Trusted Technology – Solid Strength
SAFETY AT
VASAVADATTA CEMENT
SAFETY DEPT-ORGANIZATION CHART
Plant Head
GM-Safety
VC-Safety Steward (8 Nos)
Dept –Nominated Safety Officer (15 Nos)
Manager-Safety
Contractor Safety steward (15 Nos)
Sr.Engineer-Safety
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SAFETY POLICY Trusted Technology - Solid Strength
Safety Statistic / Key Indicators Trusted Technology - Solid Strength
Sl No Audit Team 2016-17 2017-18
1 No of Fatals 00 00
2 No of Reportable Accidents 00 00
3 No Of First Aid Injury 09 07
4 No of Near Miss 13 10
5 No of Tool Box Talk 17998 19483
6 No of Task Observations 4479 4189
7 No of Dangerous Occurrences 00 00
8 No of Suggestion Received Form Employees 1361 915
9 Training Imparted to Employees 2075 2101
10 Frequency Rate 00 00
11 Severity Rate 00 00
12 Incident Rate 00 00
13 Longest Safe Mendays 712115 974915
LEGAL COMPLAINCES
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Integrated Management System Certifications ISO 14001- Environmental Management Systems ISO 9001 - Quality Management Systems ISO 50001:2011 - Energy Management System OHSAS 18001 – Occupational Health & Safety Management Systems Under which Risk assessments have been done for all task which involves risk and may cause Injury or leads to occupational decease and also made Safe Operating Procedure for each task and are displayed at work site in local , Hindi and English languages. Comprehensive Internal / External Safety Audit inviting experts From various organisation Viz, National Safety Council, M/s Green circle,CII, M/s Reliance Insurance Mumbai, BIS Etc.
Sl No
Audit Team No of
Observation No of Observation
Implemented Pending / Not
Feasible
1 M/s National safety Council Karnataka chapter
193 193 00
2 M/s National safety Council Mumbai
56 56 00
3 M/s Reliance Insurance 29 29 00
4 M/s Green Circle Inc Gujarat 138 135 03 (NF)
Sl No No of Risk Assessment No of Safe Operating
Procedure (SOP)
1 246 136
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LEGAL COMPLAINCES
We comply with all statutory requirement as per Karnataka Factories Rules 1969 / Factories Act,1948. We do Mock drill once in every quarter on Height Rescue Drill and Fire Fighting Demonstration Etc and separate emergency manual being made and circulated among all and respective team will response during emergency .
Inspection of All Tools, Tackles, Pressure Vessels & Passenger Lifts by Competent Person As per Rule 63 & 65 of
Karnataka Factories Rules 1969
Central Safety Committee being formed which includes 101 members and chaired by plant head and committee will meet once in quarter and all safety issues will be addressed and decided by committee members
Central Safety Committee Inspection Of Lifting Tools By Competent Person
Mock Drill
Directional Board & Traffic Mirror Installed At Plant Premises
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safe access with platform to eliminate risk of fall of person from tanker top while
opening / closing top doors
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Safe Over Head Platform
Vehicle Speed Check and Safety Talk To Truck Drivers
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Training to All Staff / Workmen / Contract work men By M/s Road Safety Foundation On “Defensive Driving Training’ “-23rd Dec 2017
Training on Defensive Driving to Truck Drivers On the view of Road Safety Week Celebration
Safety Suggestion & Near Miss Reporting
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Boxes are kept at convenient locations with reporting format A single form developed which includes Near Miss, Safety Suggestion, Unsafe Act & Unsafe Condition Weekly Forms are segregated in above four Categories Reward for reporting a near miss incident, a safety suggestion and at least 05 unsafe condition Monthly Awards distributed during Safety Gate Meeting holds on “No vehicle Day” Whats App Safety group has been formed to report Safety Suggestions/ Unsafe Conditions/ Unsafe Acts
With advance Information-To check the Safety knowledge and competency level of person Without Information-To monitor the Safe behaviors and attitude of person
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TASK OBSERVATION
CATEGORY-A CATEGORY-B
CATEGORY-C
CATEGORY-D
CATEGORY-E
CATEGORY-F
PPE POSITIONS OF
PEOPLE ERGONOMICS
TOOLS AND
EQUIPMENT PROCEDURES
HOUSEKEEPING
SERVICES
•Eyes and face
•Ears
•Head
•Hands and arms
•Feet and legs
•Respiratory system
•Striking against •Struck by
•Caught between
•Falling
•Temp. Extremes
•Elec. current •Inhaling •Absorbing •Swallowing
•Posture
•Type and number of motions
•Load handled •Work area design •Tools and grips •Vibration
•Temperature
•Lighting •Noise
•Right for job
•Used correctly In safe condition. •Leads tagged Ladders/work Platforms (height) •Crane operation •Electrical protection
•Scaffold •Mobile equipment
•Is standard pract. adequate for job
•Is standard practice Established? •Is standard practice Being maintained?
