1. accident prevention
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TRAINING PROGRAMME ON
SAFETY MANAGEMENT
INDUSTRIAL SAFETY & FIRE PREVENTIONINDUSTRIAL SAFETY & FIRE PREVENTION
DEPT.DEPT.
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H YUNDAI MOTOR INDIA will perform all its activities in line with Industrial Statutory Acts and Rules,
and will abide the same with a prime intention to:
1.Ensure Safety and Health of each member of the company and other members who may be
associated with day-to-day activities.
2.Ensure prevention of pollution and protection of the environment.
3.Ensure safe operation of the plant and equipment with operational standards and procedures.
H YUNDAI MOTOR INDIA is committed and firmly believes that :
j Safety, Health and Environment protection form an integral part of its production activities.
j All accidents are preventable.
j Managing and maintaining Safety, Health and Environment is the Line Management responsibility
and each individual member of the company is responsible and accountable for Safety, Health and
Environmental activities.
The above policy will be implemented through company strategies, action plans, corrective actions and
continuous monitoring with the participation of all members and others associated with it and duly
supported by proper Education and Training.
PRESIDENTPRESIDENTPRESIDENT
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THE SIMPLEST
MEANING IS THE
PREVENTION OF
ACCIDENTS &
THE LOSSES
THEREAFTER.
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What is safetyWhat is safety
No injuriesNo injuries
No accidentsNo accidents
No place for unplanned activityNo place for unplanned activity All activities well defined All activities well defined
Every one knows his job wellEvery one knows his job well
Operating excellenceOperating excellence
Every one takes pride in doing his job well.Every one takes pride in doing his job well.
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UNFORESEEN & UNEXPECTED OCCURENCES THAT
INTERRUPT THE REGULAR WORK WHICH MAY OR MAY
NOT CAUSE INJURIES TO PERSONS OR DAMAGES TO
PROPERTIES.
1. REPORTABLE ACCIDENTS - MORE THAN 48 HRS.
2. NON REPORTABLE ACCIDENTS - LESS THAN 48
HRS.
ACCIDENTS DO NOT HAPPEN - THEY ARE
CAUSED
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Safety ExcellenceSafety Excellence
It occurs only whenIt occurs only whensupervisors, managerssupervisors, managers
and executivesand executivesdemonstrate their valuedemonstrate their valuethrough actions and then,through actions and then,being credible, askbeing credible, ask
workers to help improveworkers to help improvethe system.the system.
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ACCIDENT vs. Injury ACCIDENT vs. Injury Accident is an undesired incident which Accident is an undesired incident which
may or may not result into injury.may or may not result into injury. Injury is always a result of some Accident.Injury is always a result of some Accident.
Our focus should be on eliminatingOur focus should be on eliminating
accidents, and in particular to avoidaccidents, and in particular to avoidinjuries altogether.injuries altogether.
Eliminating accidents 100% may not beEliminating accidents 100% may not bepossible.possible.
Eliminating injuries 100% is definitelyEliminating injuries 100% is definitelyachievable.achievable.
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Foundation of a lost timeFoundation of a lost time
injuryinjuryDeathsDeaths --No dataNo data
Lost work day casesLost work day cases --11 {*}{*}
Medical attention casesMedical attention cases --1010 {*}{*}First aid casesFirst aid cases --100100 {*}{*}
Near miss casesNear miss cases --10001000
Unsafe behaviors or conditionsUnsafe behaviors or conditions --10,00010,000
{*}has been proved by extensive research{*}has been proved by extensive research
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Most process and personal
incidents, injuries and
accidents are caused byunsafe acts and behaviors,
& not merely by conditionsand equipment.
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76% injuries are only due to unsafe acts.76% injuries are only due to unsafe acts.
20% due to unsafe acts and unsafe20% due to unsafe acts and unsafeconditions both.conditions both.
4% are due to unsafe conditions.4% are due to unsafe conditions.
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76% injuries are only due to unsafe acts.76% injuries are only due to unsafe acts.
20% due to unsafe acts and unsafe20% due to unsafe acts and unsafeconditions both.conditions both.
4% are due to unsafe conditions.4% are due to unsafe conditions.
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Causes of injuriesCauses of injuries
Unsafe acts involvingUnsafe acts involving Body position..30%Body position..30%
Tools and equipment...28%Tools and equipment...28%
Actions of another...14% Actions of another...14%
Not using Protective Equipment..12%Not using Protective Equipment..12%
Procedures and Housekeeping.12%Procedures and Housekeeping.12%
Total from unsafe acts...96%Total from unsafe acts...96%
Total from other causes...4%Total from other causes...4%
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ExamplesExamples BehaviorBehavior
Walked down stairs without usingWalked down stairs without usinghandrail;lost balance and fellhandrail;lost balance and fell
Behavior and conditionsBehavior and conditions Walked on water/oil coveredWalked on water/oil covered
slippery ground, slipped and fell,slippery ground, slipped and fell,broke ankle and hand.broke ankle and hand.
