage of machinery Cost of wages payable during injury Cost of loss of morale Cost of loss to the worker and his
  • 8. OBJECTIVES OF INDUSTRIAL SAFETY To prevent accidents in the plant by reducing the hazard to minimum To eliminate accident caused work stoppage and lost production To achieve lower workmen’s compensation and reduce all other direct and indirect costs of accidents To evaluate employees morale by promoting safe work place and good working condition To educate all members of the organization in continuous state of safety mindless and to make supervision competent and intensely safety minded.
  • 9. GENERAL DEFINITIONS Occ. Health: The protection of bodies and mind of people from illness resulting from the materials, processes or procedures used in the work place Occ. Welfare facilities: Facilities to maintain the health and well being of the workers at the work place i.e. washing, sanitation, resting area, drinking water, lighting, café etc Near miss: Incidents that could resulted in an accident Stats – appx. 10 near misses a minor accident Dangerous occurrence: Near miss that could lead to major accident – serious injury or death Ex. Collapse of scaffolding or embankment
  • 10. General Definitions Unsafe Act: Act of people(s)that may potentially cause harm to something Unsafe Condition: Condition or circumstance that may potentially cause harm to something Reportable Accident: Non-Reportable Accident:
  • 11. “To expose to danger ,risk, chance of accidents, loss - A hazard is any source of potential damage, harm or adverse health effects on something or someone under certain conditions at work. -"Condition, event, or circumstance that could lead to or contribute to an unplanned or undesirable event."
  • 12. Overview of Hazards What’s going on in your workplace? Images by: Diamond Rubber Products' photostream
  • 13. CHEMICAL & DUST HAZARDS (cleaning products, pesticides, asbestos, etc.) BIOLOGICAL HAZARDS (mold, insects/pests, communicable diseases, etc.) ERGONOMIC HAZARDS (repetition, lifting, awkward postures, etc.) WORK ORGANIZATIO N HAZARDS Things that cause STRESS! OTHERS HAZARDS (slips, trips and falls, faulty equipment, etc.) PHYSICAL HAZARDS (noise, temperature extremes, radiation, etc.)
  • 14. “A possibility of danger or harm”
  • 15. What is risk? Risk is the likelihood that a person may be harmed or suffers adverse health effects if exposed to a hazard.’
  • 16. Difference between Risk & Hazard "hazard". A The term is often confuse d wit h "risk " hig h voltag e power supply, a sample of radioactive material, or a toxic chemical may present a hazard, meaning that they present the potential for harm. Risk indicates probabilit y of hazard causing the harm.
  • 18. INCIDEN T An event that could or does result in unintended harm to people and /or damage to property and/or environment. Incidents are divided into two categories.
  • 21. WHAT IS ACCIDENT AN UNINTENDED, UNPLANNED EVENT WHICH HAS THE POTENTIAL TO CAUSE HARM OR INJURY. AN INCIDENT WHICH CAUSES HARM OR HAS POTENTIAL TO DO SO.
  • 22. Industrial Accidents: “Industrial Accidents are caused by chemical, mechanical, civil, electrical, or other process failures due to accident, negligence or incompetence, in an industrial plant which may spill over to the areas outside the plant causing damage to life and property.”
  • 23. Hazards/ Danger Observable or predicted from knowledge  Risk Not directly observable - probability of harm to system elements being realised from exposure to hazards and danger.  Harm Damage to system elements - long or short term  Accidents  Injuries Ill-Health Damage
  • 24. Defects in the system Existence of Hazard Employees to error Associate d Risk Accidents occur How do accidents occur ??
  • 26. CAUSES OF ACCIDENTS ACCIDENT CAUSES INDIRECT CAUSE DIRECT CAUSE PHYSIOLOGICAL UNSUITABILITIE S PHSYCOLOGICAL UNSUITABILITIES LACK OF KNOWLEDGE & SKILL UNSAFE ACT UNSAFE CONDITION
  • 27. Causes of Accident Direct Indirect Unsafe Act Unguarded or inadequately guarded machines / equipments Defective conditions of m/c’s, equipments, tools etc. Unsafe methods of storing, piling etc. Inadequate or incorrect illumination Inadequate Ventilation Improper House Keeping-- things not at their proper places Unsafe design or construction of machines and equipment etc. Operating without authority Bypassing safety devices Operating at unsafe speed Using wrong tool / equipment Unsafe Placing Unsafe Loading Taking unsafe position or posture Working on dangerous or moving equipment Not using PPE Horse playing at work place Causes Unsafe Condition
  • 28. Causes of Accident Physiological Unsuitability ’s Indirect Causes Poor eye sight Hard to hearing Intoxicated Physiological disabled Psychological Unsuitability's Negative attitude towards safety Ignorance of safety rules and procedures Frustration & Conflict Morale Individual differences Acclimatization Lack of Knowledge & Skill`
  • 30. Major Consequences  Loss of life / injuries  Impact on livestock  Damage to Flora/fauna  Environmental Impact (air, soil,water)  Financial losses to industry.