•Permit
•Isolation
•Risk Assessment
•Tidy workplace
•First aid boxes
•Emergency exit signage/clear passages
•Fire protection •Emergency Lighting • Quality of Air/Potable water •Hygiene
Done for individual or group of people
Done with or without information
Skill and Behavioral Observation is made
Done by Section Engineer/ Officer
FACTORS CONSIDER FOR CARRYING TASK OBSERVATION
SAFETY REGISTER
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Sl. No
Date
Work Description / Location
PPE’s T
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All tools /Tackles Etc Inspected
Other Appliances Provided Viz, Safety Net, Life Line, FBA, ELCB Etc
Signature R
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2
It is to ensure all required PPE’s are available with all worker.
Prior to work commencement all the safety requirements are cross checked by section engineer.
Unless the register is cross checked and signed by safety officer work cannot be started.
Applicable for working at height, scaffolding work, confined space work
Work Permit System
This is one of the most effective safety system which ensures that all control and precautionary
measures are at place to carry out critical task without any accident.
We have following work permit system and are rigidly followed by all concerned
A)-Permit to work in confined space.
B)-Permit to work at height
C)-Scaffolding work permit.
D)-Hot work Permit
E)-Excavation work permit
F)-Radiation work permit.
G)-Line Clearance permit.
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LOTO
Height work Permit
SCAR-Safety Corrective Action Request
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Planning is done for the month
Done by Safety Officer and Section Manager.
Entire plant is covered in a month
Mostly Unsafe Conditions are Reported
Observation are recorded with photographs 1300
1320
1340
1360
1380
2014 2015 2016 2017
1380
1329
1380 1370
SCAR
Procedure for Addressing Unsafe Condition
Specific
Location:
Wagon tippler-I, beside Control room
Comments/ Recommendation: Toe guard
found missing.
Responsible dept.: Mechanical
Reply Date: 15-02-2018
Reply: Toe guard fixed to festoon
platform.
SAFETY CODE OF CONDUCT FOR CONTRACTOR
Total 56 Safety points defined under six main clauses.
Every contractor shall have at least one Safety Co-ordinator at site. Wherever the number of workmen to be engaged is more than 50, a qualified safety officer shall be appointed by the contractor.
Job specific PPE (Personal Protective Equipment) such as Hand Protection, Respiratory Protection, Full body protection.etc shall be used as per IS standards.
Safety Code of Conduct is incorporated with work order. The contract is only awarded to contractor who agreed to adopt and adhere VC safety rules and standards.
