confederation of indian industry safety excellence ... · 6 safety excellence preparedness a study...

A Study Report

Confederation of Indian Industry

SEP

afety

xcellence

reparedness

OccupationalHealth andSafetyManagementSystem

in designSAFETY

in behaviour

in operation

Inspiring Excellence

This report is the result of a collaborative effort

between Verde Ventures Private Limited (VVPL),

and Confederation of Indian Industry (CII) under

the programme 'Safety Symposium & Exposition

2015.

Users of this report shall take their own

independent business decisions at their own risk

and, in particular, without undue reliance on this

report. Nothing in this report shall constitute

professional advice, and no representation or

warranty, express or implied, is made in respect to

the completeness or accuracy of the contents of

this report. VVPL or CII does not accept any liability

whatsoever for any direct or indirect damages

resulting from use of this report or its contents. The

views expressed do not necessarily represent the

views or policy of either Verde or CII, or their

member companies.

Table of Contents

Disclaimer............... ........................................................................................

Introduction .................................................................................................... 2

Background .................................................................................................... 2

Executive Summary ......................................................................................... 3

Issues Element wise .......................................................................................... 5

Contractor Safety Management ....................................................................... 5

Occupational Health and Safety Risk Management ............................................. 6

Fire Control .................................................................................................... 7

Injury and Incident Reporting ........................................................................... 8

Occupational Health and Hygiene ..................................................................... 9

Journey Safety ................................................................................................. 9

Electrical Safety ................................................................................................ 10

Training and Awareness .................................................................................... 11

General Safety ................................................................................................. 11

Major Solutions of the Issues Discussed Above The Detail Elements ...................... 11

Occupational Health and Safety Management System ........................................ 11

Safety in Design ............................................................................................... 14

Safety in Operation ........................................................................................... 17

Safety in Behaviour .......................................................................................... 21

Conclusion ...................................................................................................... 24

1Safety Excellence Preparedness

A Study Report


Introduction

Background

Indian Industries are continuously evolving with respect to methods, processes and technologies

to enhance the process of manufacturing and services. While doing so it is faced with the

challenge to meet business sustainability. Key issues like safety and environments are now

challenging the industries like never before. Failure in workplace safety is not only impacting well

being of employees and the citizens at large but also impacting profitability, reputation and brand

value directly. With the stricter regulatory regime and wider and faster media coverage the

information are available across the world in least possible time. The cost of settling compensation

and liability are much higher than the cost of prevention. Safety excellence preparedness is a step

towards prevention of safety failures which includes the safety procedure, training and

infrastructures.

Roadmap to Excellence provides the structure to meet these objectives through monitoring

This paper is an effort from Verde to have an overall notion about the current Occupational health

and safety preparedness of various sectors of Indian industries.

In this paper an effort has been made to unearth the major issues which are impacting the safety

performance of Indian Industries in the Eastern region. A survey was conducted among thirty five

industries with the help of a structured checklist covering twenty one elements. Organizations were

evaluated by highly experienced safety professionals with respect to each of the twenty one

elements and element wise score was assigned. The data was analysed and the elements causing

major impacts were prioritized for study. Each of such elements was then examined in detail to find

out the best available option to manage these elements and the associated risk and impact.

In the later part of the report, the analysis of the data, the diagnosis and the remedies are

examined in detail.

and

survey.

2 Safety Excellence Preparedness

A Study Report


Executive Summary

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Training on safety awareness :

Contractor safety management :

General safety issues :

Hazard identification, riskassessment and control :

Hierarchy of control :

Today industry cannot even survive letalone grow without addressing thesustainability issues. One such

important issues confronting industries inIndia and elsewhere is Industrial safety. Thispaper is the outcome of a study undertaken inthe industries of Eastern India to understandand unearth the issues affecting the IndustrialSafety.Thirty five industries across manufacturingand services, large, medium and small wereselected for this study. These Industries arevolunteering for survey based award onEnvironment, Health and Safety organised byConfederation of Indian Industry and thuspresumed to have a structured approach totake care of sustainability issues.A survey questionnaire was speciallydesigned with 21selected elements likeHazard identification & Risk management,Incident reporting, occupational health andHygiene etc. for this purpose andadministered. Efforts were made to bring outthe different critical causes of inadequateOccupa t i ona l Hea l t h and Sa fe t yperformance through this survey.The survey was conducted on the eastern partof India. The different industries ranging frommanufacturing to service, hazardous to non-hazardous, large scale to medium and smallscale located in different states of the easternregion mainly Odisha, Jharkhand, Bihar,Chattisgarh and West Bengal.It can be inferred that these elements ifmanaged on a priority basis will go a longway to improve the overall safety scenario inthe industries of eastern region. This will helpthe Industries to prioritize their action and usethe available resources fruitfully in theseareas for a better overall impact.

Training on safety is seems to be oftenignored as it is essentially not required since

not related to productivity. Safety cannot beachieved unless the employees are involvedin managing safety. But this needs a level ofawareness in employees which is lacking to alarge extent. 'Specific Safety Training' istherefore an important issue.

Generally the trend across industry is that,most of the hazardous work is carried out bythe contractors' workmen. In many cases theyare untrained coming from a ruralbackground and yet exposed to the gravehazards. The results are bound to bedisastrous. A structured contractor safetymanagemen t s y s t em i s the re fo reindispensable.

General safetyconcerns with safety in operation, safety indesign, and safety in project. Safety in Designis anticipating hazards in operation andhandling at the design stage and pre-emptthe same by superior design. The same is truefor safety in process which can be achieved bysafe design of processes and safe operatingprocedures. Another important dimension ofgeneral safety is the human behaviour.Statistics show that 9 times out of 10 theaccident is caused by unwanted humanbehaviour. Therefore, behavioural safetyneeds a much greater attention in improvinggeneral safety.

Hazards areassociated with all activities, and situations,movement storage of hazardous material etc.One of the important elements of safetymanagement which is often ignored is thethorough identification of all hazards and toassess their risk and to develop controls tobring down the risk to a manageable level.

Generally thecontrols are required to be commensurate tothe risk. The important requirement here is tofollow the hierarchy of control.

3Safety, Excellence, Preparedness

A Study Report


1. Elimination

2. Substitution

3. Engineering

4. Administrative

5. Personal Protective Equipment

That is if possible one should first try toeliminate the hazard and only when that is notpossible one may think of substituting theexisting hazard by something moremanageable. Similarly engineering and thenadministrative controls should be considered.PPE should be the last resort.

One ofthe most important factors in managingsafety is reporting of injury and incidentincluding near misses. The reporting andanalysing of incidents is not given theimportance it deserves even though it isessential to managing safety. Unlessreporting of all incidents are taken upseriously, analysed, communicated and thenecessary lessons are learnt, the safety systemcan never be improved.

Fire remainsthe single most important source of industrialaccident. Often it is observed that based onthe outcome of fire risk assessment lot ofcostly detection system and extinguishingsystems and equipments are installed.However, effective maintenance and trainingon operation fulfils the utilisation in realsituations and thus a fire management systemthat include f ire dr i l l , emergencypreparedness and evacuation of people atthe time of need have to be ensured.