  • 31. Bhopal Gas Tragedy Worst industrial disaster in history 2,000 people died on immediate aftermath Another 13,000 died in next fifteen years 10-15 persons dying every month 520,000 diagnosed chemicals in blood causing different health complications 120,000 people still suffering from Cancer Tuberculosis Partial or complete blindness, Post traumatic stress disorders, Menstrual irregularities Rise in spontaneous abortion and stillbirth
  • 32. IOC JAIPUR - 2009 slide 32 Uran
  • 33. IOC JAIPUR - 2009 slide 33 Uran
  • 35. COST OF ACCIDENT DIRECT COST – Insurance Claims Loss of Production or reduced output Product loss or damage Damage (plant, materials, premises) Sickness cover/ sick pay Medical treatment Repairs to plant & equipment Replacement of equipments 
  • 36. INDIRECT COST  Business interruption  Product liability  Loss of orders  Legal fees/fines/penalties  Delay in production  Start up cost  Increased insurance renewal costs  Training replacement  Cancellation of orders  Reduced  Lossof profit  Loss of corporate image  Cost of time spent on –  Investigations  Supervisors assisting victim  Workers stopping to discuss the incident  Preparation of reports  Attendance on court
  • 37. The Cost of Accidents “Iceberg” analogy of costs Direct Cost • Compensation • Medical Expenses • Equipment damage Indirect Cost • Cost of Lost time • Production loss • Over head & administrativ e expenses etc.
  • 38. HEINRICH THEORY OF ACCIDENT CAUSATION INJURY IS THE RESULT OF COMPLETION OF 5 DOMINOS 1. Social Environment. 2. Fault of the person 3. Unsafe Action / Unsafe Condition 4. Accident 5. Injury
  • 39. Domino no-3 i.e. Unsafe Acts & Unsafe conditions are the main contributory factor for accident causation. Unsafe Acts – 88% Unsafe Conditions – 10% Others – 2% It indicates that 98% of accidents can be prevented.
  • 40. What is Unsafe Act, Condition & Near miss 8 3
  • 41. Theories of Accident Causation 600 Near Miss / Unsafe conditions 300 No Injuries 300 No injury 29 Minor Injuries LT I 1 Major/ Fatal
  • 42. Theories of Accident Causation 1 Fatality 10 Minor Injuries 30 Property Damages 600 Near Miss / Unsafe conditions Reporting and investigation of “NoIinjury accidents”, “Near misses” can improve the safety performance of a unit Frank Bird analyzed 1.75 million accidents in 1969
  • 43. PRINCIPLE OF SAFETY MANAGEMENT “Unsafe action / Unsafe condition & accidents are only the symptoms of some thing wrong in the safety management systems”. “Safety should be managed like any other company function. “The key to effective line safety performance is management procedures that fix ACCOUNTABILITY”.
  • 44. Hierarchy of Controls Requires a physical change to the workplace Requires worker to wear something Elimination/Substitution Requires worker or employer to do something Most Effective Least Effective
  • 45. Reasons for Accident Prevention Accident Preventio n 1 Humanitaria n 4 Lega l 3 Socia l 2 Economi c
  • 46. What could have prevented these losses?
