Six Weeks Internship

Report OnEmbedding Safety Culture at site by improving Lock-out

Tag-out Work instructions.

Submitted By: Atul Thakur

Indian Scenario

Indian confectionery market valued at INR 95 billion in 2012- 2013

Expected to touch INR 600 billion in 2016 Sugar confectionery hold market share of around 46% Major Players- Nestle, Perfetti Van Melle, Mars India, Amul,

Parle, ITC, Candico. In chocolate section – Cadbury holds market share of 65% Nestle holds market share about 20% Emerging Trend of gifting Confectionery products Impulse buying

Company Profile company was founded on April 1, 1891 Subsidiary of Mars Incorporated, acquired on April 28, 2008 Currently selling its products in 180 countries. Maintains 140 factories in various countries including US,

Mexico, Australia, India, Canada, UK, Korea etc. Mars Principles- Quality, Responsibility, Mutuality,

Efficiency, Freedom. Associates are putting the Mars Principles in action every

day to make a difference

Major Products Of Company

Spearmint Juicy Fruit Altoids Life Savers Doublemint Orbit Winterfresh Boomer PimPom Solano Boomer Jelly On Top

ESH Department

Vision - “Protecting the Safety of People and Enhancing the Quality of Life for our Associates, their families and communities”

Manager- Mr. Deepak Rai Coordinator – Mr. Dinesh Gautam The main objective of the department is to foster a safe and

healthy work environment. Committed towards the goal of zero accident workplace.

Safety can be important for Moral, legal and financial reasons. Moral obligation would involve the protection of employee’s

health Legal reasons to prevent Punitive and compensatory effects of

laws that protect worker’s safety and health It reduce employee injury and illness related costs, including

medical care, sick leaves and disability benefit costs.

Lock-Out Tag-Out

Lockout/Tagout is a procedure used to ensure that machines, or systems are isolated from their hazardous energy source.

This eliminates inadvertent activation while work is being performed on the equipment, and protects other workers in that area.

Applicable to all the maintenance or servicing activities. Types Of Energies- Electrical. Mechanical, Pneumatic,

Hydraulic, Steam, Chemical, Hot Water.

Six Steps Of Lock-Out Tag-Out

Preparation for shutdown Shut down the equipment Equipment isolation Application of Lockout/Tagout devices Release of stored energy Verifying equipment isolation

Need Of Lock- Out Tag-Out

Lock-Out Exception Permit

required for any adjusting or setting required to be done in running machine by removing fixed guard / bypassing any interlocks or any safety device.

Issued when problem is not identified in shutdown mode. allows the associate to remove the fixed guard or bypass any

interlock guard and observe the problem when machine is running on inching mode.

Requirement of LOTO SOPs Total lines – Boomer, Boomer MP, Boomer JOT, Duet, Candy,

Gumbase, Dive, Airwaves. Total no. of Machines or Equipment- 190 machines

Why need arises???? The observations of LOTO skill survey conducted at site was

that : Six steps of LOTO procedures were not clear . As the SOPs are in English.

Comparison of SOPs

Lock-out Tag-out Survey

Conduct a survey as a part of training to analyze the knowledge of the shop floor associates regarding LOTO procedure.

To know the problems faced by them during LOTO procedure. And to check what they think about there safety in the organization On the basis of my literature review I conclude that the main

parameters that effects safety during LOTO procedure are: Knowledge about the equipment. Procedure of energy isolation. Availability of Lock & Tag. Standard procedure of LOTO. Safety Training.

Research Methodology Objective: To find out that whether the Lock-Out Tag-Out

work Instructions improves safety culture in organization.  Sampling Frame: I considered the shop floor associates who

are working on different equipment and generally engage in maintenance and servicing activities.

Target population and sample place: Shop floor associates of the organization.

Sample Size: 40 Shop floor associates who work on different equipment or machines taken as sample as being part of project based assignment on Lock-Out Tag-Out instructions.

Sampling Method: I choose random sampling technique in different lines to select my sample, to get data from the associates of different lines.

Data Analysis: The data is analyzed by SPSS program.

Skill Survey Questionnaire What is to be included in LOTO? Safety is the top priority of the organization. All the hazardous energies associated with equipment are well known. LOTO is the best way to eliminate hazards during maintenance and servicing

(cleaning) activities. New LOTO SOP helps you to understand 6 steps of LOTO procedure. LOTO equipments are easily available. Proper training is provided to you for the usage of LOTO equipment. There is strict need that every person working on equipment during maintenance

or servicing activities should individually attach there lock and tag on equipment. You feel safe during minor intervention activities. You feel safe after taking LOTO exception permit LOTO falls under the Mars Zero Tolerance Policy. Pre shift inspection is enough to ensure safety. LOTO can be removed only after informing to all associates and removing all the

tools.

Findings During preparation of LOTO SOPs

No system for verification of release of steam energy on Boomer Mixers 1, 3, 5.

No system for verification of release of steam energy on JOT Cooker 1, 3, 4.

There are still some pneumatic ball valves are used that requires additional accessories during Lock-out Tag-out.

we replaces these valves with automatic pneumatic valves on Solano milk tank, auto feeder, Duet Cooker & PimPom Metal detector

MCBs are used as electric switch in many machines that also requires additional accessories during Lock-out Tag-out.

No system for verification on Carton Sealing Machines.

Recommendations A system should be provided to verify release of steam energy on

Boomer Cooker 1, 3, 5, and JOT Cooker 1, 3, 4. All the pneumatic ball valves should be replaced with the

automatic pneumatic valves to ensure safety of the associates. MCB boards should be replaced by electric LOTO switches. By that time MCB LOTOs should be provided to associates with

proper training of how to use this LOTO. A system should be provided how to verify energy isolation on

carton sealing machines.

Finding Lock-out Tag-out Survey

62.5% of the respondents said that LOTO equipments are not easily available.

62.5% of the respondents said that they do not feel safe after taking LOTO exception permit

Only 20% of the respondents able to explain the complete procedure of group LOTO removal.

Recommendations

Al l the MCB boards and pneumatic ball valves should replaced by electric LOTO switch and automatic pneumatic valve.

The associates do not having clarity about LOTO exception permit, proper training is to be provided on LOTO exception permit.

Proper training should be provided to the associates on group LOTO removal procedure.