Personalsafety while on road is essential andimperative. However, a large part ofindustrial accidents are related to movementof vehicles either movement of raw materials,finished products or scrap. In many cases themovement is by outsourced vehicles with not

much record or other safety information. Thisarea needs to be managed professionallyand systems must be in place.

Electrical safety isimportant on two counts, firstly, as a source offire and secondly, as a source ofelectrocution. It has been seen that in mostcases fire is actually caused by faulty electricalequipment or cable joints. In either case asound electrical safety management systemcan only help. A regular electrical safetyaudit, training for immediate revival of apatient and an arrangement for emergencyresponse system will have to be developed.

For a long time occupational health andhygiene in industry has been the mostneglected element. The impact ofoccupational health issues are felt only over along period and not immediately. Perhapsthat is why this area has been neglected solong. We do not even have adequate numberof OHS specialist in many sectors of industry.Health and hygiene in industrial contextmust be given the same importance as safety.Along with safety hazard, Health hazards arealso required to be assessed and controls areto be developed. Awareness programmesshould also include occupational healthissues.

Each of these elements have been consideredin greater details in the later part of the reportwith an emphasis on putting forward ideasand their actual implementation. OHSmanagement system should be given thepriority it deserves and the necessaryresources should be allocated. A meticulousplanning should be followed up by rigorousimplementation and follow up.Segregation of the elements in two groupshas been made considering the scores below80 and above eighty and represented bycolour, blue and orange.

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Injury and incident reporting :

Fire risk management :

Journey risk management :

Electrical safety :

Occupational health and hygiene :


A Study Report


Issues Element Wise

� Contractor safety management :

Less than 80% score on any element has beenconsidered as priority areas for immediateaction. Special emphasis has been given onthese elements. These elements are training,contractor management, general safety, riskmanagement, hierarchy of control, injury andincident reporting, journey safety, electricalsafety and occupational health and hygiene.

The subsequent explanation will guide to theprobable reasons which were a directoutcome of the survey. The detailed findingsof the survey have been useful for this part ofthe exercise.

Contractor safety management has alwaysbeen crit ical element in the OHSp r e p a r e d n e s s . N o w a d a y s e v e r yorganisation, irrespective of their scale ofoperation, needs the support of thecontractors in different areas mainly in the

context of uninterrupted workforce supplyand management. With that the contractorsbring lot of variables in the system affectingthe already established standard practicesleading to considerable abnormalities in thesafety system.The contractor workers are of teninadequately trained to handle the latesttechnologies and industrial process leadingto the increase in the changes of injuries.Many of the contractor work persons comefrom rural background being completelyunaware of the typical hazards prevalent inan industry. The general educationalstandards of these persons also remain a lotto be desired. All these factors contribute tothe somewhat improper contractor safetymanagement system.A structured contractor safety managementsystem properly established in anyorganisation is probably the most importantweapon to fight the menace of unsafecontract jobs.


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The essential steps that are required foreffective contractor safety managementare :

Generally process hazards come from twosources :

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Contractor Selection

Contract Customisation

Contract Grant

Contractor Handholding

Managing the Contractors

Post Contract Evaluation

Contract Renewal or Termination

The next important element coming out fromthe study, which needs specific attention, iseffective occupational health and safety riskmanagement . Many organisa t ionsirrespective of their scale of operation and

regardless of the type of industry they belong,tend to lack in the practices of managementprinciples of Occupational Health & SafetyManagement SystemThis may be attributed by improper choice ofthe method of risk management orinconsistency in the implementation of thesystem.Occupational Health and Safety riskassessment starts with activity wiseidentification of OHS hazards, assessing therisk associated with those hazards throughsuitable risk assessment tool (3x3 or 5x5matrix), evaluating the risk, categorising therisk for prioritisation of the management andtaking suitable control measures followingthe hierarchy of control. The method ofhazard identification and risk assessment isabbreviated and commonly known as HIRA. Itis needless to mention that the foundation ofOHS management system is HIRA.

a. hazards that are characteristic of thematerials and chemistry used

b. hazards that are characteristic of theprocess variables and process plant

Either preventive or protective measures ormix of both could be used to reduce the risks.Traditionally these measures are classifiedinto three types:1. Passive: These measures the hazard by

process and equipment design features.They reduce either the frequency orconsequence of the hazard without theactive functioning of any device.Examples include firewalls, orifice platesor narrow bore piping to control flow,etc.

2. Active: These measures use engineeringcontrols, safety inter locks andemergency shutdown systems to detectprocess deviations and take appropriatecorrective or remedial action.

3. Procedural: These measures include

� Occupational health and safety riskmanagement :


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The purpose of the Post ContractPerformance Evaluation (PCPE) is toprovide a report card of a contractor'sperformance on any work site. The PCPEis a standardised tool to be used toencourage contractor(s) to improve theirperformance and eligibility for futureassignment.

The contractor(s) will be evaluated on howthey perform the work in the following fivemajor categories:

a. Safety : Compliance withLaws & IndustryStandards

b. Quality : Compliance withContract Standards& Specifications

c. Organization : Work Plan andManagement

d. Execution : Work Performance

e. Administration : ContractorPerformance andDiligence


operating procedures, emergencyresponse and other managementapproaches to prevent incidents or tominimise the effects of an incident.

OHS risk assessment should take intoconsideration the following factors

All routine and non-routine activities;

Contractors' and visitors' activities

Behavioural aspects, capabilities

Identified hazards originating outsidethe workplace which has the potentialof adversely affecting the health andsafety of persons under the control ofthe organization within the workplace.

Hazards created in the vicinity of theworkplace

Hazards assoc ia ted wi th theInfrastructure, equipment andmaterials at the workplace,

Management of change i.e. changes orproposed changes in the organization,its activities, or materials

Modifications to the existing OH&Smanagement system, includingtemporary changes, and their impactson operations, processes, and activities

Any applicable legal obligationsrelating to risk assessment andimplementation of necessary controls

The design of work areas, processes,installations, machinery/equipment,operating procedures and workorgan i za t ion , inc lud ing the i radaptation to human capabilities.

Thus it can be said conclusively that theImplementation of an effective OHSmanagement system following globalstandards will definitely address the issue ofOHS risk management.

The hierarchy of controls need to be strictlyfollowed while selecting the type of controlmeasures for mitigating any risk.

We are aware that the biggest menace in theindustry is fire. It is the single most reason forcatastrophic loss in life and property. Over theyears we have witnessed the tremendouslyadverse consequence of the outbreak of fire.Often fire protection measures are restrictedto minimum statutory requirement. However,workplace need to be adequately fireprotected. Much activity is taking place todayregarding fire safe workplace design. Theknowledge in the field of fire protection isundergoing development and recognitionthat will enable workplace to be designed forfire safety with more reliability and efficiency.The emphasis should be put on fireprevention and early detection of firefollowed by fire mitigation. For preventionand early detection of fire, planning at thedesign stage is necessary. Both active andpassive fire defences provide reasonablesafetyf r o mt h eeffectsof fire.E m p loyeesh a v e

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� Fire control :


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Elimination

Substitution

Engineering Controls

Administrative controls

Personal Protective equipment


the right to feel safe and secure in theworkplace. In order to uphold workplacesafety the management should always keepthe welfare of their employees in mind whilecreating a work environment. Merecompliance to the statutory requirements isnot sufficient. Some of the rules have not beenrevised for years even though the groundrealities have changed. Emergency ActionPlans, rescue and evacuation process andescape routes are the core of safety & firemanagement system and require adequateresources during planning and execution. Toassess the preparedness towards emergencyresponse plan including evacuation andrescue process a system of regular drills arenecessary.While conducting this study one of the specialobjectives was to gauge the fire controlactivities, initiatives and preparedness ofdifferent organisations across industries. Theresult from the survey substantiates ouranticipated concern regarding fire control.Fire safety remains a major area forimprovement for the organizations. Firecontrol system accounts for various elements,starting from the hardware or infrastructuralpart like fire protection arrangement for bothportable and fixed fire protection system, firehydrant and water spray system, early firedetection and alarm system to the soft part i.e.

t h e m a n a g e m e n tsy s tem cons i s t i ngm a n a g e m e n t o femergency evacuationand preparedness,regular emergencydrills, administrativecontrols etc.