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Contractor Evaluation Trusted Technology - Solid Strength
CONTRACTOR’S PERFORAMANCE EVALUATION 1 Department
2 Name of the contractor
3 Work Order Reference
4 Work Order Date
5 Validity of order From : To:
6 Period under evaluation From : To:
OCCUPATIONAL H&S AND HOUSEKEEPING (To be filled in consultation with Safety Manager)
Statistics on Safety Performance of Contractor - Inputs for evaluation on H&S performance
Sr. No. Description of incidents No. of incidents Remark
1 No of Accidents
2 No of first aid cases
3 No of danger occurrences
4 Fatal Accidents
5 No. of events of Non compliance of Safety terms &
Conditions
(A) EVALUATION PARAMETER
Sr. No. Parameter/ Description Maximum score Score on Evaluation Remark
1 Training on safety prior to start of job 100
2 Use of PPEs as per job requirement 100
3 Safety precautions taken on the job 100
4 Supervision and Monitoring w.r.t. safety compliance 100
TOTAL 400
% Total of Evaluated Score
(B) SERVICES RATING – SERVICES PROVIDED BY CONTRACTOR
Sr. No. Parameter/ Description Maximum score Score on Evaluation Remark
1 Having proper quantity of tools as per job requirement 100
2 Having proper quality of tools as per job requirement. 100
3 Contractor has supplied proper quantity of man power as
required. 100
4 Contractor has supplied proper quality of man power as
required. 100
5 Punctuality of the manpower at their job. 100
6 Arrangement of manpower during shutdown, breakdown,
emergency or odd hours. 100
7 Understand the job & following instructions of concerned
engineer 100
8 Technical skill & ability for carrying out the assigned job 100
9 Quality of the assigned job performed 100
10 Promptness & adherence to the schedule 100
11 Compliance of housekeeping during and after of work 100
12 Services of supervision 100
TOTAL 1200
% Total of Evaluated Score
( C ) COMPLIANCE OF STATUTORY REQUIREMENTS (To be filled in consultation with HR department)
Sr. No. Parameter/ Description Maximum score Score on Evaluation Remark
1 Timely submission of deployment / other required report/
information to HR department as per need 100
2 Compliance of statutory requirement as per acts and rules 100
3 Compliance on payment of wages as per state minimum wages 100
4 Compliance to maintain satisfactory Industrial Relation 100
TOTAL 400
% Total of Evaluated Score
SUMMARY OF CONTRACTOR’S EVALUATION/ ASSESMEMENT
Sr. No. Evaluation Parameters weightage Evaluated Scores % Signature of concerns
(A) Compliance on OH&S and Housekeeping 20%
(B) Quality of Services provided by contractor 60%
(C) Compliance on Statutory Requirement 20%
% Total of Evaluated Score 100%
OVERALL ASSESSEMENT / EVALUATION BY HODs
OVERALL ASSESSEMENT / EVALUATION BY HRD
Corrective measures, if any:
Remarks, if any:
Evaluated by
(Concerned Deptt.
Representative/
Section Incharge)
Reviewed by
Signature: Date:
Name :
Designation : HMO
EVALUATION CRITERIA/RATING
SN Score description OVERALL RATING (%)
1 Excellent. No significant faults. >95% - Excellent
2 Good. One or two minor faults. No significant faults >80% - <=95% -Very Good
3 Average. Several minor faults >60% to <=80% - Good
4 Poor. Some serious failings >40% to <=60% - Average
5 Unsatisfactory. Many potential serious failures <40% - Poor
Contractor Evaluation Trusted Technology - Solid Strength
Statistics on Safety Performance of Contractor - Inputs for evaluation on H&S performance
Sr. No. Description of incidents No. of incidents Remark
1 No of Accidents
2 No of first aid cases
3 No of danger occurrences
4 Fatal Accidents
5 No. of events of Non compliance of
Safety terms & Conditions
(A) EVALUATION PARAMETER
Sr. No. Parameter/ Description Maximum score Score on
Evaluation Remark
1 Training on safety prior to start of job 100
2 Use of PPEs as per job requirement 100
3 Safety precautions taken on the job 100
4 Supervision and Monitoring w.r.t. safety
compliance 100
TOTAL 400
% Total of Evaluated Score
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Fire Fighting Measures Taken 08 numbers of trained and qualified fire men appointed. Smoke detector installed in all load Centers and CCR Fire resistance paint applied on all Power cables. CCTV cameras installed on Hot Disc Alternate fuel feeding belt. Hydrant sprinkler installed on coal handling conveyor belts. Stand by pumps/ alternate power provision is made for all Fire Pump. Apart from Disaster management plan, Emergency plan has been prepared and responsibilities have been assigned to individuals. Quarterly mock drill on Fire Emergency, Rescue etc. Hydrant System at various locations of Plant Total Hydrants Points:79 No., Dry Riser:17 No. Water Monitors :04 No. Based on the Fire Load Assessment Total 1140 no. of portable fire extinguishers have been installed at various locations including Offices, Store & all sections.
