Sfty Mngt & Acc. Preven

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Safety ManagementSafety Management

AndAnd

Accident PreventionAccident Preventionby

B.K.Sadananda DGM ( Safety ), BEL (Retd)

& Hon. Treasurer, NSC:KC

33

What is Safety?What is Safety?

Safety is the state of Safety is the state of

being free from bodily injury, being free from bodily injury,

being free from occupational diseases being free from occupational diseases being free from mental tensionbeing free from mental tension

44

What is Accident?What is Accident?

An accident is an

un-planned,

unforeseen,

unexpected event

which may or may not result in injury

to the person or

damage to the material or equipment.

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Like Like Material ManagementMaterial Management

Finance ManagementFinance Management

Personnel ManagementPersonnel Management

Production ManagementProduction Management

Quality ManagementQuality Management

Marketing ManagementMarketing Management

Sales Sales Management Management

Safety Management is alsoSafety Management is also a branch of Management a branch of Management

in any Organization in any Organization

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Safety Management -Safety Management -

The accomplishment of Safety objectives by first establishing the safety objectives and then attaining them through the process of planning, organising, staffing, executing, evaluating, controlling and directing (i.e. motivating and coordinating all efforts and organising groups of people and also innovating to improve the safety objectives for the feature)

77

Objectives of Safety ManagementObjectives of Safety Management

• To prevent Accidents, injuries, property damages

• Minimize Unsafe Act and Unsafe condition

• Good working condition

• Providing healthful environment

• Continuous vigil and improvements.

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Functions of Safety management -Functions of Safety management -1) Planning- Setting Safety objectives

Formulation of Safety Policy

Safety programmes

Budgeting

Determining procedures

2) Organising- Establishing formal structure

3) Staffing-

4) Directing-

5) Controlling-

6) Coordinating-

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Factory Act 1948Factory Act 1948

Consists ofConsists of

12 chapters having 120 Sections12 chapters having 120 Sections

3 schedules3 schedules

1010

ChaptersChapters inin Factory Act 1948Factory Act 1948

1. Preliminary1. Preliminary2. The Inspection Staff2. The Inspection Staff3. Health.3. Health.4. 4. Safety.Safety.5. Welfare5. Welfare6. Working Hrs.6. Working Hrs.7. Empl of young 7. Empl of young

persons.persons.8. A.L. with wages.8. A.L. with wages.9. Spl. Provisions9. Spl. Provisions10. Penalties 10. Penalties

&Procedures&Procedures11. Supplements.11. Supplements.

1 to 71 to 78 to 108 to 1011 to 2011 to 2021 to 4121 to 4142 to 5042 to 5051 to 6651 to 6667 to 7767 to 7778 to 8478 to 8485 to 9185 to 9192 to 10692 to 106107 to 120107 to 120

SectionsChap.

1111

SchedulesSchedules inin Factory Act 1948Factory Act 1948

I I List of Industries involving List of Industries involving hazardous hazardous

processprocess

II Permissible levels of certain II Permissible levels of certain chemical chemical substances in wok substances in wok environmentenvironment

III List of notifiable diseasesIII List of notifiable diseases

1212

Chapters in Factory Act 1948 (sec 21-41) Chapters in Factory Act 1948 (sec 21-41) SafetySafety

21. Fencing of Machinery21. Fencing of Machinery 22. Work on or near m/c in motion22. Work on or near m/c in motion 23. Employment of young persons on 23. Employment of young persons on

dangerous m/c.dangerous m/c. 24. Striking gears &devices for cutting of 24. Striking gears &devices for cutting of

powerspowers 25. Self acting Machines25. Self acting Machines 26. Casing of new Machines26. Casing of new Machines 27. prohibition of employment of woman & 27. prohibition of employment of woman &

children children near cotton openers near cotton openers 28. Hoists & lifts28. Hoists & lifts 29. Lifting m/c, Chains, ropes & lifting tackles29. Lifting m/c, Chains, ropes & lifting tackles

1313

Chapters in Factory Act 1948 (sec 21-41)Chapters in Factory Act 1948 (sec 21-41)

30. Revolving Machinery30. Revolving Machinery 31. Pressure plant31. Pressure plant 32. Floors, Stairs & means of access32. Floors, Stairs & means of access 33. Pits, Sumps, Openings in floors33. Pits, Sumps, Openings in floors 34. Excessive weights34. Excessive weights 35. Protection of eyes35. Protection of eyes 36. Precautions against dangerous fumes 36. Precautions against dangerous fumes