The undesired outbreak of fire can beefficiently managed through incorporation ofdesign safety, process safety management,fire safety management system, behaviourbased safety and training and awarenessbuilding.

A robust Injury and incident reporting systemspeaks volumes about an effective OHSsystem well in the journey towards safetyexcellence.

The importance of this issue could bediscussed in the backdrop of the safetytriangle. One can well understand theimportance of near miss and minor injuries inthe ultimate result of fatality. One of the mostimportant and crucial way of avoiding theunwanted occurrences of fatality is recordingthe near-misses and minor injuries. Theobvious analogy is that if we can eliminate thenear misses the situations of occurrence offatalities should never arise. Most industriestend to ignore the system of incident reportingas it does not bring immediate returns. Byvirtue of incident reporting a lot of hiddenhazards can be identified and eliminatedwhich otherwise does not come intoreckoning in normal course.

� Injury and Incident reporting :


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Fire causes loss of Property and Life.

The amount of damage to property isproportional to intensity of fire andduration. Life risk is predominantly posedby smoke and other toxic products ofcombustion which travel faster and fartherthan fire. The amount of combustionproducts and speed of their travel isdirectly proportional to the intensity of fire.


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Occupational health and hygiene :

Journey Safety :

It is the backbone of any safety system.Occupational health and hygiene affects thewellbeing of the work person directly. Lack ofadequate health and hygiene facilities leadsto reduced productivity. Although it is animportant factor it is most neglectedespecially in the developing countries likeIndia. As it can be readily understood fromthe survey, a lot of work needs to be done inthis area. Most of the initiatives should comefrom the top management. It should be a topdown approach.

According to the World Health Organization(WHO) the low- and middle-incomecountries had higher road traffic fatality rates,which is in between 18.3 to 20.1 per lakh ofpopulation. India has estimated road trafficdeath rate of 18.9 per lakh (based on roadfatality data 2010).

Journey safety has become one of the keyelements of general safety. It includes onsiteand offsite safety initiatives that anorganisation needs to undertake. Vehicle andtraffic safety, movement of any mobileequipment inside the premises for materialhandling purposes, road safety are part of theoverall journey safety. It includes but notlimited to:

All typeso fjourneys(e.g. air,r a i l ,road)

Businesssegments, functions and regions

Road safety risk assessment

Journey Risk Management Plans (riskmitigation plan and actions)

Risk Management Plans across similarenvironments in the same geography

Process to recognize any temporaryhazards or review of appropriate routeand inform drivers on a timely basis

Enforcement driving safety rules andregulations on controlled site

Journey safety is mainly impaired byinfrastructural constraint, lack of presence oftraffic safety rules & regulations, procedures,inadequate training and awareness of thepeople concerned. Behavioural safety plays avery crucial role in the context of journeysafety. State of the art infrastructure andfacilities won't be able to contribute much incase behavioural aspects influence a driver oroperator adopting an unsafe act or practice.

The importanceof behaviouralsafety and itslinkages withconvent ionalsa f e t y havebeen discussedlater.

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Right to healthy environment is one of thefundamental rights and also protectionand safety of the health of workersenshrined under article 21 of the IndianConstitution.

Accident in Indian industry is underreported. Most industries do not hold dataregarding non reportable injuries or nearmisses. The base line on accident or injurywill help identifying the issues andeliminating them.Most of the workers who die because oftheir work environment succumb tocancers and other work related diseases.This is contradictory to the belief that mostwork related deaths are caused byaccidents. Occupational safety andhealth invariably means prevention ofaccidents as occupational diseases doesnot get the due attention. Only accidentfree workplace does not imply a safeworkplace.


� Electrical safety :

Two main electrical hazards are:a. Shock or Flush over andb. Fire and Burn.

Inadequate preparedness in electrical safetyaspects is one of the key contributors inindustrial accidents. Exposed electrical partsare those that are not suitably guarded,isolated, or insulated. They are capable ofbeing inadvertently touched or approachednearer than a safe distance by a person. Toolswith insulation that is worn or that exposes

electrical parts create a shock hazard. If aworker contacts any exposed electricalcomponents, it has severe consequenceswhich might lead to fatalities.E l e c t r i c a lreasons arealso the maincause in thec o n t e x t o fou tbreak off i r e .O v e r l o a d e dcircuits create fire damage. Manyorganisations across industries lack inimplementing proper safety system andfeatures in this area. It can be easilysubstantiated from the survey acrossindustries of different size. Tools andequipment that are not tested and approvedby an Accredited Testing Laboratory or are notproperly grounded may pose a hazard.

Hazards arisingo u t f r o melectrical safetyrelated source,situation anda c t c a n b ee l i m i n a t e dthrough design

safety, operational safety, behavioural safetyand proper training and awareness.


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Journey risk has two factors - vehicleconditions and road conditions along withrelated risk ratings. Vehicle condition isinspected by development of suitablevehicle inspection check list that includetyre conditions, brakes, lights, turnindicators, rear view mirror or camera etc.Road conditions should include road riskper leg of journey. Road risk consists ofpoor surface condition, bad berm, narrowbridge, busy intersections, steepgradients, cattle grazing fields, wildanimal corridor, school, hospital, marketplace etc. This also includes helplines likepolice stations, repair stations, medicalaids, hotels and eateries etc. Finallyfactors like Journey Start Timing andDuration, Terrain, Climate, Visibility,Security etc. are also assessed todetermine the risk of journey.

People are injured when they become partof the electrical circuit. Humans are moreconductive than the earth (the ground westand on) which means if there is no othereasy path, electricity will try to flowthrough human bodies. Do not work closeto power lines. Recommended distancesvary with both jurisdiction and electricalutility company when working, driving,parking, or storing materials closer tooverhead power lines. Do not forget toisolate electricity from source. PracticeLock Out Tag Out (LOTO).