  • 48. •Strict & Rigorous approach in following the Relevant Standards , Codes & Practices •Built in Safety Devices and Safety System •Field Monitors for Different Toxic Gases Physical Protection
  • 49. •Provision of Wind Cones •PPE •Passive Protection System •Active Protection system •Automatic Protection system
  • 50. PROCEDURAL PROTECTION •Fire Emergency Procedure •Disaster Preparedness Plan •Mutual Aid Scheme •No Smoking Policy •Investigation of All Accidents •Hazard Identification through Safety Committee, House Keeping Committee, Safety audit Committee •Conducting Plant Survey, safety survey •Work Permit System
  • 51. Contd. • Safety promotional activities •Information notes on unsafe conditions • MSDS – Material Safety Data Sheet •Annual Medical Check up of Employees •Safe Start up & Shut Down Procedure • Regular and Preventive Maintenance •Periodic testing of Fire Fighting
  • 52. EDUCATIONAL PROTECTION •Periodic Training Program on Safety, Fire Safety and Hazardous properties of materials •Mock Fire Drill •Safety Manuals •Health & Safety News Bulletins, leaflets •Safety Motivation schemes •Plant Operating Manual •Educating the Public Living nearby
  • 53. SAFETY SYSTEM AT WORKPLACE Safety Policy: To establish a safety policy as per sub section 3 of section 7A (General duties of Occupier) as per Factories Act 1948 & M.P.Factories Rules 1962. Purpose: 1. To eliminate the incidence of work related injuries, diseases, fatalities, disaster and loss of assets 2. Ensuring achievement of high level of occupational safety, health and environment performance through proactive approaches. 3. To enhance the well-being of the employee
  • 54. Safety Organization The Occupier shall employ such number of Safety officer as per Section 40B of Factories Act 1948. In every factory, a. Wherein 1000 or more workers are ordinarily employed or b. Wherein, in the opinion of the state Govt, any manufacturing process or operating is carried on, which process or operation involves any risk of bodily injury, poisoning or disease, or any other hazards to health, to the persons employed in the factory. Conditions of service: 1. Where the number of safety to be appointed in a factory, one of them shall be designated as a Chief Safety officer. 2. Safety officer shall work directly under the control of Chief Executive of the Factory.
  • 55. Roles and Responsibilities of Officers & Supervisors 1. He/ She shall responsible for ensuring the health and safety of their respective section 2. He/ She shall have to arrange to provide or made available for required PPEs 3. He / She shall have to ensure the effective functioning of all the emergency switches, trip switch, control mechanism or any other mechanism provided for the purpose of worker safety. 4. He/ She shall have to report all kind of accident to immediate officer, Fire wing, Dispensary, safety department, Factory Manager & Occupier 5. He / She Shall have to conduct accident investigation 6. He / She shall have to fill IOD form 7. He shall have to organize on the job training program 8. He shall have to follow work permit system 9. He shall have to display SOPs at designated location. 10. He shall have to depute their employees for safety training
  • 56. Workers Responsibilities 1. The worker shall have to follow safety rules and regulation 2. To obey or follow the safety instruction by supervisor / officer 3. To wear all PPE 4. To report near miss, minor & major accident to concerned person 5. To identify unsafe condition and unsafe act 6. To cooperate with emergency rescue team at the time of emergency 7. To all safety training program.
  • 57. Employees participation 1. Safety committee meeting 2. Statutory function like National Safety week celebration - Industrial Safety Day 3. Involvement in Accident prevention method
  • 58. ACCIDENT/INCIDENT MINOR ACCIDENT/ INCIDENT MAJOR ACCIDENT/ INCIDENT Responsibility of shift supervisors / shift officers Sectional In-charge 1.To inform safety department and higher authority. 2.Implement the corrective action to avoid similar kind of accident in future CONCERNED SUPERVISOR/OFFICER Accident reporting system chart Reportable/Major accident: As per Section 88 of the Factories Act, 1948 if an accident occurs in any factory which causes death, or bodily injury by reason of which the person injured is prevented from working for a period of 48 hours or more. Non-Reportable / Minor accident: If any small injuries by reason of which the person injured is prevented from working for a period of less than 48 hours or less is called as Non-Reportable accident. Sectional In-Charge 1. To sign IOD form I & II and send to concerned authority. 2. Implement the corrective action to avoid similar kind of accident in future. 1.To inform respective section in charge & Safety 2.To inform Factory Manager & Occupier 3. To inform Ambulance in case of injury & Fire 4.To inform CISF-Fire in case of fire or requirement evacuation. 5. To fill IOD form –I&II 6.To arrange to send injured person to dispensary/ Local hospital 7.To send accident observation report along with duly filled & Signed IOD forms I&II to safety department. 1.To inform respective sectional in charge & Safety. 2.To inform Factory Manager & Occupier 3.To inform CISF-Fire in case of fire. 4. To inform Ambulance 5. To fill IOD form –I 6.To arrange to send inju red person to dispensary/ local hospital 7.To investigate the incident
  • 59. 5 9
  • 60. Permit To Work A safe work permit is document that identifies the work to be done, the hazards involved, and the precautions to be taken. It ensures that all hazards and precautions have been considered before work begins. Safe work permits should always be used when work is performed by an outside agency or employer.
