human assets need special care

8/8/2019 Human Assets Need Special Care

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HUMAN ASSETS NEED SPECIAL CARE- project

work done at BERGER PAINTS (INDIA) LIMITED on

Industrial Safety.

POST GRADUATE DIPLOMA IN MANAGEMENT

By

Sandip Mandal

PGDM 2nd

Year, 4th

Tri-mester

Roll no. pg09092

Under the valuable guidance of

Mr. M.K. SEN (Sr. IR Manager) (external guide)

Ms. Bhawna Garg (Faculty, INMANTEC) (internal guide)

Ghaziabad

INTEGRATED ACADEMY OF MANAGEMENT AND TECHNOLOGY

Ghaziabad


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Industrial Safety.

Summer project submitted

in

Partial Fulfilment of the Requirements for the Award ofPost Graduate Diploma in Management

(Recognized by AICTE, Ministry of HRD, Govt. of India)

By

Sandip Mandal

Pg09-092

Ghaziabad

Integrated Academy of Management and Technology

Ghaziabad


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Industrial Safety.

By

Sandip Mandal

Pg09-092

Under the guidance of

Dr. Bhawna Garg, Faculty

INMANTEC, Ghaziabad

Integrated Academy of Management and Technology

Ghaziabad


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Acknowledgement

The author of the project work wishes to express his gratitude

to BERGERPAINTS (INDIA) LIMITED, Howrah Works branch

for allowing the degree latitude and providing effective guidance indevelopment of this project work.

The author also take this opportunity to acknowledge the help

rendered by the personnel of BERGER PAINTS (INDIA)

LIMITED for helping going forward to complete the project. He is

also indebted to his teachers and friends for their constant

encouragement and insisting that deadline of times does stand in the

way of making of this project.

________________

Sandip Mandal

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I declare that project titled Human assets need special care

project work done at BERGER PAINTS (INDIA) LIMITED On

Industrial Safety is done by me and has not been submitted in part or

full to any authority for award of any degree/diploma.

_________________

Sandip Mandal

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Contents

Particulars Page no.

1.Introduction

y Objective of the study 8y Limitation of the study 9y Profile of the company 10y Location of the Shibpur plant 12y Methodology 13

2.An overview of industrial safety

y Concept of industrial safety 14y Need for industrial safety 15y Concept of accidents 16y Causes of accidents 17y What is unsafe work behaviour? 17y What is unsafe work condition? 18y Classification of accidents 18y Accident reporting and investigation 19y Steps are taken in the plant, after occurrence 20

of an accident

3.Safety hazards and corrective actions

y Major hazards that can take place in such 21a factory

y Safety measures undertaken in different 23manufacturing process

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4. Safety training in BERGER PAINTS (INDIA) Ltd.

y Importance of Training on safety 26y Benefits of good training efforts on safety 26y An overview of safety training in Berger paints 27

5.An overview workers participation in safety

y Employees participation in safety 29y Safety committee 29y Function and duty of safety committee 31y What is the difference between a safety committee

and a safety meeting 32

y Trade unions 336.Analysis and findings of the questionnaire

y Response of the workers towards questionnaire 35y Findings 40y Suggestions 41y Conclusions 42

7.Annexure

8.Bibliography 43

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Limitations of the study

yDue to the limited time span of the project period it was difficultto study the vast area.

y As the rate of accidents were too low, determining the actualcause of happenings was almost impossible. The accidents

which took place were minor hence the work of trend analysis

came with no result.

y The data relating to absenteeism due to occurrence of accidentswas so complicatedly recorded that it was impossible for me to

retrieve and analyse the same in such a short span of time.

y The motivation level would not be measured due tounavailability of specific tools and ample time.

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Profile of the company

BERGER PAINTS is the culmination of over seven decade process of

evolution and growth that began in 1923. Its growth has been closely

linked with the business and industrial development of modern India.

BERGERS performance is anchored today in a wide variety of

Decorative and Industrial paints which continue to gain an increasing share

of the highly competitive Indian paint market. Being an ISO:9001 company

its quality products have attained instant recognition worldwide and

continues to meet quality requirements that are demanded today even in the

domestic market.