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Training and awareness :

General Safety :

Occupational Health and SafetyManagement System :

Major Solutions of the IssuesDiscussed Above : The DetailElements

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An enlightened mind can prevent a lot ofabnormalities and mishaps. We all know inall facets of our life specially in the context ofsafety prevention is always better than cure .That is where the importance and relevanceof training and awareness generation comeinto being. This is another area where onecan find inadequate preparedness in differentorganisations. This is definitely a concernareaand every organisation need to invest at leastin training and awareness generation. Wecan understand there might be limitations ineliminating some of the hazards which mayincur significant capital expenditure. Trainingcan be given in different phases of workerswork life cycle beginning from joining which iscalled an Induction Training. It cansubsequently be given in phases includingrefresher training to keep them abreast of thechanges and new developments in their areaof operation.Effectiveness of the training mechanism startswith person wise and activity wise trainingneed identification thereby framing up acomprehensive training calendar. Thendifferent training needs to be imparted as perthe plan or following the training calendar.Finally the effectiveness of the training beingimparted should be evaluated properly.Effectiveness of a training programme isessential as the programme itself. Absence ofthe effectiveness would lead to incompletecapacity development of a person & thusgiving rise to a vicious circle.

This is a bigger umbrella of safety. It gives us apanoramic view of the fundamentals of basicsafety elements. General safety is a crucialindicator of the overall safety preparedness ofan organisation. It mainly deals with unsafeact or practice and unsafe situation.Behavioural safety or behaviour based safetyis the single most influencer in the different

unsafe practices that surfaces often in theOHS parlance. Lack of proper training andawareness about different OHS hazards andthe different risks associated with it also playsa vital role in adopting unsafe act of the workperson.Presence of robust Occupational health andsafety management system greatly facilitatesprevention of unsafe act and generation ofunsafe situations in the industries. It acts as acheckpoint to the management to preventunwanted situation.

A structured and robust Occupational healthand safety management system can beconsidered as the panacea of major OHSrelated shortcomings many of thosementioned above as inferred from the studywhich was conducted.Occupa t i ona l Hea l t h and Sa fe t yManagement Systems (OHMS) are designedto manage health and safety issues to give


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Unsafe situation is greatly affected by

design safety, engineering and its

limitations. Some example of general

safety are air receivers, boilers, lifting

tools and tackles, platforms, structures,

conveyors, machine guards etc. One

should see that the design and material

specifications are fulfilled as per Indian

standards or other international

standards. Locally fabricated non

standard design and materials are strictly

not allowed even to compromise on cost

or taking short cuts.


organisation best chances of having anincident-free workplace. Most organisationshave elements of an OHSMS in place;however it is less likely for organisations tohave a system in place that coordinates theseelements to improve OHS. A systematicapproach to OHS ensures that importanthealth and safety issues are brought toattention to the person concerned so that theycan be fixed. As all other managementsystems OHSMS also revolves around thePlan-Do-Check-Act (PDCA) approach.There are 5 major elements to implementinga successful OHSMS. These include:

1. Management commitment and policy

2. Planning

3. Implementation

4. Measurement and evaluation

5. Review and improvementThe importance of an OHSMS should not beunderestimated. It allows your workplace tosystematically eliminate the possibility ofaccident, illness, injury or fatality caused byworkplace hazards arising out of source,situation or act. Not only is this obviouslybeneficial for anyone working in theorganisation, it is also beneficial for theorganisation as a whole.Employers have a legal responsibility toprovide a safe workplace for employees.Having an OHSMS does not exempt you fromyour legal requirements; however it shouldhelp you to identify and comply with them. Incase an organisation fails to meet the legalOHS requirements it is most likely to faceprosecution. This will tarnish the brand to thestakeholders.As well as legal ramifications, if a workplacelacks OHS protocols, standards, andpractices in place it can decrease the moraleof the organisation. An improvement ofworking methods and the workingenvironment will lead to an increase in workermorale which in turn can lead to an increasein productivity. By improving OHS in

workplace, the risk of losing working daysdue to illness, injury or accident can also begreatly reduced.Although they say, it takes time and money toimplement an OHSMS, more than anything ittakes true initiatives; it is well worth to protectemployees and organisation.It is notable that, management safetyinterventions are there in almost all the 21elements which are covered in this study.

Safety leadership requires understanding ofthe leadership practices that can helppromote better work health and safetybehaviours among employees. The challengefor senior leaders is to not only improve safetybut also develop skills and qualities thatenhance management and workercapabilities. Research has shown strong linksbetween safety leadership practices andsafety compliance and safety participation.Safety leaders behave as role models,inspiring others, communicating their visionclearly, seeking creativity and innovation andempowering workers to take measures formaking the workplace safe. This stylerepresents specific qualities and attributesthat are necessary for strong safety leadershipand a positive safety culture.

Responsible safety leaders need to takeownership of ensuring safety and health ofthe employees leading by example. Theyshould be Keen to adopt latest technologiesfor innovation by introducing a technologydriven safety culture. The leaders mustpossess collaborative mindset in order tolearn from good practices of others. Theyneed to ensure access to the expertise andskills the company requires. Moreover,securing the commitment of the board andsenior management to ensure the visibleleadership through policies and resourcesregarding health and safety should be the toppriority of the responsible safety leader.

Involvement of managements throughleadership - Visible Leadership


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I n vo l vemen t o f peop le th roughparticipation

Improving safety cultures

Allocation of all types of resource

Unsafe Conditions & Unsafe Acts

Another crucial factor of effectivemanagement system is involving employeesthrough participative approach. As workersor employees are the persons who actuallyencounter the hazards at the ground level itbecomes imperative to take their view whiledesigning and implementing an OHSmanagement system. Suitable mechanismneed to be devised for employee consultationand participation.In the context of OH&S hazards and OH&Smanagement system, the organization needsto establish, a system for internal and externalcommunication with different stakeholders. Itis desired that the organisation receive,document and respond to the relevantcommunications including suggestions fromexternal interested parties.Employee involvement is particularlyimportant for hazard identification, riskassessments and determination of controlsalso in the case of incident investigation. Asthe employees/workers will eventuallymaterialise the organisational target andobjectives their involvement in thedevelopment and review of OH&S policiesand objectives at the first place is absolutelyparamount. This process needs to be furtherfacilitated through management of changewhenever such situation occurs.

Safety means freedom from unacceptablerisk, injury and ill health. Safety culture is theways in which safety is managed in theworkplace, and often reflects the attitudes,beliefs, perceptions and values thatemployees share in relation to safety. AnyCulture takes time to develop. It cannot bedeveloped overnight. So an organisation hasto invest its time and patience in developing asafety culture.An unsafe workplace can affect an

organisation in a number of ways. Quiteoften these effects result in direct or indirectlosses with its adverse impact on the bottom-line. There are instances where companieswent bankrupt because of absence of safetyculture leading to unsafe situations and itsdisastrous outcome to the larger society.An inadequate safety management system inan organization may lead to various losseswhich include:

Loss of skilled manpower throughdeath, injury and disablement

Loss of property, equipment or otherresources

Loss of employee morale andproductivity

H i g h e r i n s u r a n c e c o s t a n dcompensation cost

Legal liability

Loss of company's image andreputation

Loss of business to more sensitivecustomers (e.g. selected overseasbuyers)

An attempt to reduce the losses wouldeventually bring higher return to theorganisation directly and indirectly. Tocombat these losses or adverse impacts onthe bottom-line it is essential to inculcate aneffective safety culture throughout theorganization.

Through the OHSMS the top managementneed to ensure the availability of resourcesessential to maintain and improve aneffective OH&S management system.Resources broadly include human resourcesand specialized skills, organizationalinfrastructure, technology and financialresources.

