Loss Controland Safety Management

7/31/2019 Loss Controland Safety Management

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LOSS CONTROL AND SAFETY

MANAGEMENT IN INDUSDTRIES

BY

C.V.RAGHUNATHAN,B.TECH;DIS(HONS):MIE;MSEA

DY.CHIEF SAFETY MANAGER

THERMAL POWER STATION-INEYVELI LIGNITE CORPORATION LTD


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NEED- I

TODAYS BUSINESS SCENARIO Liberalisation

Globalisation

Open Economy

Increased Competition

Customer driven market Survival of the fittest


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NEED-II

STATUTORY COMPLIANCE FACTORIES ACT 1948 AMENDED IN 1987 Power Generation Industry comes under sec2(cb)

Applicability of Sec 41B,41C,41E,41H

Sec7A (a) Plant to be maintained safe without health risk

(b) Safe handling and usage of substances

(c) Information , instruction,training andsupervision on safety

(d) Safe access and eggress

(e) Maintenance and monitoring of work place

environment


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THE TWO MANTHRAS

QUALITY

PRODUCTIVITY

(CONTROL OF LOSS PRODUCING EVENTS,

OPTIMUM UTILISATION OF MONEY,MACHINES,

MATERIALS,METHODS,MEN)


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DEFINITIONS

HAZARD

Source/inherent property of a substance which has the

potential to cause harm to human by way of injury/ill

health,damage to property and environment

RISK

The combination of likelihood and consequence of a

hazardous event

INCIDENT

An event that has potential to cause an accident(includes

near miss)

ACCIDENT

Undesired event that causes injury, ill health,death,

damage to property and environment


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ACCIDENTS

LOSS PRODUCING EVENTS

ECONOMIC LOSS

SOCIAL LOSS

IMPAIRS INDIVIDUAL AND GROUP

PRODUCTIVITY

RETARDS ADVANCEMENT AND

STANDARD OF LIVING


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ACCIDENTS ACCIDENTS DO NOT HAPPEN; THEY

ARE CAUSED

ALL THE HUMAN ERRORS DO NOT

END UP IN ACCIDENTS

BUT MOST OF THE ACCIDENTS ARE

RESULTS OF HUMAN ERROR

ACCIDENT PREVENTION VITAL FOR

NATIONAL PROGERSS


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LOSS PREVENTION & CONTROL

MANAGEMENT

CONTROL OF MACHINE

PERFORMANCE

CONTROL OF MEN PERFORMANE

CONTROL OF PHYSICAL

ENVIRONMENT

CONTROL OF MATERIALS


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CONTROL OF MACHINE

PERFORMANCE Safety in conceptual stage

Safety in design stage

Safety in construction stage

Safety in transportation stage

Safety in operation & maintenance stage Safety in dismantling stage


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CONTROL OF MATERIALS

Inventory Control

Storage & Handling

MSDS

Antidotes


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HUMAN PERFORMANCE

ORGANISATIONAL BEHAVIOUR

INDIVIDUAL BEHAVIOUR

ATTITUDE

PERSONALITY

(AGE,SEX,EDUCATION, UPBRINGING, EXPERIENCE,

ENVIRONMENT, BELIEFS,VALUES, POSITION, SITUATION)

PERCEPTION


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CONTROL OF MEN

PERFORMANCE Recruitment

Selection

Placement

Induction

Training

Devolopment Retraining

Motivation & Discipline


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ACCIDENT COSTING

(Affected parties) Accidentee

Management

Immediate Supervisor

Government

Society


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ACCIDENTEE

Loss of life/limb

Pain,Anxiety

Loss of livelyhood,wages

Incapacity to perform normal work


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SUPERVISOR

Anxiety

Loss of prestige/Reputation

Legal implications

Loss of skill

Time and energy for the devolopment ofsubstitute


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MANAGEMENT

DIRECT COST

Cost of Compensation

Cost of medical expenses

Cost of investigation

Cost of rehabilitation


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MANAGEMENT INDIRECT COSTS

Lost time of accidentee

Lost time of fellow workmen

Lost time of Supervisors & Executives

Lost time of clearing the accident site Lost time of repairing the damaged equipments

Lost time for restarting the process/production

Reduced quality of output due to the emotional upset ofsupervisors/workmen

Blocked Capital Loss of skill and experience

Lost time for the training of the replaced workman

Lowered employee morale

Increased labour conflict

Unfavourable public image/relations


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ACCIDENT PREVENTION

INDENTIFY AND ESTABLISH

CONTROL OVER THE CAUSE OF

ACCIDENTS


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INVESTMENT FOR SAFETY

Cost of accidents are 10 times morethan the cost of accident prevention

programmes, as the indirect cost of

accidents are 10 times more than the

direct costs.