  • 61. SCOPE OF PERMIT TO WORK (PTW) The work permit should be filled for all the jobs where hazards and probability of accidents are more. Permit is requiredfor the following jobs :  Major & Minor Maintenance work (Cold Job).  Entry into confined space.  Work at Height  Excavation.  Electrical job at height  Electrical maintenance  Hot work (Cutting, welding and grinding work)
  • 62.  Section 7A : General duties of occupier Sub section (d)  Section 36 : Protection against dangerous fumes gases etc. 6 3  Section 36A: Precautions regarding use of portable light  SCHEDULE XI] CHEMICALWORKS PART -I (State Factories Rules
  • 63. TYPES OF PERMIT  Hot Work  Electrical Shutdown  EOT Crane/ EOT Crane Gantry Work  Work At Height  Confined Space Safe work permit should be prepared in triplicate:  First copy to Permit tee.  Second copy for safety department  Third copy as book copy. 6 4
  • 64. Issue of Safety Work Permit 24 Understand the task Site visit / Identify hazards Identify precautions to be taken & PPE to be used Fill up the permit clearly stating jobs, agency concerned, date and validity period, hazards & precautions (Cross Reference) Ensure all precaution are taken e.g. electrical isolation Sign the permit authorizing the person concerned to carry out the task Explain the details to person carrying out the job After job completion the person signs the permit - ensure all safety fittings are in place Authorise electrical for energisation if isolated Permit acceptance Permit closure 6 5
  • 65. Hot Work A process in which spark and heat is generate. Ex. : Welding, Cutting etc. 6 6
  • 66. ARC WELDING  Use welder suit, welding screen/shield, leather hand gloves, and tight shoes.  Remove combustible materials from the vicinity of welding or cutting operations.  Keep tight connections of cables to avoid overheating of welding cables.  Use suitable screen for out-door jobs.  Always memories the location of fire extinguishers.  Do not use electrode holders with defective jaws.  Do not attempt to repair welding machine. Always take help of electric department.  Do not use wet hand gloves and shoes while welding.  Switch off the welding machine when not in use.
  • 67. GENERAL PRECAUTION FOR WELDING & CUTTING JO B  Welding and cutting jobs are to be carried out in areas away from inflammable or combustible substances.  Don’t carry out any welding jobs in confined spaces without adequate ventilation.  Don’t pick up hot objects.  Don’t look at on electric arc with naked eye.  Don’t use cracked welding shields.  Don’t attempt to repair equipment’s.  Don’t do any chipping without suitable goggles.  Don’t drop or abuse cylinders and do not roll.  Never tamper with cylinder safety devices.  Always protect hose/welding cable from being trampled on or run over.  Protect the hose and cylinders from flying sparks, hot slag, hot objects, and open flame.  Don’t use match stick for lighting torch, hand burns may result. Use friction lighters, stationery pilot flame or some other suitable source of ignition.  When the welding or cutting is to be stopped for long time or taken down, close the cylinder valves and then release all gas pressure from the regulators and hoses.  Hose pipes of oxygen and acetylene use are to be tested to make sure that the same are free from any leakage. Damaged/leaked hose pipes should never be used.
  • 68. Confined Space Confined Space refers to any place, including any vessel, tank, container, pit, bund, chamber, cellar or any other similar space which, by virtue of its enclosed nature, creates conditions that give rise to a likelihood of an accident, harm or injury of such a nature as to require emergency action due to the presence or reasonable foreseeable presence of lack of oxygen : These conditions can be present in a confined space: - flammable or explosive atmospheres - harmful gas, fume or vapour - free flowing solid or an increasing level of liquid - excess of oxygen - excessively high temperature 6 7
  • 69. Height Work 85  Any work to be performed at a height of 1.8 m./ 2m. from ground level where a person is standing is defined as work at height. Or above  Height where there is no permanent platform, the job require a permit to work along with a work at height checklist. WORK ON ROOF TOP AND WORKING IN HEIGHT  Authorized PERMIT TO WORK is a must.  Use safe work ladder and safety belt.  Use safety helmet.  Job must be carried out under strict supervision.  People under work zone should be warned/ evacuated and area may be cordoned, if necessary.  Working platform/stir used for working must be of sufficiently strong in construction.  Single person should not be allowed to work on a height.