Every accident, including the minor injuryaccident is a potential lesson to be learned bymanagement. An accident investigation is a

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systematic effort to establish all relevant factsand interpretations regarding how and whyan accident occurred. Preventing recurrenceis the true objective of the accidentinvestigation. Experience has shown thatmost accidents result from unsafe acts andunsafe conditions.

Unsafe conditions involve the generalwork environment, equipment andwork place

.

Bo th the aspec t s have beenenumerated further considering thecriticality of the same.

Unsafe acts are activities and/or jobperformance which employees areinvolved in and may include: workerspractices

This aspect has also been enumeratedfurther considering the criticality.

Safety in design aims to prevent injuries anddisease by considering hazards at early stageduring the planning and designing ofprocess, which includes design of plant,structures, substance as well as the work itself.Designs for Safety reduce equipmentdamages and injuries.

In order to manage work health and safetyrisks during the design stage, designersshould consider

Designing Physical Product(machinery,equipment)

Designing Safe Process

Designing Workplace and Work Layout

Designing Work

Safe design refers to the inclusion of hazardidentification and risk assessment methodsearly in the design process to eliminate orminimise the risks of injury throughout the life

of a machinery or equipments and structuresor workplaces being designed. I tencompasses all designs includingequipment, products, hardware, systems,facilities, layout and configuration.Globally a number of countries have includedthe requirements of Safe Design in theirhealth and safety legislation. This is to ensurethat hazards and risks that may exist in thedesign of a workplace are eliminated orcontrolled at the design stage as far as isreasonably practicable. Incidentally Indiadoes not have any such legislation wheredesigning safe equipment, workplace or workitself has been guided through or asked for.Despite the fact whether it is legally requiredor not, the designs that are safe and withoutrisks as far as reasonably practicable will takean organization on the journey towards safetyexcellence.

An important step while considering safety aspart of physical design of machinery,equipment or tools is right understanding ofthe scope.

a. What the product is being designed todeliver?

b. How do raw materials get into themachine and finished parts get out ofthe machine?

Safety in design is critical to the machine'send products as well as profitability, whetherthe equipment is designed to delivercompressed air; compressed liquid, cuttingo rshapingm e t a lp a r t s ,used forassembli n g o fparts orm a k e swidgets.Safety in

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This could be eliminated byconsidering Safety in Design andSafety in Operation

This could be eliminated byconsidering Safety in BBS

Designing physical product

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design includes an evaluation andunderstanding of the machine throughputand in-feed and out-feed requirements. It isequally important to determine during thedesign phase the method (manual orautomatic) of machine loading andunloading process.Floor space requirements can best bedetermined during the design stage as well.One has to map the machine footprint, suchas how much space is needed for themachine, the operator, material handlingaccess. Often this could be attributed to thedirections of machinery installed so that thehigh risk components like electricity panel,rotary parts etc. are placed towards lesshuman exposure or interference side.Another important approach to machinedesign and adjusting floor space is front-endloading system, which can help bring to mindeverything that needs to be considered.Machinery, equipment or tools designingmight include ergonomics during the designphase. Adjustable equipment should be ableto be operated by any person. Adjustabilitymay be considered to be designed into theoperator's panel and input stations allowingfor risk-free and efficient operation of theequipment.

The management of hazards and risks duringthe design process is essential for any industrythat can be built safely and maintained safely.Designers are required to assess the risks

implicit in their designs to carryforward with its prevention. Thehierarchy of control increases theeffectiveness and sustainability untilelimination or substitution of processis implemented through its processdesign. This is to eliminate a hazardcompletely or to reduce itsmagnitude sufficiently to avoid theneed for elaborate safety systemsand procedures. Hazard elimination

or reduction can be done by means ofchanging to a process or materials which arenon-hazardous or less hazardous. Reductionof hazards in this way is inherently saferprocesses. By definition, they are permanentand inseparable from it. Such an approachleads to what are called inherently saferprocess or plant. It is easier to considerinherently safer process or plant at the earlieststages of process development.The four main methods for achievinginherently safer design are:

Minimize: Reducing the amount ofhazardous material present at any onetime, e.g. by using smaller batches

Substitute: Replacing one material withanother with lesser hazards, e.g.cleaning with water and detergentrather than a flammable solvent

Moderate: Reducing the strength of aneffect, e.g. having a cold liquid insteadof a gas at high pressure, or usingmaterial in a dilute rather thanconcentrated form

Simplify: Eliminating problems bydesign rather than adding additionalequipment or features to deal withthem. Only fitting options and usingcomplex procedures if they are reallynecessary

Risk control based on inherently saferconcepts and passive protectionmeasures is more reliable. This is

Designing Safe Process

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because it depends on the physical andchemical properties of the systemrather than the successful and correctoperation of instruments, devices,procedures or people.

Designing workplace contributes significantlyto reduce work related serious non-fatalinjuries. Safe by Design should be applied tostructures used as workplace. Thesestructures are not limited to:

Buildings or structures used asoccasional workplaces

Parts of the building or structureincluding fixtures integral to its use as aworkplace

Temporary structures

'The Factories Act 1948' describes the legalrequirements for the followings as a generalguideline to design the work lay out. They are:

The emergency response plans toevacuate effectively like, emergencyaccess, egress, exits, assembly pointand emergency response signage, etc.

Size of exit doors and routes

The layout and spread over of First aidfire fighting equipment like manual callpoints, fire extinguishers, waterbuckets, fire beaters etc.

If the machine has running or movingparts that would require guarding

Illumination of work place andsurroundings

Temperature, Humidity, Ventilation andflow of fresh air

Wash area and Ablution areas

Elimination of high noise and dust&fumes in air

Certain specific laws are also there to provideclear guideline to design areas of potentialhazard like,

Storage of inflammable materials

Storage of hazardous or toxicchemicals

Lay out of power distribution andtransformer area

Segregation and disposal of hazardouswastes

Besides, all operating hazards must beidentified during design so that interlockingguards can be included to protect those whowill operate the machine and require accessfor maintenance activities. Stoppers alsoneed to be designed and labelled so thatequipment can be immediately shut down ifan out-of-control situation were to occur.Lockout and tag out (LOTO) of hazardousenergy source like, as air, electricity, water,vacuum, etc. Finally allotting and designingmovement area for material handling byforklifts or other vehicles.

Designing Work or Work Design is effective tominimise the risks to workers. Creatinghealthy and safe work requires jobs and tasksbe designed to accommodate the abilities,diversity and vulnerabilities of workers,including those returning to work followinginjury or illness. Some of the works that couldbe designed to safe allocation to workers andalso meet the requirements of task are:

Manual loading and off loading

Excavation

Work at height

Hot work

Confined spaceWork design is the work arrangement andrearrangement of jobs in order to satisfyt e chno log i ca l and organ i za t iona lrequirements on one side and the social andpersonal requirements of workers on theother side. Its simple philosophy lies in thecrux of how the nature of a person's job affectstheir attitudes and behaviour at work,particularly relating to characteristics such asskill, independence and physical ability. Themodern BBS has the technique to mapindividual's characteristic based on the abovecharacteristics.