& gases & gases 36A. Precautions regarding use of portable 36A. Precautions regarding use of portable

electric electric light light 37. Explosive or inflammable dust, gas etc.37. Explosive or inflammable dust, gas etc. 38. Precautions in case of fire38. Precautions in case of fire

SafetySafety

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Chapters in Factory Act 1948 ( Chapters in Factory Act 1948 ( sec 21-41 sec 21-41 ))

39. Power to require spec of defective 39. Power to require spec of defective partsparts

40. Safety of building & m/c s40. Safety of building & m/c s

40A. Maintenance of building40A. Maintenance of building

40B. Safety officers40B. Safety officers

41. Power to make rules to supplement this 41. Power to make rules to supplement this chapter chapter

SafetySafety

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Implementation of Safety Implementation of Safety

I. Safety council (Apex body) as per sec. 41A of factory act 1948. ( workers

participation)

II. Safety Engg. Dept. Exclusively working for safety activities as an advisory body

III. Safety committee Small groups formed in various Dept. to take care

of safety aspects of their

Dept ./ Section

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Safety council -Safety council -as per sec. 41A of factory act 1948. ( workers participation)

• Comprising - Chairman (G.M. grade)

- Secretary ( Head of Safety)

- Mangt. Reps (5 AGM/DGM )

- NTU. Reps (5 Members)

• Meet at least 3 months once as per statutory requirement

• To take care of Safety Mangt. Issues

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Objectives of Safety council -Objectives of Safety council -• To work as a part of Management function.

• Help the management in specific area of Safety.

• To work as a group of Safety representatives

for Group suggestions

Decision,

Co-operative Safety efforts

• Two way channel of Communication through which suggestions can flow from Employees to Management and vice versa.

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Safety Engg. Dept. -Safety Engg. Dept. -

• Headed by Chief Safety officer

Directly reporting to Unit head.

• Assisted by number of Safety officers & office staff.

All Safety Officers should have additional qualification of

“post Diploma in industrial Safety”

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Functions Safety Engg. Dept. – Functions Safety Engg. Dept. –

• To meet all statutory requirements

• Accident statistics

• Accident Reporting

• Preparation of MSDS

• Conduct Safety Survey, Inspection & Audit

• Lifting devices & pressu. vessels certification

• To bring Safety Awareness to all Employees /

Executives.

• To meet PPEs requirements and usage.

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Safety Committees -Safety Committees -• Headed by Chairperson (Sect./Dept. head ) assisted by. 2 or 3 Executives,

2 or 3 Supervisors, 2 or 3 Non Exec. along with one safety officer

• Number of Safety Committees depends on Number of Employees, Type of Industry Complexity of Industry

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Functions of safety Committee -Functions of safety Committee -• To maintain interest of shop floor staff & To maintain interest of shop floor staff &

Executives to understand safety as Executives to understand safety as prime prime concern. concern.

• Periodical shop floor visits to suggest Periodical shop floor visits to suggest improvements In safety.improvements In safety.

• To assist in investigation of accidents.To assist in investigation of accidents.

• Contribute ideas/ suggestions to improve Contribute ideas/ suggestions to improve Safety. Safety.

• Promote Safety awareness. Promote Safety awareness.

• Persuade the fellow workmen to use PPEs .Persuade the fellow workmen to use PPEs .

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Some misconceptions about safety Some misconceptions about safety

1) 1) Accidents do happen – they are inevitable.Accidents do happen – they are inevitable.

2) 2) If a worker is destined to meet with an If a worker is destined to meet with an accident no effort can save him.accident no effort can save him.

3) 3) When there is huge machineries and fast When there is huge machineries and fast moving production line, accidents are moving production line, accidents are inevitable.inevitable.

4) 4) Production and safety do not go together. Production and safety do not go together. We can have high production only at the We can have high production only at the cost of cost of safetysafety

5) 5) Safety rules are for new comers.Safety rules are for new comers.

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SomeSome misconceptionsmisconceptions about safety about safety (Cont.)(Cont.)