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ACCIDENT CAUSES

PROXIMATE CAUSE

CONTRIBUTING CAUSE

IDETIFY AND ATTACK THE ROOT

(CONTRIBUTING) CAUSES


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PROXIMATE CAUSE

UNSAFE PHYSICAL CONDITION

UNSAFE WORK PRACTICES

COMBINATION OF BOTH


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CONTRIBUTING CAUSE

Inadequate knowledge and skill

Anatomical /Physiological unsuitability

Improper Psychological charecteristics


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ROOT CAUSE

FROM THE PART OF SUPERVISOR

Inadequate leadership

Inadequate motivation

Inadequate instruction(No instruction,Incomplete

instruction,Erroneous instruction)


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ROOT CAUSE

FROM THE PART OF WORKMAN

ANATOMICAL/PHYSIOLOGICAL UNSUITABILITY

Loss of limbs Shortage of limbs

Poor eye sight

Poor hearing(THL/PHL) Astigmatism

Epileptic


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ROOT CAUSE FROM THE PART OF WORKMAN

PSYCHOLOGICAL

Over confidence

Lack of confidence

Haste

Short cut practices

Chance taking

Inattention

Absent minded

Thoughtlessness

Fatalistic attitude


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ROOT CAUSES

FROM THE PART OF WORKMAN

DISCIPLINE

Disobedience Disregard to instructions

PHYSICAL CONDITION

Sick/Weak/Fatigued

KNOWLEDGE/SKILL

Inexperienced

Ignorant


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CLASSIFICATION OF INDUSTRIAL

ACCIDENTS AS PER IS 3786 CLASSIFICATION ACCORDING TO

B1 AGENCY

B2 UNSAFE PHYSICAL CONDITION B3 UNSAFE ACT

B4 UNSAFE PERSONAL FACTOR

B5 TYPE OF ACCIDENT B6 NATURE OF INJURY

B7 LOCATION OF INJURY


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B1 AGENCY

MACHINES(Prime movers,Transmission

machineries,metal/wood/agricultural,mining

machineries) TRANSPORTATION/MOVING

EQUIPMENT(Lifting

machines,Road,Rail,Air,Water transportation

OTHER EQUIPMENTS(Pressure

vessels,Electrical installations,Electric hand tools)


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B2 UNSAFE PHYSICAL CONDITION

Inadequately Guarded machinery

Inadequate Ventilation

Inadequate illumination


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B3 UNSAFE ACT

Operating without authority

Failure to warn

Operating at unsafe speed

Making safety devices inoperative


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B4 UNSAFE PERSONAL FACTORS

Inadequate knowledge and skill

Anatomical /Physiological unsuitability

Improper psychological charecteristics


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B5 TYPE OF ACCIDENTS

Fall of persons

Fall of objects

Striking against objects

Struck by objects

Caught in between objects

Exposure to extra temperature

Exposure to electric current


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B6 LOCATION OF INJURY

Head

Neck

Trunk

Upper limb

Lower limb

Multiple locations


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B7 NATURE OF INJURY

Fractures

Dislocations

Sprains

Concussions

Burns

Acute poisoning

Asphyxia


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ACCIDENT INVESTIGATION

COLLECTION OF PRELIMINARY DATA

SPOT VISIT AND COLLECTION OF

OBJECTIVE EVIDENCES INTERACTION AND RECORDING

ANALYSIS AND CONCLUSION

RECURRENCE AVOIDANCE MEASURES PREPARATION OF REPORT


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ACCIDENT INVESTIGATOR

KNOWLEDGEABLE

EXPERIENCED

PROMPT

UNBIASED

FACT FINDING

SOUND IN JUDGEMENT

DIPLOMATIC


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REPORTING

SYSTEM OF REPORTING

(INCIDENTS,NEAR MISSES,ACCIDENTS)