Designing Workplace and Work Layout

Designing Work

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Managing safety during the work design canalso make a big difference to the lives, healthand well-being of those who work on thebuildings and other structures that they areinvolved with. It affects construction workers,maintenance workers, the building users andmembers of the public.For existing site or workplace, the effectivedesign could be taken up out of riskassessment and thereby setting engineeringcontrol which safeguards or arrest the risk.The control could be implemented throughmanagement of change focussing safety.Small on- spot changes to workplace or worklayout might be taken up by Kizen Group.However, for administrative control,management system could introduceprocedures for work, permit to work and jobsafety analysis.

Change management is one of the mostimportant though little bit subdued aspects ofan effective OHS Management System. Itdoes not get the kind of importance andattention what it actually deserves.Understanding the nuances of managementof change is absolutely imperative in theprocess safety point of view.In any organisation, changes are inevitablefor and part of continual progress. Theprogress might be on productivity, quality,and efficiency. But it can also increase risksthat, if not properly managed, createconditions that may lead to injuries orproperty damage. Ineffective management ofchange is one of the major contributingfactors in many of the incident investigations.Changes or proposed changes in theorganization, its activities, or materials,modifications to the OH&S managementsystem, including temporary changes, andtheir impacts on operations, processes, andactivities leads a work person to an unknownterritory fully exposed to new and hiddenhazards. Now, this work person needs to be

adequately briefed about the type of changeshappened in the workplace, machinery orequipment, which are the new type of hazardsassociated with change so that he/she can beaware of the same and can take suitablepreventive actions. Before contemplating anychanges to process it must be evaluated toassess their impact on employee safety andhealth

Making sure that work, work processes andsystems are designed to reduce the risk toworkers is an important part of a work healthand safety management system. One of thebest ways to prevent and control workplaceinjuries is to design out or minimise hazardsearly in the design process.

Operation has a risk of safety if leftunidentified frequently known as Processsafety. The quantum of such risk isdevastating and time and again leads tomajor accidents in industries.

Process safety might be discussed through:

Process Safety Information

Process Hazard Analysis

Operational control

Management of change

After adequate precautions considered indesign safety the next step towards thejourney for safety excellence is definitelysafety in operation. Safety in operation startswith inbound logistics material handling i.e.the input of raw materials into the plantpremises then processing the raw materialstowards realisation of the desired endproduct. Safety in operation deals with all thepreventive measures throughout the chain ofoperation irrespective of the type ofindustries.

The major areas of concern in the safetyscenario as coming out from our survey canbe adequately addressed through safety inoperation.

Management of change

Summary

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Process Safety is a blend of engineering andmanagement skills focused on preventingcatastrophic accidents, part icularlyexplosions, fires, and toxic releases,associated specially with the use of chemicalsand petroleum productsProcess safety needs to be consideredseparately from general occupational healthand safety. Accidents involving personalsafety that tends to occur frequently oftenhave little consequence in contrary to processsafety incidents which happen morefrequently can have catastrophic results whenthings go wrong. Some typical examples ofprocess safety incidents include rapidoverpressure events in process plants arisingfrom dust, gas and vapour explosions,detonation of highly energetic materials,rapid decomposition of thermally unstablesubstances or mixtures and runawayexothermic chemical processes. The results ofthese unfortunate events going out of controlmay range from insignificant to catastrophicconsequences. Furthermore, they can resultin fatalities or serious injuries, loss of assets,resentment in stakeholders, unwelcomemedia attention and large financial losses.

Process Safety Information refers to theinformation related to the Hazards of theChemicals Used in the Process. Completeand accurate written information concerningprocess chemicals, process technology andprocess equipment is essential to an effectiveprocess safety management program andsubsequently to a process hazard analysis.An employer is required to develop andmaintain written safety information beforeconducting any process hazard analysis.PSI or process safety information might beconsidered the key element of a PSMProgram. It tells you the dealings with bothfrom the equipment and the processstandpoint. The process safety information

should include information pertaining to thehazards of the highly hazardous chemicalsused or produced by the process, informationpertaining to the technology of the processand information pertaining to the equipmentin the process.

Information pertaining to the hazards of thehighly hazardous chemicals in the processshould consist of at least the following:

Toxicity information

Permissible exposure limit

Physical data

Reactivity data

Corrosively data

Thermal and chemical stability data

Hazardous effects of inadvertentmixing of different materials that couldprobably occur.

Information pertaining to the technology ofthe process should include at least thefollowing:

A block flow diagram or simplifiedprocess flow diagram

Process chemistry and its properties

Maximum intended inventory

Safety upper and lower limits for suchitems as temperatures, pressures, flowsor compositions

An evaluation of the consequences ofdeviations, including those effecting thesafety and health of the employees.

Information pertaining to the equipment inthe process should include following:

Materials of construction

Piping and instrument diagram (P&ID's)

Electrical classification

Relief system design and design basis

Ventilation system design

Design codes and standards employed

Safety system ( for example interlocks,detection or suppression systems)

The employer should document that

Process Safety Information

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16 Innovative Safety Approachestowards Emerging OHS ChallengesA Study Report


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equipment complies with recognized andgenerally accepted good engineeringpractices (RAGAGEP).

This is arguably the most important andcritical phase of process safety managementprogram which leads any organisationtowards excellence in safety eventually.Process hazard analysis includes theidentification of a suitable basis of safety toprevent or mitigate process safety hazardsand therefore a pre-requisite for safeoperation. However, realising andimplementing the proposed basis of safetyinvolve an in-depth knowledge of thematerials in use, the process operations,equipment specifications and the facilitiesthat house the processes. The ability of havingthorough understanding of all the hazards iscritical in developing a suitable basis of safety.Process hazards analysis is performed by theProcess Safety Management (PSM) team. Itrequires significant time and effort.Key steps of the process hazards analysisinclude:

Developing a block diagram of the totalprocess

Developing a detailed P&ID

Numbering each and every processequipment following a suitableprotocol

Developing a comprehensive list ofequipment elements

Choosing an appropriate PHA methodSome of the commonly used methods areWhat-If analysis, Checklist, Hazards andOperability Study (HAZOP), Failure Modeand Effects Analysis (FMEA), Fault-Treeanalysis etc.The PHA must address the following

Equipment in the process

Hazards of the process

Identification of previous incidents

Engineering and administrativecontrols

Consequences of failure

Facility sitting

Human factors

Qualitative evaluation of S and Heffects

Consequences of deviation

Steps required to correct or avoiddeviation

Operational control can very well feature ineither of the segments i.e. managementsystem or safety in operation. The importanceof operational control in this segment hasbeen discussed herein.

Operational control is particularly essential tothose operations and activities that areassociated with the identified hazards andwhere the implementation of controls isnecessary to manage the OH&S risks.

It is an authority over normal businessoperations at the operational level, asopposed to the strategic or tactical levels.Operational control includes control overhow normal business processes areexecuted, but does not include control overthe strategic business targets or high-levelbusiness priorities.