Two Dedicated Fire Tenders for Emergency Fire Fighting
Manual Fire
Fire alarm Panel
Trail Run / Demonstration of Fire Hydrant Line At New Coal
Yard
Portable fire extinguisher installed on all gas cutting sets Portable fire extinguisher installed on all Vehicles including loco engine. Monthly inspection carried out for all fire hydrant system by Security/Safety Departments. Periodic demonstrations of portable and fixed fire fighting system are conducted. At all coal mill and transfer tower of coal conveyor belts ,dry risers have been installed.
Installation of fire extinguisher (2kg DCP type) on all cutting sets
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Fire Fighting Measures Taken Portable fire extinguisher installed on all gas cutting sets Portable fire extinguisher installed on all Vehicles including loco engine. Monthly inspection carried out for all fire hydrant system by Security/Safety Departments. Periodic demonstrations of portable and fixed fire fighting system are conducted. At all coal mill and transfer tower of coal conveyor belts ,dry risers have been
installed.
Installation of fire extinguisher (2kg DCP type) on all cutting sets
Mock drill at Hot Disc belt & Railway Yard
EMERGENCY PREPAREDNESS
Disaster Management Plan approved by Director -Factories & Boilers Karnataka state.
Emergency Response manual
Team constituted for various work
Role and Responsibility fixed
Mock Drill on Regular Interval
Rescue kit is readily available to reduce response time.
Portable welding machines and a gas cutting set is kept separately for emergency situation.
Emergency contact numbers are displayed at various location.
Workers have been briefed about emergency response procedures.
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PLANT HEAD DEVESH MISHRA
SAFETY & RESCUE
BISWAKARMA SINGH
RESOURCE MANAGEMENT P K JOSHI
L Vegi
FIRE COMBAT
Reji.K
ELE. ISOLATION & EMERGENCY POWER SUPPLY
R K Gupta
EVENT CONTROLLER
Mahesh Chand Gupta
FIRST AID
Dr. Jagadish Kulkarni
TYRE PRESSURE SENSOR
FLASH BACK ARRESTOR WITH FIRE EXTINGUISHER ON ALL CUTTING SET
SAFETY NET IS BEING USED FOR HEIGHT WORK
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(A)-Engineering Control
ANTI NAP DEVICE FOR MINES OPERATORS
(A)-Engineering Control
MESH GUARD PROVIDED AT EITHER SIDE OF CONVEYOR BELT
SMOKE DETECTORS INSTALLED ON HOT DISC CONVEYOR
REAR VIEW CAMERA ON TIPPERS
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Note: All conveyor belts are guarded by installing mesh guard on both side of the conveyor including low speed belt Approximate length – 08 km
UNDERNEATH AREA OF TAKE UP PULLEY/COUNTER WIEGHT IS GUARDED
WATER SPRINKLER INTALLED ON HOT DISC CONVEYOR N2 AND CO2 PURGING SYSTEM AT COAL MILL
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(A)-Engineering Control
Automatic Fire Suppression System on Dumpers
Speed Governor Installed on Dumpers
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(B)-Motivation & Campaigns
Safety Pledge during Monthly Safety Gate Meeting.
SHE Pillar Swatch VC Campaign
Safety Rally during National Safety Week Celebration.
Observance of National Events connected to Safety Such as Road Safety Week Fire Service Week National Safety Day National Chemical Disaster Prevention Day
Defensive driving Trainings to Lorry drivers on 24th September 2016
Fire Service Week & National Chemical Disaster Prevention Day
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47th National Safety Day, Safety Gate Meeting & No-Vehicle Day Celebration on 06th March 2018
We have established system for identification of training needs of personnel and provide training as per OHSAS-FS-001 (a) (Identification of Training Needs) procedure. We conduct safety training program for Management staff and workmen including contractor laborers to create more and more safety awareness. We have following safety training ppt. modules for safety training program
Visitor safety Induction training module Electrical safety Scaffolding safety Safety while working at height Defensive driving Excavation safety Gas cutting and welding safety Rigging safety Material handling safety Chemical handling safety Principles of safety management Confined space safety Housekeeping and 5s
In addition to above modules “M/s-Dupont Safety Solution “ DVD is being used for training.