6)6) A willing worker will meet with accidents, A willing worker will meet with accidents, not an idlernot an idler

7)7) Only the man who works sincerely gets Only the man who works sincerely gets injuredinjured

8)8) A lazy worker is always safeA lazy worker is always safe

9)9) Maintaining safety is only a managerial Maintaining safety is only a managerial function, employees have nothing to do with it.function, employees have nothing to do with it.

10)10) It is cowardly to be afraid of accidents It is cowardly to be afraid of accidents and and hide yourself behind safety appliances hide yourself behind safety appliances and and guards.guards.

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Accident RatioAccident Ratio

Un preventable = 2%

Preventable = 98%

1 Major Injury

29 Minor Injury

300 Near Miss cases

Henrich theoryBased on 75000cases

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ACCIDENT CAUSATION ACCIDENT CAUSATION --

Many theorists and psychologists Many theorists and psychologists have conducted in-depth studies in have conducted in-depth studies in the field of industrial safety. the field of industrial safety.

Those studies prove that Those studies prove that

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Accidents do not occur

but

They are caused

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ACCIDENT CAUSATIONACCIDENT CAUSATION - - (cont)(cont)

Dr.H.W.Heinrich, One of the pioneer researchers in safety management, after analyzing 75,000 accidents, came to the conclusion that

98% are Preventable and

2% are Unpreventable.

Further, he classified the causes into two-

i.e. Unsafe actions (88%) and

Unsafe conditions (10%)

All such accidents are found to be due to human failure.

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ACCIDENT CAUSATION:- ACCIDENT CAUSATION:- (cont)(cont)

Dr. Heinrich further explained that the process of accident causation is a chain of events.

This sequence of accident causation process is termed “Five Domino Theory”, with each Domino appearing one after another viz.

1) Faulty social environment 2) Fault of persons3) Unsafe actions / Unsafe condition4) Accidents5) Injury / Losses

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ACCIDENT CAUSATION:- ACCIDENT CAUSATION:- (cont)(cont)

Frank E Bird has gone further to identifyexact causes of accidents. Lack of control by the management would be

the primary link in the chain of accidents causation. i.e. the root or basic cause of accidents is

“The lack of control by the management.”

Wherever substandard practices and conditions are permitted to exist, the accidents do mostly occur.

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• Edward Adam confirms that the unsafe actions and unsafe conditions are arising out of operational errors made by the Managers or Supervisors.

• In other words the interest taken by the top management will reflect on the Safety of the company as a whole.

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• D.A.Weaver has updated the Domino Theory of Heinrich and concluded that

the unsafe action or unsafe condition are only proximate causes ascribed to an accident .

Where as management practices in

Policy, Priorities, Organizational structure, Decision making, Evaluation, Control and Administration are the root causes behind them.

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Accident Causation Model

(Used to predict accidents)

Inadequate:• System•System Stds.•Compliance

to Std

Personal factors

orSystem/Job

factors

Unsafe act

unsafe condition

event

Unintended Harm

and/or

Damage

Loss Control Model

(used to analyze accidents)

Lack of Control Basic Causes

Immediate Causes

Incident Loss

Threshold limit

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Causes of AccidentsCauses of Accidents• Simple careSimple care

• InexperienceInexperience

• Failure to follow InstructionFailure to follow Instruction

• Poor engineering EquipmentPoor engineering Equipment

• Bad House keepingBad House keeping

• Bad Lighting & VentilationBad Lighting & Ventilation

• Improper Chemical handlingImproper Chemical handling

• Unsafe LoadingUnsafe Loading

• Improper AttitudesImproper Attitudes

3434

Causes of accidents:-Causes of accidents:-

• Direct causes Unsafe practices

Unsafe conditions

* Indirect causes Supervisory safety performance

Mental condition of persons

Physical condition of persons

3535

DIRECT CAUSES:

UNSAFE CONDITION

UNSAFE ACT

3636

UNSAFE CONDITIONS

* Slippery Floors, Hazard Material Storage

* Unsafe Dresses

* Unsafe tools

* Bad Housekeeping

* Bad Illumination and Ventilation

* Over crowding, Obstructions

* Unsafe methods & Procedures

* Noise & Vibration

* Improper Storage of Chemicals* Defective conditions

* Unguarded

hours dBA

8 90

6 92

4 95

3 97

2 100

1.5 102

1 105

. 75 107

0. 5 110

0. 25 * 115

* No exposure to continuous noise in excess of 115 dBA

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* Using unsafe Equipment

* Operating at Unsafe Speed

* Making Safety Devices Inoperative

* Unsafe Loading, Placing & Mixing

* Taking unsafe Position / Posture

* Distracting, Teasing, Abusing & Startling

* Failure to use Personal Protective equipment

* Removing Guards of Machines

* Operating without authority

UNSAFE ACTS

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RESULTSInjury / Fatality

Minor injury / Disabling

Production delay

Reduced quality

Spoilage

3939

Economics of AccidentsEconomics of Accidents Rs 1000Rs 1000 Insurance Costs

Covering injury, ill health & damage

Hidden Costs

Rs. 8,000-36,000

Product & Material DamageTool & Eqpt DamageEmergency SuppliesProduction DelaysTemporary LabourSupervisors TimeFines

Plant & Building DamageLegal CostsClearing SiteOvertime WorkingInvestigation TimeClerical EffortLoss of Expertise

4040

4141

4242

4343

Prevention of accidentsPrevention of accidents (4Es) (4Es)

• Engineering

• Education

• Encouragement

• Enforcement

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Engineering :-Engineering :-• By designing and providing guards,

• Good ventilation,

• Good illumination,

• Changing processes

Eg. Dry process to wet process, Manual handling to Mechanical handling,

Enclosing and isolating process.

4545

Education:-Education:-

• Educating employees and training them in different safety aspects.

E.g.: pre-employment training, On the job training ,

Periodical training.

4646

Encouragement:-Encouragement:-• Safety competitions,

• Safety education,

• Safety exhibitions,

• Safety films and video shows,

• Seminars and debates,

• Safety awards etc.

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Enforcement:-Enforcement:-

• By implementing safety rules and to have administrative controls and following the same.

E.g. Pre-medical exam

4848

TYPES OF HAZARDS:-TYPES OF HAZARDS:-

• CHEMICAL

• PHYSICAL

• BIOLOGICAL

• ERGONOMICAL

# Physiological

# Psychological

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CHEMICAL HAZARDS:-CHEMICAL HAZARDS:-

• CHEMECAL • Explosives• Corrosives• Flammable Liquids• Toxic Chemicals• Oxidizing Materials• Dangerous Gases

• AIRBORNE PARTICULATES

• Dusts• Fumes• Smokes• Aerosols• Mists• Gases• Vapors

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PHYSICAL HAZARDS:-PHYSICAL HAZARDS:-

• Noise

• Vibration

• Temperature

• Radiation# Ionizing# Non – Ionizing

* Infrared* Ultraviolet* Microwave* Laser

5151

BIOLOGICAL HAZARDS:-BIOLOGICAL HAZARDS:-

• Bacteria

• Fungi

• Moulds

• Mites

• Insects

• Plants

• Viruses

5252

ERGONOMICAL HAZARDS:-ERGONOMICAL HAZARDS:-

PHYSIOLOGICAL

• Lifting

• Cumulative Trauma

Disorders

• Fatigue

PSYCHOLOGICAL

• Monotony

• Personal Relation ships

• Work – Rest Cycles

5353

Measurement of Measurement of Safety performance:-Safety performance:-

There are 3 types of injury rates:

1) Frequency rate

2) Severity rate

3) Incidence rate

5454

Frequency rate :Frequency rate :i.e., How often do injury occur ?

-Defined as the disabling (lost time) injuries per 106 man-hours worked

FA = No. of reporable lost time injury * 106

Man hours worked

5555

Severity rate :Severity rate :-i.e., How serious are the injuries ?

-Defined as the number of days of lost time per 106 man-hours worked

SA = Man days lost due to lost time injury * 106

Man hours worked

5656

IIncidence rate :ncidence rate :-i.e., How serious are the injuries ?-is the ratio of the number injuries

to the number of persons during the period under review.