Operational control is particularly applicableto the

Controls, as applicable to theorganization and its activities

Controls related to purchased goods,equipment and services

Controls related to contractors andother visitors to the workplace

The operational controls are typicallydocumented procedures to cover situationswhere their absence could lead to deviationsfrom the OH&S policy and the objectives.Selection of operational control has to bebased on OHS risk assessments. It is as perthe hazard which has significant OHS risksassociated with it. The existing ones should beintegrated to the OHS management system

Process Hazard Analysis

Operational control

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and OHS Manual. Operational control canbe achieved by a variety of effective methodssuch as training, engineering specifications,preventative maintenance programs, andwork instructions. One of the most importantand effective methods is documentedoperating procedures. Documentedprocedures ensure that the necessary stepsand activities for mitigating risks effectively, atthe right time, by the right people, and thesame way every time. Conformance to OHSManual will help to ensure that anorganization will use the informationgathered during the Hazard and Riskassessment to identify those activities thatcontribute to the significant impacts andestablish effective controls on the most criticalactivities. These impacts could be identifiedthrough regular monitoring, review and thirdparty inspections.

Operational controls may include:

Electronic or mechanical technology toreduce emissions

Routine preventive maintenanceprograms to reduce wear andbreakdown of equipment

Monitoring and observation ofequipment performance

Different common types of operationalControls include :

Standard Operating Procedures

Contract Language

Signage

Log Books

Check Lists etc.

Operational controls also include themanagement of change discussed earlier.

It is now clear that the process safety eventstake the toll on the lives of our loved ones andproperty. What are some ways we can

proactively take steps toward achievingprocess safety excellence

What does being a process safety leadermean? It means realizing everyone in theorganization plays a critical role in preventingprocess safety incidents. This can be throughmanagement o f change, inc iden tinvestigations or even through participatingin audits of the process safety managementsystem. Process safety leaders holdthemselves and their peers accountable forexecuting these tasks correctly each time.Through time the process safety culture in anorganization may be challenged with thenormalization of deviance think of this assomeone saying, That's the way we've alwaysdone it and nothing bad has ever happened.So why change how we do things now?Process safety leaders are quick to identifythese situations and diffuse them beforecomplacency sets into the organization.

Process safety excellence is achieved whenemployees and contractors across theorganization are working in sync with oneanother. Each subset of employees in theorganization may have developed a niche setof skills over time and it is easy for folks tobuild a comfortable silo to work within. Thebiggest hurdle to process safety excellence iscrossed when employees consistently breakdown these silos and engage folks in otherareas of expertise.

A key step in achieving process safetyexcellence involves growing the knowledgebase within the organization. The basic toolsfor conducting incident investigations lead usto answer for who, what, where, when andwhys of process safety events. Anorganization that communicates theseaspects of an incident with the work forceheightens awareness and helps maintain a

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The Journey towards Process SafetyExcellence

Leadership

Work force engagement

Knowledge

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sense of vulnerability for future process safetyevents. A deeper knowledge base can bedeveloped by actively participating in industryevent sharing workgroups.

Process safety excellence isn't achievedthrough hope. Instead it is achieved by thetimely response to leading indicators prior toexperiencing a significant process safetyevent. The organization's leading indicatorsshould include some data pertinent to thesmall leaks and spills that could result inbigger events. Programs should beestablished to drive down these smallerincidents in order to prevent the likelihood ofa significant process safety event.

An indicator of a strong process safety cultureis the timely closure of recommendationsfrom audits. The organization shouldimplement a process safety audit protocolthat is balanced in the review of managementsystems and tactical execution of policies. Forexample, an organization may have world-class process safety policies sitting in binders.However, there may be a significant gapbetween these policies and what is actuallyexecuted in the field. An audit protocol thatbalances these two areas is effective inpreventing process safety events.

Finally, an organization must take the time toreflect on how far they have come in thejourney to process safety excellence. Theorganization will realize excellence wasachieved through everyone's contribution.Celebrating the fact every employee andcontractor played a vital role in the journey isa powerful way to keep folks engaged incontinuous improvement.

Safety approach to a work aborts many riskthat otherwise prevails and could happenrepeatedly if right and safe approach is not

practised while attempting such works.Psychological observation and interventionplays important role in developing behaviourthat is safe. This could be achieved through:

Changing Attitudes Can ChangeBehaviour

Physical mapping, Social life mappingand Hazard perception mapping

After spending on resource, time and effortfor improving safety, usually by addressinghardware issues and implementing safetymanagement sys tems and regularmonitoring of the system by conductingsafety audits, over years these contributes toreductions in accident rates.However, a number of minor incidentsremain that appears to be stubbornlyresistant to all efforts to eliminate them.Although many of these are attributed topeoples' carelessness or poor safety attitudes,most of these are triggered by deeplyingrained unsafe behaviours. BehaviouralSafety addresses these by making use ofproven management techniques whichalmost always results in a positive stepchange in safety performance and safetyattitudes.Although difficult to control, approximately80-95 percent of all accidents are triggeredby unsafe behaviours, which tend to interactwith other negative features (termed asPathogens) inherent in workflow processes orpresent in the working environment.Habitually inadvertently introduced by theimplementation of strategic plans, everyentity has its fair share of accident causingpathogens. These pathogens lie dormant andare relatively harmless, until such time as twoor more combine and are triggered by anunsafe behaviour to produce an accident.

People often behave unsafely because theyhave never been hurt before while doing their

Metrics

Auditing

Celebrate!

Psychology of Behavioural Safety

Why Do People Behave Unsafely

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job in an unsafe way: 'I've always done the jobthis way' being a familiar comment. This maywell be true, but the potential for an accidentis never far away as illustrated by variousaccident triangles. Heinrich's triangle, forexample, suggests that for every 300 unsafeacts, 29 will result in minor injuries and 1 in amajor or lost time incident. Over an extendedperiod of time, therefore, the lack of anyinjuries for those who are consistently unsafeis actually reinforcing the very behaviours thatin all probability will eventually lead them tobe seriously injured. The principle beingillustrated here is that the consequences ofbehaving unsafely will nearly alwaysdetermine future unsafe behaviour, simplybecause reinforced behaviour tends to berepeated.Although it is not unusual to find thecontinuation of unsafe behaviours beingsupported by more than one type ofreinforcers, some will exert stronger effects onpeople's behaviour than others. This isparticularly the case for reinforcers that aresoon, certain and positive. Smokers, forexample, find it hard to stop because theconsequences of smoking are soon(immediate), certain (every time) and positive(a nicotine top up), whereas the negativeconsequences (e.g. lung cancer) are late(some years away) and uncertain (not everysmoker contracts or dies from lung cancer). In

exactly the same way, employees will find ithard to follow certain safety rules andprocedures if they are consistently (certain)rewarded by an immediate (soon) timesavingthat achieves extra production (positive) bybehaving unsafely.

Comments on accident reports often say Soand so should take more care. With betterattitudes and safety awareness, this accidentwould not have happened . Where thisoccurs, attempts to change unsafe behaviourusually hinge upon the belief that attitudesdetermine behaviour. An additional factorthat enhances attitude change by focusing onbehaviour is the positive reinforcementbrought about by peer pressure.Psychologists have known for some time thatgroup membership demands conformity tothe groups 'behavioural and attitudinalnorms'. If a workgroup adopts the 'norm' that'thinking and behaving safely' is best for allconcerned, the group as a whole will tend toapply social 'sanctions' to the individual whodeviates from this norm and behavesunsafely.