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Level of Employees
Number of
employees
covered
Frequency of training
No of training Modules covered
(Weekly/Monthly/Quarterly/Annua
lly)
Senior Management
126 Annually 2
Middle Management
486 Annually 4
Junior level Management
425 Half-
yearly 5
Supervisors 58 Quarterly 7 Workers 413 Quarterly 10 Contract Workers
768 Quarterly 12
TOTAL 2276 40
Training & Education
DEFENSIVE DRIVING
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GAS CUTTING & WELDING BY M/S-MESSER’S ENG. SCAFFOLDING SAFETY BY NSC FIRST AID BY ST. JOHN AMBULANCE
(A)- Training by Outsourced Faculties
Training Programme on “Lead Acid Battery Safety” .Faculties from HBL Power Systems Limited,
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On 6th Jan 2018 ‘Safety Training’ was organizes for Staffs by Shri.DC.Jagadeesh, Joint Director of Factories & Boilers-KSSI and Shri.R.K.Parthsarthy DDF Kalaburgi ,Dr.Naresh-M/s:Orient Cement Chittapur,Shri.Kalil-M/s:Rajshree
Cement,Malkhed,Shri.Durairaj-M/s:Kalaburgi Cement,Kallur
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Fire Fighting & Emergency Rescue Training was conducted on 23rd & 24th June 2017 at SRC by Kalaburgi Regional Fire officer Shri.S.E.Lakkappa & Divisional Fire officer Shri.T.Parsuram,Karnataka Fire & Emergency services
Health & Welfare
Pre-employment health check up
Annual health check up
Rest room and sanitary facilities.
Creche room facility
Drinking water
First Aid box
First Aid Centre with Ambulance
Qualified doctors are appointed
Qualified and experienced paramedic and nurses
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Height Pass test : For working at Height Fitness test Facility Provided at VC- OHC
FIRST AID FACILITY IN PLANT
First-aid supplies are made available in the plant at all
sections(38 First Aid Boxes)
Fully Equipped ambulance room is constructed and 24*7
services is ensured by deputing qualified paramedic staff
in all shifts.
Total 207 employees have been trained through Saint
John Ambulance and now all of them are certified first
Aiders.
AWARDS RECEIVED Trusted Technology - Solid Strength
SI.No. Year Award Received
1 2018 1) Received award for Zero Fatality in KRISC level 2) Received award for best Health, Safety & Environment Monitoing system in KRISC level 3) Received award for Longest Accident Free Man days in KRISC level
2 2017
1) Received award for best Innovative system in KRISC level 2) Received Second prize in safety skit competition at KRISC level. 3) Received third prize in Safety quiz competition at KRISC level 4) Received Unnatha Suraksha Puraskar award from NSC Karnataka Chapter.
3 2016 1)First Prize in First Aid Facility . KRISC Level 2) Second Prize in Best Safety Induction Training
4 2015 Vasavadatta received Award for ‘Best Innovative Safety Systems’ in KRISC level under the agies of Dept Factories and boilers
5 2014 Green Tech Safety Award for Best Safety Performance
6 2014 Vasavadatta won First Prize in best Engineering control System
7 2014 Vasavadatta Won First Prize In Safety Skit Competition in GRISC Level
8 2013 Vasavadatta won trophy for best innovative safety systems in GRISC level
9 2013 Vasavadatta won first prize in safety quiz at GRISC and BKRISC level
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Award for Zero Fatality Award for Maximum Safe Mandays Award for Best Health, Safety &
Environment (HSE) Monitoring system
Trophy Received in KRISC Level During KRIS-Day Celebration on 28th
March 2018
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Received ‘Unnatha Suraksha Puraskar’ Award from National Safety Council Karnataka Chapter on 9th Sept 2017 at Bangalore. A top most state level safety award under large scale industries category. Award was given by Honourable Directorate of Factories and Boilers (Health & Safety Department) Karnataka State, Secretary-National Safety Council-
Karnataka, Chairman-National Safety Council-Karnataka and Deputy Chairman-National Safety Council-Mumbai
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We won Best Innovative System Award & Second Prize in Safety Skit competition in KRISC level function hosted by M/s: UltraTech Cement Ltd,Malkhed on 25th March 2017 under the aegis of
Deputy Director of Factories Kalaburagi Region Shri.R.K.Parthasarathy
“WORK SAFELY ALL THE WHILE, GO HOME WITH A SMILE”
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