  • 70. Gate Entry (With propel COVID-19 Precaution) Security Check up Personnel Department (Check all required Documents & Legal Formalities Eg. ESI, Insurance, Competency Certificates, Medical Certificate by Civil Hospital) Safety Department (Document check, Safety Induction) Site visit by User + Safety Department (For Safety Concern) Method Of Statement (With all work procedure, Rolls & Responsibility, Tools and Tackles) Tool Box Talk (Daily Basis before start the work , in the presence of Workers, Vendor Supervisor & Site Supervisor) Work Start (With all precaution and arrangement as per Method Of Statement) Vendor Selection (By Purchase Department As per Guideline Given By Safety Department) OHC (For Thermal Scanning & Check-up Regarding COVID -19) Permit To Work (Work above 2m. Required PTW for Height Work) Procedure For Height Work
  • 73. MACHINERY OPERATION  Employees should not operate a machine without knowing the correct operating and stopping procedures.  Before starting a machine, be sure the guards of moving parts of the machine and other safety devices are in proper place and in order. If you find any irregularities with the safety devices, report it immediately for rectification.  Do not wear loose clothing’s/ chappals around moving machineries. Use tight fitting clothing’s and covered shoes.  Do not leave running machinery, unattended.  Detected electrical irregularities are to be attended immediately
  • 74. Machine guarding is a safety feature on or around manufacturing or other engineering equipment consisting of a shield or device covering hazardous areas of a machine to prevent contact with body parts or to control hazards like chips or sparks from exiting the machine. Nip Point Nip Point Ni p Point Nip Point Ni p Point 6 9
  • 75. Types of Guards 7 0  Fixed :- Provide secure barrier.  Interlocked :- Cuts off power when guard opened or removed.  Adjustable :- Barrier manually moved to accommodate stock or operation .  Self-adjusting :- Barrier automatically moves to accommodate operation.
  • 76. Fixed Guards  Advantages – Maximum protection – Variety of applications – In-house fabrication – Low cost & maintenance  Disadvantages – Poor visibility – Must remove for repairs requiring LOTO 7 1
  • 77. Interlocked Guards Switch that when opened stops power.  Advantage :  Disadvantage :  Maximum protection  Portion of guard easily removed for access Can be overridden by employee High cost Maintenance required 7 2
  • 78. Adjustable Guards  Advantage – Flexibility – In-house fabrication  Disadvantage – Not maximum protection – Rely on worker to properly position – May prohibit easy access Bandsaw adjustabl blade e guard 7 3
  • 79. Self-adjusting Guards • Advantage – Employee not involved in positioning – Readily available • Disadvantage – Not maximum protection – May need frequent fine tuning 7 4
  • 80. Cranes A crane is a type of machine, generally equipped with a hoist rope, wire ropes or chains, and sheaves, that can be used both to lift and lower materials and to move them horizontally. It is mainly used for lifting heavy things and transporting them to other places. 7 6
  • 81. CRANES, HOISTS, LIFTS  Make sure that the load does not get over the maximum allowable load.  Never walk or stand under a suspended load.  Check cranes, hoists, limit switches, operating switches, chains and slings for any defects before using them. Do not use defective slings or chains.  Use caution boards while attending any maintenance jobs in cranes, hoists, lifts.  Every lift-way shall be sufficiently protected by an enclosure fitted with gates and the lift and every such enclosure shall be constructed as to prevent any person or thing from being trapped between any part of the lift and any fixed structure or moving part.  The cage gates and floor landing gates (lift-way gates) shall be fitted with interlocking or other efficient device to secure that the gates is at the landing and the cage cannot be moved unless the gate is closed.  The maximum safe working load shall be plainly marked and no load greater than such load shall be carried thereon.  Thoroughly examined by a competent authority at least once in twelve months.