ConditionsConditions
Food poisoning at a seminar.Food poisoning at a seminar.
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Risk perception with timeRisk perception with time Lack of risk perception / reduction in riskLack of risk perception / reduction in risk
perception is responsible for accidents resultingperception is responsible for accidents resultinginto severe injuries.into severe injuries.
Risk perception reduces with time if there areRisk perception reduces with time if there areno accidents/injuries.no accidents/injuries.
Risk perception is Safety Attitude.Risk perception is Safety Attitude.
Safety norms are followed only if the risk is
Safety norms are followed only if the risk isperceived. Education/information is important.perceived. Education/information is important.
This has to be developed and maintained in theThis has to be developed and maintained in themanagement as well as the employees.management as well as the employees.
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Time
Serious
accident/incident
Rules and safeguards
devised here may be
violated, when riskperceptions decay with
passage of time
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COMMON ORG ANIZATIONALCOMMON ORG ANIZATIONALPROBLEMS WHICH IMPEDE S AFETY PROBLEMS WHICH IMPEDE S AFETY
Management interpretation that safety can beManagement interpretation that safety can be
hired.hired.
Tolerance of unsafe behavior by management.Tolerance of unsafe behavior by management. Priority to business over safety.Priority to business over safety.
Enforcement of rulesEnforcement of rules (different standards)(different standards)
Responsibility/Accountability is not defined clearlyResponsibility/Accountability is not defined clearly
demonstrated prodemonstrated pro--activelyactively
Champions in safety initiatives lose interest.Champions in safety initiatives lose interest.
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Behavior improvement modelBehavior improvement model Every one likes to be appreciated.Every one likes to be appreciated. No one has all the good things.No one has all the good things.
Every one has something good or bad.Every one has something good or bad.
It is very difficult to change behavior of It is very difficult to change behavior of people. It is one of the most difficult jobs.people. It is one of the most difficult jobs.
To change the behavior of people is aTo change the behavior of people is achallenge.challenge.
ThisThis cancan be achieved slowly but surely.be achieved slowly but surely.
Organized, concerted and conscious effortsOrganized, concerted and conscious effortsfrom all management personnel is required.from all management personnel is required.
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Look for safe behaviorLook for safe behavior Body position, eyes on work, eyes on path,Body position, eyes on work, eyes on path,
lifting practice, holding practice,lifting practice, holding practice,
Work condition, selection of tools, use of toolsWork condition, selection of tools, use of tools
, labeling, proper tags, permits well prepared,, labeling, proper tags, permits well prepared,work area free of trip, slip hazards, signs,work area free of trip, slip hazards, signs,barricading, lighting, ventilation, fall protection,barricading, lighting, ventilation, fall protection,
PPE condition, use of eye/face protection,PPE condition, use of eye/face protection,helmet, respirators, N2 blanketing, earthing.helmet, respirators, N2 blanketing, earthing.
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Understanding Accident Causes
Accidents are caused by:
± Unsafe act (88 %)
1. Working on unguarded m/c
2. Horseplay
3. Standing under a suspended load.
± Unsafe conditions (10 %)
1. Unguarded machines2. Oily floor
3. Gangway congested
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Cause of Accident Cause of Accident
Unsafe ConditionsUnsafe Conditions
Unsafe ActionsUnsafe Actions
Personal CausesPersonal Causes
Proximate CausesProximate Causes
Green Triangle
For Safety
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HEINRICH AN ALYSISHEINRICH AN ALYSIS
OF ACCIDENTSOF ACCIDENTS
1ACCIDENT
29NEAR ACCIDENT
300INCEDENTS
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HEINRICH ACCIDENT PREVENTION
Ancestry &
Social
environment
Fault of
persons
Unsafe act
(or) unsafe
condition
Accident Injury
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UNSAFE CONDITIONSUNSAFE CONDITIONS
Unguarded & inadequately guardedUnguarded & inadequately guardedmachinesmachines
Unsafe design & constructionUnsafe design & construction
Defective machines & toolsDefective machines & tools
Hazardous processHazardous process Improper IlluminationImproper Illumination
High noise levelsHigh noise levels
Hot working environmentHot working environment
Dusts, Fumes & GasesDusts, Fumes & Gases
Inadequate VentilationInadequate Ventilation
Hazardous RadiationsHazardous Radiations