Focusing on people's safety behaviour willbring about the desired changes and thatattitude changes follow behavioural changes.The social approval and encouragement canbring about positive changes in safety'norms'. The workforce is best placed toredefine their safety 'norms, as they controlthei r own behaviour. Accordingly,behavioural safety approaches are very muchdriven and shaped by the workforce, inconjunction with line management. In thisway, the workforce is given responsibility andauthority for identifying, defining andmonitoring their own safe and unsafebehaviours, as well as setting their own 'safetyimprovement' targets. As a result, workgroupsare able to redefine their own safety related'norms' in an enabling atmosphere.

How To Stop People Behaving Unsafely

Changing attitudes can change Behaviour

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Employers that introduce BBS programs aretrying to say that, all have equalresponsibilities when it comes to health andsafety. The following exercises are designedfor management and other members to askthemselves about who does share theresponsibilities on health and safety.

Responsible Person in terms of Safety:The Aim of this exercise is to draw apicture of who is responsible for what inthe workplace.

Decision Makers: BBS programs getworkers observing each other with theaim to encourage workers to makedifferent decisions about how theywork.

Lost time injury: Many workplaces havea sign up listing the numbers of dayssince a 'Lost time Injury'

A health and safety Map: This exerciseis sometimes called "mapping"'. Byanswering these questions you can geta snap shot of where the holes are inyour organisation around health andsafety or what immediate risks need tobe addressed.

What's hurting you

Substances - vapours, liquids, fumes,mists, solvents, dusts

Environments - noise, vibration,radiation, dry, wet, hot, cold,ventilation, indoor air quality

Job design - control, stress, bullying,ergonomics, work pressure, insecurity,harassment, discrimination, violence

Welfare - toilets facilities, cleanliness

Accidents - trips, falls, slips, cuts, scalds,burns, lifting, reaching

Work patterns - overtime, long hours,piecework, shifts, homework, callcentre work, rest breaks, rush jobs

As Health and Safety Reps, you can use BodyMapping find out "what's hurting members",to collect information about workers' health,such as:

diseases

illnesses

injuries

aches and pains

stress symptoms

fatigue/impairment

reproductive problems

other related problems

Body Mapping is a way of identifyingcommon patterns of health problemsamongst workers in a particular workplace,doing the same or similar job. (Differentgroups within a workplace are likely toidentify different problems.) It means thatwhen all the workers doing a particular jobpool their information about health problems(past or current) that are unexplained or justmight be related to the job, patterns canquickly emerge.

Not all the identified common healthproblems may be work-related, but doing theBody Mapping exercise means that these allmerit further investigation at the very least.

Often we fail to recognise the impact thatwork has on our families, our ability toparticipate in social activities, and on ourrelationships. Work is central to our livesbecause it takes up so much of our time, ourthoughts, and our energy even when we arenot physically at work. Usually we can't leaveour aches and pains and stress at work whenwe go home after work. Our fatigue andinjuries and health problems often stay withus sometimes for years after our work hasfinished. Injuries, illnesses and stressescaused by poor working conditions and thelack of basic security can have a profoundeffect on our quality of life.

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Physical mapping

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How "Your World" Mapping can help

Hazard Mapping

Your World Mapping looks at the impact ofthe job on your whole life. Your WorldMapping is a do-it-yourself research tool, acomplement to Body Mapping and HazardMapping. It's a way of examining all thoseniggling, hurting, irritating problems arisingout of the job, and assessing how they impacton your entire life.

The approach is very simple, but it (like theother mapping tools) gives a visual picture ofhow problems inside work cause problemsoutside of work. Instead of negotiatinghealth and safety improvements piecemeal,the real underlying issues can be identifiedand tackled.

Using "Your World" Mapping can help youcollect information about the effects ofworking conditions on workers':

family lives

social lives

communities

neighbour hoods

mental and emotional health.

Where and what are the hazards causingproblems in your workplace?

Physical Hazards: Noise, radiation,vibration, temperature, more.

Chemical Hazards: Cleaning agents,solvents, exhaust fumes, asbestos.

Biological Hazards: Infectious diseases,bacteria, needle sticks, body fluids,working with animals.

Work design Hazards: Ergonomichazards, working alone, violence andaggression from third parties.

Stress Hazards: Workload, hours ofwork, shift work, harassment, anddiscrimination.

After completing the three mapping exercisesBody, Hazard and mapping "Your World" thenext step is to take the results and prioritize thehazards and plan what action to take. Once

again, this should be done with the wholegroup, with everyone participating in theactivity.

This activity will help an organization and itsemployees to develop a plan to change yourwork environment. It is unlikely that we canchange the root causes of many problemswithout a much larger movement in society,but every step we take in our individualworkplaces to change the immediate causesbuilds towards this broader goal.

In the meantime, however, health and safetyrepresentatives can address problems in theirown workplaces and ensure that the risksassociated with hazards are eliminated orreduced as far as practicable.

Safety scenario in Indian industries is far fromsatisfactory. In this write up as attempt hasbeen made to identify and isolate the issueswhich impact the safety preparedness ofIndian Industries. Albeit the samples ofindustries were drawn mostly from easternpart of India we believe the issues areconfined to the eastern region only. A generaldirection therefore can be derived from thesefindings.

The paper presents the larger issues facingindustries in managing safety at work placesand the areas where the organisations shouldfocus.

Some ideas are presented to overcome thesituation. As is known to every safetyprofessionals the biggest stumbling block inth i s endeavour i s the success fu limplementation.

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24 Safety, Excellence, Preparedness

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Verde Ventures provides industry focused Advisory and Assurance services on Risk Management,Responsible Business, Sustainability and Business Excellence. With access to affluence of intellectualcapital, Verde delivers

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About CII

The Confederation of Indian Industry (CII) works to create and sustain an environment conducive to thedevelopment of India, partnering industry, Government, and civil society, through advisory and consultativeprocesses.

CII is a non-government, not-for-profit, industry-led and industry-managed organization, playing a proactiverole in India's development process. Founded in 1895, India's premier business association has over 7400members, from the private as well as public sectors, including SMEs and MNCs, and an indirect membership ofover 100,000 enterprises from around 250 national and regional sectoral industry bodies.

CII charts change by working closely with Government on policy issues, interfacing with thought leaders, andenhancing efficiency, competitiveness and business opportunities for industry through a range of specializedservices and strategic global linkages. It also provides a platform for consensus-building and networking on keyissues.

Extending its agenda beyond business, CII assists industry to identify and execute corporate citizenshipprogrammes. Partnerships with civil society organizations carry forward corporate initiatives for integrated andinclusive development across diverse domains including affirmative action, healthcare, education, livelihood,diversity management, skill development, empowerment of women, and water, to name a few.

In its 120 year of service to the nation, the CII theme of Build India Invest in Development, A SharedResponsibility, reiterates Industry's role and responsibility as a partner in national development. The focus is onfour key enablers: Facilitating Growth and Competitiveness, Promoting Infrastructure Investments, DevelopingHuman Capital, and Encouraging Social Development.

With 64 offices, including 9 Centres of Excellence, in India, and 7 overseas offices in Australia, China, Egypt,France, Singapore, UK, and USA, as well as institutional partnerships with 300 counterpart organizations in 106countries, CII serves as a reference point for Indian industry and the international business community.

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