  • 82. LIFTING MACHINES, CHAINS, ROPES, SLINGS & LIFTING TACKLES All lifting appliances must be of good mechanical construction, sound materials, and adequate strength and free from all defects. Keep them in good order through proper inspection and maintain relevant records. Ropes, chains, slings, etc. used in erection or dismantling must be of proper dimensions and properly connected to strong attachment points. Make sure that the load does not go over the maximum allowable load. Check chains, ropes, slings, etc. for any defects before using them. Do not use defective chains, ropes, slings, etc. Do not tie the load chain of pulley block with the load. Use separate chain or sling with the load for lifting. Avoid angular lifting of load by chain pulley block. perpendicular lifting is always advisable. Never walk or stand under a suspended load. All these equipment’s should be thoroughly examined by a competent authority at least once in every twelve months and records of such test certificates should be maintained.
  • 83. Hazards of Crane 7 8  Over Loading  Excessive Speeds  No Standard hand signals.  Inadequate Inspection and Maintenance.  Unguarded Crane rotating parts.  Over Head Electrical Lines.
  • 84. ELECTRICAL I.E Rules must be followed for electrical installations and work system . Power supply from the mains must have the prior approvals of electrical Manager/Engineer. Proper insulated power tools to be used. Hand lamps of 24 volts with proper earthing to be used in confined space/damp locations. Temporary/loose wirings are to be avoided at all costs. Lock-out system is essential for any electrical jobs in addition to removal of fuses, display of caution/warning notices. Wire/cable should not be drawn on road/sharp objects/hot surface of plant equipment’s. All electrical equipment/machines including portable equipment are to be tested by authorized competent person of electric Dept., before taking the same in line/use.
  • 85. Electrical Use flame-proof electrical equipment’s and fittings in restricted areas. All electrical panel doors/distribution boards/starters/fuse boxes are to be properly closed. Irregularities detected in connection with earthing need to be rectified immediately. Only authorized electricians can work on electrical equipment and /or circuitry. Never touch loose or fallen electric wires. Consider them as live and inform your supervisor immediately for early rectification. Check electrical extension cords for any defects and cracks before plugging them. The electrical contractor’s employees must have necessary work permits as prescribed for different jobs. They must strictly follow the company’s standing safety rules/code of practices. While working in confined space always use portable equipment of 24 Volts supply.
  • 86. SAFE CHEMICAL HANDLING All employees should know the correct fire, health and safety precautions to be taken while working at the chemical areas. Use suitable types of PPE. Avoid breathing, chemical dust, mist, gas and vapors Wear correct PPE while handling toxic and hazardous substances. Never put chemicals into unmarked container or use chemicals from unmarked containers. Do not lift PVC drums, tied with rope by crane, hoist, etc. Do not handle chemicals or containers, jars, etc. without labels. Never add acid with water. For dilution add water with acid. In case of inhalation of toxic gases, remove the victim to fresh airy are and immediately take help of first aid facility.
  • 87. Material Safety Data Sheets MSDS  A Material Safety Data Sheet (MSDS) is designed to provide both workers and emergency personnel with the proper procedures for handling or working with a particular substance.  MSDS's include information such as physical data (melting point, boiling point, flash point etc.), toxicity, health effects, first aid, reactivity, storage, disposal, protective equipment, and spill/leak procedures. These are of particular use if a spill or other accident occurs.  MSDS's vary in length depending on their format, content, and font size. 7 9
  • 88. FIRST AID  Take help of First Aid facility for immediate treatment.  There are eye wash fountains and emergency showers. Know where they are located in your plant and know how to use them properly. These equipment’s must be kept cleaned and in order.  If a corrosive chemical splashes on skin, eye or any part of body, use safety shower or eye wash fountain for at least 15 minutes, or until the feeling of sickness disappears.  For breathing trouble, if any, due to inhalation of chemicals, gases, inform the safety department / HR department immediately. If the victim is conscious but has difficulty in breathing. -Remove the victim to quite and fresh air, from affected areas. -loosen his clothes immediately. -Keep him warm using blanket. -Lay him down with his legs raised. If the victim is unconscious - Place the patient in a comfortable position with head and trunk elevated. - Remove dentures. - Immediately call for help of medical assistance. Safety induction manual
  • 90. What is Fire?  The rapid oxidation of a fuel evolving heat, particulates, gases and non-ionizing radiation 8 9
  • 91. Fire is chemical reaction in which substance (fuel) combines with oxygen making an exothermic reaction with the emission of light, heat & smoke. 9 0
  • 92. Classification of fire As per factory Rule 9 1  Class A fire.—Fire due to combustible materials such as wood, textiles, paper, rubbish and the like.  Class B fire—Fire in flammable liquids like oil, petroleum products, solvents, grease, paints etc.  Class C fire—Fire arising out of gaseous substances.  Class D fire—Fire from reactive chemicals, active metals and the like.  Class E fire—Fire involving electrical equipment and machinery and the like.