-It is expressed as the no. of injuries per 1000 persons employed

IA = Number of lost time injuries * 1000

Average No. of persons employed

5757

Three major concerns of a supervisor to prevent accidents

The Worker

The work method

The work area

5858

The WorkerMake sure that all of your team:Make sure that all of your team:

-Know the correct & safe way of doing job-Know the correct & safe way of doing job

-Understand the dangers they may face-Understand the dangers they may face

-Wear their PPEs-Wear their PPEs

-They must report faults immediately-They must report faults immediately

-Fire eqpts. & their usage-Fire eqpts. & their usage

-Maintain personal hygiene-Maintain personal hygiene

Take action to control the danger byTake action to control the danger by

-Train, Explain, Acceptance of safety -Train, Explain, Acceptance of safety instructionsinstructions

To prevent recurrence byTo prevent recurrence by

-Stop, Correct, Retrain & Follow up-Stop, Correct, Retrain & Follow up

5959

The Work methodEnsure that Ensure that

-Prescribed safety procedure are maintained-Prescribed safety procedure are maintained

-Guards are secure and in good condition-Guards are secure and in good condition

-Lighting is adequate for the job-Lighting is adequate for the job

-Materials, tools and equipments are safe-Materials, tools and equipments are safe

-Layout is safely maintained-Layout is safely maintained

-Stacking of goods and equipments is safe-Stacking of goods and equipments is safe

-Dust and fume extraction works propely-Dust and fume extraction works propely


-safe method of working -safe method of working

-Watch for dangerous working practices-Watch for dangerous working practices


-Eliminate, Guard, warn, Report-Eliminate, Guard, warn, Report

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The Work areaCheck that in all working areasCheck that in all working areas

-Lay out and work spots are safe-Lay out and work spots are safe

-Access is adequate and free from danger-Access is adequate and free from danger

-Fire eqpts are ready for immediate use-Fire eqpts are ready for immediate use

-Floors, gangways etc. are in good -Floors, gangways etc. are in good condition & free condition & free from from obstruction, oil etc.obstruction, oil etc.

-Handrails and covers for openings are -Handrails and covers for openings are securesecure


-Eliminate, guard, warn, Report-Eliminate, guard, warn, Report


-Take action on potential hazards-Take action on potential hazards

6161

Proactive Measures to avoid Accidents in hazardous area

* ‘Work permit system’ is to befollowed strictly

* Display of MSDS (Material Safety Data Sheet) at the concerned Chemical storage / handling and process areas

* Issue of Chemical / Electrical Oil resistance Shoes

* Issue of job related PPEs to employees

* Well organised Hazardous waste Management

6262

Special attention in case of the followingSpecial attention in case of the following

• House keeping• Fire• Electicity• PPE usage• Guards• Chemicals• Tools• Machines

• Material handling

• High temperature

• High speed

• Lighting

• Ventilation

• Flooring

• Falling objects

6363

What to do in case ofAccident involving an injury:

1) Be calm2) Remove the danger3) Attend to the injured person4) Call medical help if necessary5) Inform to the manager6) Investigate the cause7) Complete the accident report form

6464

4 “A”s for Safety:

1) First A …Attitude 2) Second A …Awareness 3) Third A …Action 4) Fourth A …Accountability

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Accident Prevention –Accident Prevention – What can What can youyou do? do? Do not cut corners, always use the correct Do not cut corners, always use the correct

equipment for the task equipment for the task Think of others, be observantThink of others, be observant Make sure you fully understand any Make sure you fully understand any

instructions, instructions, if in doubt ASKif in doubt ASK

NEVER ignore safety instructionsNEVER ignore safety instructions

Remember Remember accidents are accidents are

preventablepreventable

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Any Questions

?

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NOTIFIABLE DISEASES1. ANTHRAX

2. ARESENIC POISONINGS

3. ASBESTOSIS

4. BENZENE POISONING

5. BERYLLIUM POISONING

6. BYSSINOSIS

7. CARBON MONOXIDE

8. CARBONBISULPHIDE

9. CHROMIUM ULCERATION

10. COAL MINERS PNEUMOCONIOSIS

11. DEMATITIS

12. HALOGEN POISONING

13. ISOCYANATE POISONING

14. LEAD POISINING

15. LEAD TETRAETHYL POISONING

16 MANGANESE POISONING

17 MERCURY POISONING

18 NOISE INDUCED HEARING LOSS

19 NITROUS FUMES POISONING

20 OCCUPATIONAL CANCER

21 OCCUPATIONAL DERMATITIS

22 PHOSGENE POISONING

23 PHOSPHORUS POISONING

24 PRIMARY SKIN CANCER

25 RADIUM & X-RAY HAZARDS

26 SILICOSIS

27 TOXIC ANEAMIA

28 TOXIC JAUNDICE

29 TOXIC NEPHRITIS

Documents

Sfty Mngt & Acc. Preven