The countrys third largest paint manufacturer with its Headquarters in

KOLKATA, BERGER controls a distribution network comprising of 66

stock points and approximately 10,000 dealers, spread across the country.

BERGER PAINTS (INDIA) LIMITED has an unmatched range of

products and service; Berger Paints India Ltd. Is a leader in paints, offering

its customers a variety of innovative painting solutions, be it Decorative or

Industrial.

Whether it is home or office, shop or factory, interiors or exteriors,

metal, wood, plastic or any other surface they have a paint solution for

it! with an ever evolving profile and rich history. Berger Paints India Ltd.

(an ISO:9001 Company) has come a long way in the highly competitive

Indian paints industry.

Today the Berger and Lewis Berger are synonymous with

colour. Berger Paints continues to be inspired by the creation and

innovation of Mr. Lewis Berger, who through his marvellous shades, had

offered people a chance to transform their homes through the power of

imagination. At Berger they believe in taking paints to the level of fine art,

enriched by the imagination ofLewis Berger since 1760.

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The history of BERGER PAINTS (INDIA) LIMITED is literally

as colourful as the business it is in. In1760, a young colour chemist

Lewis Berger developed a method for manufacturing Prussian blue

using a secret process that every designer and householders coveted. His

business was nurtured by his descendants and others till it merged with

Jenson and Nicholson Ltd. to form Berger, Jenson & Nicholson Limited.

On 17 December 1923, an Englishman, Mr. Hadfield, set up

Hadfields (India) Limited a small paint company in CALCUTTA.

Hadfields (India) Limited started with a small factory in Howrah, West

Bengal. Controlling stake in this Company was acquired by British Paints

(Holdings) Limited, England in 1947 and its name was changed to British

Paints (India) Limited. At that time the Company produced 150 tons of

ready mixed stiff paints, varnishes and distempers. Our 1947 sales were apaltry sum of Rs.2.5 million, with total employee strength of 100.

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Location of the Howrah Works

The factory is located at Swarnamoyee Road, Botanical Garden,

Howrah-03. Nearest railway station Shalimar is situated to North-East of

the factory at distance of about 1km.

The factory is surrounded by other factories and residential areas on

the eastern, northern as well as on the western side. Swarnamoyee Road ison the western side of the factory. The Bengal Engineering & Science

University campus and Botanical Garden are on the south and southwest

side of the factory respectively within a distance of 1 km. The Hooghly

river is situated within 2 km. of the factory towards the east & south.

Initially, the factory was engaged in the manufacture of paints,

varnishes & enamels. The present installed capacities of paints & resins are

14000 TPA & 4200 TPA respectively. The company was a strong in-house

R&D laboratory. The company also has a technological tie-up with

Herbets, Germany for automobile paints with Vasper corporation, USA, for

protective heavy duty coatings & tudor N.V., Holland for powder coatings.

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Methodology

y During the study, discussions were held with Mr. M.K.Sen(Senior Manager IR) and Mr. S.Dhara (Safety Officer) who

provided with relevant information, documents and process

details.

y The data required for the study was collected with the help ofquestionnaire comprises numerous questions, which invite

accurate answers from the other ends. The random sampling

method was used. Hence the graphical representation of and

analysis of data was done.

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Concept of Industrial Safety

The concept of Industrial Safety is as old as man. Even reflex-

action in the human body is designed to meet safety needs. The term

safety means freedom from the occurrence of risk of injury or loss of

life. Industrial or employee safety refers to the protection of workers

from danger of industrial accidents.

The basic measures for preventing accidental injury in order of

effectiveness & performance are-

Eliminating the hazard from the machine, method, material orplant structure.

Controls the hazards by enclosing or guarding it at its source. Train personnel to be aware of the hazard & to follow safe job

procedures to avoid it.

Prescribe personal protective equipment for personnel to shieldthem against the hazard.

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[b] Moral:- Safety is important on human grounds too. Managers

must undertake accidents prevention measure to minimise the pain &

suffering the employee and his/her family often exposed to as a result

of the accident. An employee is a worker in the factory & the breads

earners of his family. Thus a fatal or non-fatal injury entitles his/her

dependence or him to compensation as per the Worksman

Compensation Act, 1923.