  • 93. Removal of heat. (Best cooling media is water) Reducing % of oxygen. Cutting off the supply of oxygen. (Blanketing, Use foam) Removal of fuel or removal of combustible material 9 2
  • 94. * Keep your back to a clear escape route, *Stand back 6 to 8 feet from the fire, * PASS Using a Fire Extinguisher P.A.S.S. PULLRemember the PASS word : AIM SQUEEZE SWEEP 9 4
  • 95. FIRE SAFETY COMMON CAUSE OF INDUSTRIAL FIRE: Leak/spillage of inflammable/combustible materials. Electrical short circuiting/overloading. Welding, gas cutting, soldering and other hot jobs. Smoking in prohibited areas. Chemical reaction. Spontaneous combustion. Mechanical/Frictional heat/spark. Naked flames. Molten substances. Spontaneous ignition. Static sparks/lightning. Safety induction manual
  • 96. BASIC PREVENTION MEASURES  Know the place of your work, the fire hazards present and the location of firefighting equipment’s.  Keep firefighting equipment’s well maintained and easily accessible.  Know how to operate and use proper type of extinguisher.  Keep emergency telephone numbers handy.  Ensure good housekeeping standard.  Do not smoke in plant premises.
  • 97. USE OF FIRE EXTINGUISHERS 9 1 CLASS OF FIRES A B C D TYPE OF EXTINGUISHERS Water Type S NS NS NS Foam Type S S NS NS DCP Type S S NS S CO2 NS S S S NS: Not suitable S: Suitable ESTINGUISHERS CHART (SUITABILITY) WATER (CLASS -A): WOOD, RUBBER, PAPER, PLASTICS MECH. FOAM (CLASS – A&B) RUBBER, PLASTICS, OIL, PAINT DCP (CLASS- B, C &D) OIL, PAINT, GAS, METAL, Electrical CO2 (CLASS- B, C &D) GAS, CHEMICALS, ELECTRICAL DO NOT USE WATER IN ELECTRICAL FIRE
  • 98. GENERAL SAFETY RULES  You are responsible for your own safety. Make sure you know these rules, any special safety rule and where equipment’s are located in your plant and also try to know the proper and correct use of safety equipment’s.  The Supervisor of the department must enforce safety rules with all employees in his department.  Be sure you understand your job completely. If not, ask the supervisor or officer.  Pay close attention to your work and avoid unsafe acts and practices. Do not take chances or risk or shortcuts.  Read and follow warning signs and operation procedures of your machines/ equipment’s.  Clean your work area before commencement and at the end of duty.  Any unsafe condition detected should to be informed to the supervisor for necessary rectification at an early time.  Eating is allowed in designated areas only.  Consumption of alcoholic beverages and/ or drugs, and smoking is strictly forbidden anywhere in the unit premises.  Use of audio / camera mobile phone instrument by individuals are prohibited.
  • 99.  Work on powered equipment shall not proceed until it is assured that the said equipment has been disconnected.  Opening pipe lines that may contain hazardous materials or under pressure shall not proceed unless authorized by company safety representative.  When walking in the plant, always watch out for trip hazards.  When climbing stairs use hand-rails. Do not run up or down or take two stairs/steps at a time.  Never use compressed air to dust off your clothes or parts of your body.  No horseplay allow in plant.  Always use- tight-fitting clothing and covered shoes.  All outside contractors and their laborers must obey the company safety rules.  Plant visitors must obey the plant safety rules.  Walkways/passage ways should never be obstructed/ blocked.  Use of mobile phones is strictly restricted in inside the mill area.