Unsafe DressUnsafe Dress
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UNSAFE CONDITIONSUNSAFE CONDITIONS
Unsafe storage of materialsUnsafe storage of materials
Defective Machines & ToolsDefective Machines & Tools
Unsafe floors & passageUnsafe floors & passage
Unsafe Electrical wiring & fittingsUnsafe Electrical wiring & fittings
Unsafe Lifting & Transport MachinesUnsafe Lifting & Transport Machines Unsafe Pressure VesselsUnsafe Pressure Vessels
Working on HeightsWorking on Heights
Improper Personal ProtectiveImproper Personal ProtectiveEquipmentsEquipments
Unsafe House KeepingUnsafe House Keeping
Unsafe Waste disposalUnsafe Waste disposal
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UNSAFE ACTIONSUNSAFE ACTIONS
Disregard to Safety Rules & ProceduresDisregard to Safety Rules & Procedures
Working without authorityWorking without authority Unsafe speed of actionUnsafe speed of action
Making Safety Devices inoperativeMaking Safety Devices inoperative
Sleeping in the work placeSleeping in the work place Playing & Teasing in the work placePlaying & Teasing in the work place
Quarreling with the coQuarreling with the co--workers &workers &supervisorssupervisors
Smoking in work placeSmoking in work place
Eating in work placeEating in work place
Intoxication with Alcohol or DrugsIntoxication with Alcohol or Drugs
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UNSAFE ACTIONSUNSAFE ACTIONS
Disregard to Hygiene & CleanlinessDisregard to Hygiene & Cleanliness
Improper work DressImproper work Dress
Failure to use Personal ProtectiveFailure to use Personal ProtectiveEquipmentsEquipments
Using improper toolsUsing improper tools
Using tools improperlyUsing tools improperly
Joy Ride on material handling machinesJoy Ride on material handling machines
Working on roofs without SafetyWorking on roofs without Safety
EquipmentsEquipments Improper handling of materials & machinesImproper handling of materials & machines
Unsafe use of electrical equipments & toolsUnsafe use of electrical equipments & tools
Cleaning & Lubricating machines in motionCleaning & Lubricating machines in motion
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PERSON AL FACTORSPERSON AL FACTORS
1. Good Physical condition1. Good Physical condition
( Good Food, Sleep & Habits )( Good Food, Sleep & Habits )
2. Good Mental condition2. Good Mental condition
( Correct thinking, avoid anger, envy,( Correct thinking, avoid anger, envy,greed & worry )greed & worry )
3. Good Social Relationship3. Good Social Relationship
( Good Friends, Social Service etc.)( Good Friends, Social Service etc.)
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Cost of Accidents:
The Iceberg Effect
On average, the indirectcosts of accidentsexceed the directcosts by a 4:1 ratio
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Cost of Accidents Direct Costs
± Medical Costs (including worker¶s comp)
± Indemnity Payments
Indirect costs
± Time Lost (by worker and supervisor)
± Schedule delays
± Training new employees
± Cleanup time / equipment repairs
± Legal fees
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Cost of the ACCIDENTCost of the ACCIDENT
DIRECT COSTDIRECT COST INDIRECT COSTINDIRECT COST SUFFERINGSSUFFERINGS
Medical ExpenseMedical Expense Loss of productionLoss of production Physical SufferingPhysical Suffering
CompensationCompensation Damage to MachinesDamage to Machines Mental SufferingMental Suffering
Unproductive wageUnproductive wage Loss of MaterialsLoss of Materials Family SufferingFamily Suffering
-------------------------- Legal ExpenseLegal Expense ----------------------------
-------------------------- Loss of MoraleLoss of Morale ----------------------------
-------------------------- Loss of ReputationLoss of Reputation ----------------------------
20 %20 % 80 %80 %
Cannot beCannot be
CompensatedCompensated
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ARM SLEE VE GLOVES SAFET Y SHOES
GOGGLES APRON C ANISTER MASK
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DUST MASKHELMET
DUST MASK NITRILE GLOVES FACE SHIELD
E AR PLUG
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SAFETY MANAGEMENT IN HMI
1. ACCIDENT REPORTING & INVESTIGATION
2. HOT WORK PERMIT SYSTEM
3. COLD WORK PERMIT SYSTEM
4. JOINT SAFETY INSPECTION SYSTEM5. PERIODICAL SAFETY AUDITS
6. DAILY SAFETY OBSERVATION TOURS
7. CONTRACTORS SAFETY MGMT
8. MATERIALH
ANDLING SAFETY AUDIT9. MACHINE SAFETY AUDIT
10. FIRE SAFETY MGMT
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SAFETY PROMOTION ACTIVITIES
1. EDUCATION & TRAINING
2. SAFETY CAMPAIGNS
3. SAFETY DAY CELEBRATIONS
4. SAFETY COMPETETIONS
5. SAFETY PUBLICATIONS ± ARTICLES IN VANAKKAM
5. DISPLAYING SAFETY MESSAGES IN THE PLANT
6. REWARDING FOR SAFETY PERFORMANCE
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BE AWARE OFBE AWARE OFTHE
SE
THE
SE
H AZARDSH AZARDS
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WINNING ATTITUDE WINNING ATTITUDE FILMFILM