[c] Legal:- There are legal reasons to for undertaking safety measure.

There are laws covering occupational health & safety & penalties for

non-compliance has become quite servers. The responsibility extends

to the safety & health of the surrounding community too.

The Supreme Court held,

an accident enterprise which is engaged in a hazardous on inheriting

dangerous industries which causes a potential threat to the health &

safety of the person working in the factory and industry in the

surrounding areas, owes an absolute & non-delegable duty to the

community to ensure that no harm results to anyone on account of the

hazardous or inherently dangerous nature, this implies unlimitedliability.

Concept of accident

Industrial accident can be described as an unplanned &

uncontrolled event in which an action or reaction of an object, a

substance, a person, or a radiation results in personal injury.

An accident is a mishap caused by unsafe work behaviour &

unsafe work condition or by combination of both.

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Causes of accident

____________________________________________________

Direct Cause Indirect Cause

Unsafe work behaviour Unsafe work condition

* Physical

(eg. defective P.P.E.,

inadequate machine guarding)

* Environmental

(eg. noise,radiation,dust,fumes

& stress)

Lack of knowledge Physiological anatomical of

& skill psychological problems

What is unsafe work behaviour?

Operating without authority, failure to secure or warm.Operating or working at unsafe speed.Making safety devices inoperative.Using unsafe equipment, hands instead of equipment,

equipments unsafe.

Unsafe loading, loading placing, mixing, combining etc.17


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Accident Reporting and Investigation

Records of accidents are essentials to efficient and successful

safety work. The completeness and accuracy of the entire accident

record system depends on the information transmitted in the

individual accident reports. Thereof, simple forms which certain all

essential information should be used for reporting. They are two

types:-

y First Aid Report: The collection of injury data generally beginsin the first aid department. The first aid report is filled by by the

first aid attendant for each new case.

y Supervisors Accident Report: The line supervisor makes adetailed report which explains about each injury. Hence the

purpose and method of filling accident report should be

explained to every supervisor in the course of supervisory

training.

The primary objective of accident report is to give complete

and unbiased information on the cause of an accident.

The proper reporting of an accident and investigation based

proper accident report helps to:

y To learn the cause of accident so that similar accident can be prevented by mechanical improvement, better supervision

and employee instruction.

y To publicize the particular hazard among the employees andtheir supervisors and direct attention to accident prevention in

general.

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Below mentioned steps are followed in the plant, after

occurrence of accident:

1.Take the injured person in the ambulance room where thefirst aid treatment is given.

2.If the injury is a major one and needs further treatment, thenperson is taken to nearest hospitals.

3.The supervisor who was present there at the time of accidentprepares a supervisors accident report.

4.Preparation of accident investigation report.5.If on the basis of investigation, it is found that the accident

due to fault of unsafe work condition or unsafe work

behaviour, then the company attend for the rectification ofunsafe act or unsafe condition.

6.In case of any major injury caused to any worker, it isintimated to the factory inspector within 48 hours who will

investigate the matter if needed.

7.In case of fatal accident, local police station and the factoryinspector is informed as early as possible.

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Major hazards that can take place in such a factory

1.Fire:Different types of chemicals are being used to make paint.Since various chemicals are used over here, so, the possibility of

catch fire is much more. And it has been labeled as Red

Category Hazard Factory.

2.Leakage from pipelines:

Preventive measures:

y Stop the pump.y Control the area around the leaks etc.y Station operator near the leak.y Send information to supervisor.y Repair the leak and start the plant.y Enter proceedings in logbook.

3.Electrical flash: Preventive measures:

y Make the main switch off.y Supervisor will organize finding out the

fault and nature of loss.

y Repair the fault and start the plant.y Enter proceedings in logbook.

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4.Fire/Toxic gases leakage:Preventive measures:

y Press the emergency alarm.y Stop all the operations in a plant.y Inform Supervisors/Departmental in-

charge /Shift in-charge.

y Supervisors/Departmental in-charge/Shiftin-charge will direct to stop all the

operations of the plant, if necessary.

y Call other key personnel with necessaryPPEs and emergency kits to control the

situation at the affected area.

y Departmental in-charge/Shift in-chargewill inform all the key personnel to dotheir own roles in respective area

5.Other types of faults:Preventive measures:

y Press the alarm.y

Make power switch offy Identify the fault.y Start the plant.y Enter proceedings in the logbook.