  • 100.  In the event of fire, inform control room/ security dept. /safety officer and Department heads.  Keep all the firefighting appliances clear from obstructions.  Oil soaked cotton wastes are to be kept in covered containers and emptied regularly.  Segregate inflammable substances from source of ignition.  Promptly eliminate oil/gas leaks and clean spillages of inflammable substances.  All storage vessel and pipelines carrying inflammable substances should be properly grounded, bonded and marked.  Strictly adhere to WORK PERMIT instructions for welding, gas cutting and other hot jobs in areas where inflammables are present.  Store incompatible chemicals separately.  Use fuses and circuit breakers of correct capacity.  Avoid multi-socket connections.  Do not use damaged electric cord and avoid temporary/extension connections.  Lubricate, maintain and align all machines/equipment’s to prevent generation of heat.  Use only non-ferrous tools while opening the cans/drums/containers containing highly inflammable substances.
  • 101. SAFETY INSTRUCTIONS- Do’s & Don’ts DO’S  Do ensure machine safety mechanisms are in order before start.  Do ensure machine safety guards are in position and properly fixed.  Do keep the machine/equipment and surroundings clean, free of oil/ service leakages.  Do follow sequences of operation of machine/equipment and avoid shortcuts.  Be alert when you are working.  Ensure availability of water and suitable types of portable firefighting appliance before start of gas cutting/electric welding/other hot process jobs.  Do inform concerned person in case of any abnormality.  Report all injuries to your supervisor / Department head /Safety department / HR department
  • 102. DON’TS  Don’t leave machine, running unattended.  Don’t use loose clothing and chappals.  Don’t play with machines.  Don’t undertake repair/maintenance of the machine/equipment’s while running/in line.  Don’t touch any bare electrical wire.  Don’t pull/snap any electrical wire.  Don’t touch any chemicals, till you know the same or hot objects with bare hand. Always use suitable type hand gloves.  Don’t put machine in ‘auto’ if you are working on manual’ mode. Completely stop manual mode before switching machine on ‘auto’.
  • 103. HOUSE KEEPING Part of your job is to work neatly and keep your working area clean. This includes stacking objects neatly and keeping of waste materials neatly in proper locations/bins. Clean up spills as soon as they happen or as soon as you find them. Keep pathway clear by storing everything away from the marking lines. When stacking objects, do not block doors, exits, firefighting equipment’s, safety equipment’s or electrical accessories. Inform your supervisor about leaky drums/ containers, storing vessels, tanks. Inform your supervisor about the unguarded moving parts of machineries and provide temporary arrangement, if possible. Inform your supervisor about temporary/loose/un-safe electrical installation. Don’t leave any material/things around the work place that could cause accident to anyone. Remove unwanted materials from high places which could fall and hit somebody. Use only those pallets that are in good condition.
  • 104. PERSONAL PROTECTIVE EQUIPMENT  Must wear tight-fitting clothes and covered shoes while on duty.  Helmets are for protection against head injuries.  Safety goggles and face shields are for the protection of eye and face against chemical flash.  Hand gloves, Aprons and Gum boots are for the protection of hand, body, and foot respectively.  Make sure you use the correct eye, face, body protection equipment’s when performing mechanical jobs.  While working critical jobs where presences of toxic gases are there, suitable type respirator must be used.  The concerned department and their Supervisor must ensure that contractor’s men use proper and correct PPE.  Safety belt need to be used when working at height.  Loose clothes are not allowed while working in or near machines. HAND TOOLS  Learns the correct use of the tools and portable equipment’s and use the right tools for the right job.  Use only the tools that are in good shape and condition.  Use non-sparking tools where fire hazard is there due to spark.  Portable power tools are to be inspected and tested by authorized Person/ department before use.
  • 105. IN CASE OF EMERGENCY  In case of emergency dial Fire, Safety & Security department and shout loudly Fire…… Fire … … . . Fire……..  Act as per written emergency plan.  If you are not involved in control of emergency go to nearest Assembly point and wait for instructions.  Ensure everything is safe before you leave your area.  Do not start vehicles, unless it is safe to do so.  Do not create panic, confusion and crowd at emergency site.  Leave room and road for Fire Tender and Ambulance.  Guide contract personnel and visitors to assemble at the nearest assembly point. Safety induction manual
  • 107. Don’t try to change the people Change the environment i.e. method of working, training, instructions, supervision, inspection & Safety culture to