STATUTORY REPORTING

FACTORIES ACT

SECTION 88- NOTICE OF ACCIDENTS

SECTION 88A-NOTICE OF DANGEROUSOCCURENCES

SECTION 89-NOTICE OF DISEASES


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REPORTING

TNFR/RULE 96

(FATAL,SERIOUS,DANGEROUS OCCURRENCE)

Immediate information to CIF/DCIF/IF through telephone/Fax,District

Magistrate,Inspector of Police Form 18/18A within 12 Hrs.

Other cases of reportable accidents within 72 Hrs in Form 18

Electrical accidents in Power Generation, Transmission,Distribution

systems involving injury to human or animal to be reported to the

Electrical inspector by telephone within 24 Hrs and in FORM as perANNEXURE XIII within 48 Hrs.(as per Rule 44A of IER 1956)


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MANAGEMENT OF INTOLERABLE RISKS

Reduce the risk level by reducing the likelihood &consequence THROUGH

Introduction of New Technology

Modification of Existing Technology

Substitution

Separation

Administration Training

PPE


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FEASIBILITY STUDIES

TECHNICAL VIABILITY

ECONOMIC VIABILITY

OPERATIONAL VIABILITY

LEGAL REQUIREMENTS


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AREAS OF OSH AUDIT AS PER IS 14489

Health & Safety Policy

Safety Organisation (Safety

Dept/Committee/Safety Budjet

Accident Reporting,Investigation & Analysis

Safety Inspections

Safety Education & Training

First Aid Occupational Health Centre


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OSH AUDIT AS PER IS14489

General Working Condition(House

Keeping,Noise,Illumination,Ventilation)

Hazard Identification & Control

Safe Operating Procedures

Work Permit System

Waste Disposal System

Personal Protective Equipment


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OSH AUDIT AS PER IS 14489

Fire Protection

Emergency Preparedness

Plant Layout and Area Classification

Static Electricity

Pressure Vessels(Fired & Unfired)

New Equipment Review

Lifting Machines & Tackles


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OSH AUDIT AS PER IS 14489

Mobile Equipment & Vehicular Traffic

Safe Access

Material Handling Pressure Vessels/Tanks Safety

ON SITE Gas Cylinder Storage Area

Plant Communication System Transportation of Hazardous Materials

(Road/Rail/Pipelines)


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SAFETY PERFORMANCE INDICES

FREQUENCY RATE

(Number of accidents x10,00,000)/Man

Hours worked

SEVERITY RATE

(Total mandays lost x10,00,000)/Man

Hours worked


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DETERMINATION OF RISK LIKELIHOOD

Highly Unlikely1

Full control over the identified hazardby way of Technology, Operational

Control,measurement and

monitoring,Competence(NO GAP)

Unlikely

2

Minor Gap exits over the control of

identified hazard

Likely

3

Major Gap exits in control over the

identified hazard

Very Likely

4

No Control over the identified hazard


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CRITERIA FOR RISK ASSESSMENT

LIKELIHOD(L) COSEQUENCE( C ) RISK=LxC

Highly Unlikely(1)

Slightly Harmful(2)

Trivial(2)

Unlikely

(2)

Harmful

(4)

Moderate/

Tolerable(4-8)

Likely

(3)

Very Harmful

(6)

Substantial

(12-18)Very Likely

(4)

Extremely Harmful

(8)

Intolerable

(24-32)

DETERMINATION OF RISK CONSEQUENCE LEVEL


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DETERMINATION OF RISK CONSEQUENCE LEVEL

RANKING HUMAN PROPERTY

Slightly Harmful2

MomentaryDiscomfort No Damage

Harmful

4

First Aid./Non

Reportable

injuries

Minor Damage

Very Harmful

6

Reportable

Minor/Major

injuries(Temp

disability)

Severe Damage

Extremely Harmful

8

Fatal/Perm.

Disability(Incide

nts involving

large number of

Complete

Distruction

Documents

Loss Controland Safety Management