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Safety measures undertaken in different manufacturing

processes:

a. Resin: Resin is considered as a base for making paints. Here

various chemicals and solvents are used to make resin. Thesechemicals are heated in the kettles and thus they become resin. Resin

can also termed as the raw material for making paints.

These chemicals are highly inflammable. So in this plant,

accident may occur due to fire. Following are the safety measures

taken by the management, such as:

y Any kind of naked lighting is strictly prohibited.y Non-sparkling tools are used.y Well ventilated shed.y Flameproof motors and tubes are used.y There is fire station and fire alarm.y Workers are given PPE.y Work instructions are displayed.

b. Ball mill: Resin is brought here for grinding. The main safety

measures, taken for this department are:

y When the machine is running if any one tries to go to themachine, the machine will stop automatically. There is an

interlock between and top and bottom door of the

machine.

y When the machine is running some gases formed in themachine, so to avoid blasting of the machine after four to

five hours interval gases, are released.

y Thus it prevents accidents.y Regular tests are carried out to ensure proper earthlings

of all electrical equipments.

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y Proper ventilation and hose keeping.y PPEs are supplied to workers, especially earmuff plug for

high noise level.

c. Bead mill: The function of bead mill is also grinding. But, here the

grinding is done through glass beads to get the finest result. Following

are the safety measures for bead mill:

y To prevent escape of inflammable vapors in the workarea, vessels containing materials from bead mill are kept

closed with lids.

y All equipments are under proper earthing to avoidchances of accidents caused by short-circuit.

y Good house-keeping and proper illumination.d. Mixing shop: From ball mill and bead mill paints are taken to

mixing department. Here, the experts of the quality lab check the

quality of the products. Following are the safety measures for mixing

shop:

y Flameproof type electrical supply lines and fittings are provided.y Satisfactory illumination.

e. Protecton: Here liquid industrial paints are manufactured. So to

avoid accidents, the following measures are taken:

y Instructions on safe operating as well as workprocedures/ instructions in Hindi are displayed.

y Local exhaust ventilation arrangement with cycloneseparator provider at the feed and high speed dispersion

machine and twin shaft dispersion machine.y Dry cleaning of the floor is carried out.y Mechanical guarding of the transmission machinery

ports provided and maintained.

y First aid and fire fighting arrangements are provided.24


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f. Powder coating department: Here powder paints are

manufactured mainly for industrial purpose. Here, dust is the main

cause of health hazard. To prevent this, some measures are takenwhich are as follows.

y Mechanical ventilation system is there for ensuringadequate supply of fresh air at ambient temperature.

y Wet cleaning and washing of the floor are carried outevery two to three hours interval.

y In this department, main emphasis is given on mask andcap.

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Importance of Training on Safety

Safety training is must for everyone. Training on the job and

training in safety are two areas that pay quick dividends in any safety

program. These contribute to effective safety management in three

ways. Firstly, better knowledge and better skill leads to better

performance and training helps to impart these. Secondly, it helps to

develop correct attributes among employees towards the job and

safety. Thirdly, efforts in training and organizing training programs

are a direct way of demonstrating employees and his safety, thus

promoting mutual understanding. This leads to better all roundperformance.

Investigation into most of the accidents which take place on the

shop floor, irrespective of whether they arise out of unsafe physical

working conditions prevailing or action of persons, reveal underlying

cause which relate to inadequacy or lack of training. In sharp contrast,

success stories of industrial units with good safety performance give

evidence of planned training effort.

Benefits of good Training effort in safety:

i) Training activities indirectly demonstrate companysinterest in employees. This leads to good humans at work.

ii) Gaining knowledge and skill help to improve perceptionsand hence improve safety performance.

iii)

Training saves the time spent by supervisors to instructand correct.

iv) Training process results in close between participants andfaculty, in a congenial atmosphere away from work. This

fosters better interpersonal relations.

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v) Training helps personalize the attitudes of persons and isone of the best, practical means available to the manager

for effective communication with groups.

An overview of safety training in Berger Paints

Basically, Berger Paints is an organization which deals with

different type of chemical regent. Hence, it is obvious that there is a

great possibility of health hazards of the employees which very occur

due to the chemical used. To minimize these kinds of health hazards,

proper training for safety should be imparted to the employees.

The normal and most common reason for most of the accidents

are unsafe act pr unsafe work condition or the combination of both.

The training on safety can reduce these above mentioned possibilities

to great extent and can make the factory a better environment for

work.

The safety officer is the person who decides whether the training

is needed or not and if needed to whom. The need assessment is doneby mainly two procedures:

y Firstly, by visiting the shop floor and talking to workers.y Secondly, by analyzing the rate of accident occurring in the

shop floor.

The departmental heads also has role to play. He/she decides

which among the workers needs the proper training.

The process of imparting training takes place in two methods. Firstly,in the process of Group Discussion organized in the shop floor itself

and secondly, the training may be off the job type. The off the job

type method includes seminars, classroom lecture, practical, audio

visuals, etc.

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An important point which should be mentioned is that the need

for training is in apex when the new recruitment of new employees is

just over.

As far as contract workers are concerned, they are mostly

unskilled. In that case if he needs to handle a sophisticated machine

and contribute the organizations output, training is must. This

responsibility is taken by organization itself. Normally, contractors

employ the same workers when needed by the factory time to time.

Suppose, in any unavailable case they employ a new person for the

job, the contractor needs to inform the safety of the factory and the

safety officer on the other hand evaluates the need of training for new

person very personally. If such a need is detected, the necessary

actions are taken at no loss of time.

According to the workers, the training which is imparted in the

factory helps them to combat the hazards and accidents in the shop

floor. Hence, the more they get it the more they feel the need of it. As per the view point of employees the training procedure of the

company is highly satisfactory.

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Employees Participation in Safety

The concept of employees participation in safety was first

brought out by Mr. Henrich as early as 1931, when he wrote the book

Industrial Accident Prevention the concept of participation

recommended by Henrich was of voluntary nature and included

involvement of workers in safety committees, there taking part in

promotional work and co-operation with the management in safety

activities.

Participation of employees in safety can be formal and informal.

Formal participation is through trade unions or safety committees.

Informal participation takes place at the shop floor when the

supervisors take employees concerned into confidence and involve

them in decision on safety management.

y Safety Committee:Safety committees have been traditionally the forum for

workers participation in safety. They are very much relevant today as

well as can contribute substantially to safety performance, if objective

conditions are made.

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Establish and conduct safety committees:

If Then

y The organization employed250 or more ordinaryworkers.

y The manufacturing processdeclared as dangerous

(under section 87 of

Factories Act,1948.

y The factorysmanufacturing processes

are hazardous [under sec

2(cb)].

Establish a safety committee.

The third condition is fully applicable and visible in Berger

Paints the forming of safety committee can be done without any

other further interruption.

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Trade unions:

Trade unions consists an integral part of the social control

system in industry. Their involvement in production has beenrecognized as a means to better performance. Involvement of trade

unions in safety management can do considerable good in many ways.

They act as a formal means of safety management communication

with the employees and their support adds to the credibility of the

safety programs. They can also help in resolving conflicts and arrive

at workable solutions to shop floor. The scope activities of trade

unions widened over the times and now to include all aspects of

working conditions and obtaining protection by way of agreementswith employers and government.

Now a days, Trade Unions have a higher role in the

organizations, not only towards maintaining harmonious relationship

but also towards safety, environment at the socity as a whole.

y Trade unions are expected to come forward for encouragingtheir followers to observe safety parameters as let down in the

Factories Act, 1948 and the West Bengal Factories Rule, 1958.

y Participation of employees in safety committee is a muchawaited matter in our country where literacy level is not at per

with that of the developed countries.

y Trade unions have the responsibility to instill knowledge abouttheir own safety in place of work.

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y Trade union representatives should be encouraged to participatein seminars and workshops for exchange of views.

y It is needless to mention that workers have greater practicalideas about their own safety. They only need to be encouraged

by Trade Unions.

Participation of employees is surely one of the keys to

effective safety management. But, the key itself is, technically inthe hands of the management to ensure that a climate for effective

participation is created in the organization and that managers

and employees work together to perform safety.

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Responses of the workers towards the questionnaire

Q1). Do you i orm/ reot ers to follow safety rules and

regulations?

E erybody is well aware of the rules and do communicate with

their colleagues and persons related to shop floor.

Q2). Does t e company provide any personal protective equipment s)

to you?

According to the workers, all the equipments necessary for

safety is provided by the organi ation on time without any defect.

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100%

Yes

No

100%

Yes

No


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Q5). Do you feelt att e training programs are effective?

According to the workers, most of them i.e. 9 % feel

that the training programs are effective and a minor

percentage i.e. % do not feel that.

Q6). Is t ere any safety committee in your factory?

After analyzing the survey data, it has been seen that % ofthem are aware about the existance of the safety committee in the

plant and 2 % of them are unaware about the fact.

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93%

7%

Yes

No

73%

27%

Yes

No


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Q7). Do you communicate wit t e members oft e safety committee?

The above chart shows that the unawareness of the people

about the Safety Committee results in a communication gap

between the management and the workers.

Q8). Are you interested tojoin t e Safety Committee?

0% of the workers are willing to join the Safety Committee but a

substantial portion of them are willing only if an offer comes from

the management, but not voluntarily. On the other hand some are

not ready to accept such an offer.

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67%

33%

Yes

No

60%

40%

Yes

No


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Q9). Are you satisfied wit t e safety provisions, undertaken by t e

company for your safety?

rom the survey, it has been seen that 8 % of the workers

are satisfied with the safety provisions, undertaken by the

company. But 1 % of them are not satisfied with it.

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87%

3%

Y

No


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Findings

1.During the project period it has been that most of the workers do

not use the personal protective equipments while working. Like,

they do their work without using sun-glass, helmet, gloves,

mask etc.

2.It has also been observed that the presence of many hazardous

chemicals and parts of machines are on the shop floor, may

become the cause of accidents.

3.Some workers needlessly take risk, while working.

4.After completing the survey, it has been that almost all the

workers agrees with the fact that training is necessary but most

of them thinks that experience has made them quite well skilled

to handled difficult jobs. Thus, absence of training affects the

organization.

5.Though there is a safety committee in the factory but a few

workers are unaware about this fact. And a minor percentage of

workers feel that the personal protective equipments, provided

by the company, are not sufficient for their safety.

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Suggestions

y Many workers take needless risk and casual approach whileworking. So to avoid the accidents the supervisors should look

after the matter and take necessary steps.

y Though there is a safety committee in the factory, but still someworkers are unaware about this fact due to communication gap.

Thus proper communication to make them aware about the fact,

their effects and side effects, should be extended towards the

workers.y During the project period, it has been seen that some workers do

not use the personal protective equipments, provided by the

company for their safety. So the supervisors should take

necessary steps and make them aware of the fact that their

casual approach could have been the cause of accidents.

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Conclusion

Good safety performances always the result of well planned and

coordinated efforts on the part of both management and workers.Safety work cannot be seen as different from work itself. It is directly

linked with the persons involved with work. It naturally follows the

method to improve work as a whole will be by and large the same.

During the project period, I have seen that the management is

really much concerned for the safety of the workers. The analysis alsoshows that most of the employees are satisfied with companys safety

activities. There is no complain about Personal Protective Equipments

supplied by the management and safety program organized by the

management to eliminate unsafe work behaviour and unsafe work

condition. To eliminate the rate of accident, the management has

issued proper safety measures for different departments with respect

to the hazard related to the respective departments.

However, there are areas where further attention is required.

Research revealed that most of the workers are unaware of the fact

that there exist a safety committee and how it is functioning. So,

managements attention is needed in developing awareness among the

workers about the safety committee.

Discussion with key personnel depicts that in last few years there

has been a huge change in number of safety conscious and educated

workers which helps to curtail the number of accidents. Thus it is

more advantageous to the management to conduct safety awareness

campaigning which will lead to negligible mishap in the near future.

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Bibliography

1.Human resource and personnel management K. Aswathappa.

2. Industrial Relation and LabourLaws Srivastava.

3.www.google.com.

4.On site emergency plan Berger Paints (India) Limited.

human assets need special care

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