safety- a question of mind set

8/12/2019 Safety- A question of mind set

1/36


2/36

Two ay nationa seminar on

industrial safety

GITAM university

26-27 March 2014


3/36

Safety- A question of mind set

Dr. Y. Manohar

Former Director, RINL/ Vizag Steel Plant

&

Sr Professor, HBS-GITAM University


4/36

What is mindset

Fixed mental attitude


5/36


6/36


7/36

7

General Safety Rules


8/36

8

An avg. of 200-250 No.s of Accidents / Yr.

Includes both Work place and Road Accidents

Fatal, Reportable, Nonreportable.

For both Regular and Contractor employees

Many more Near misses

Certain facts


9/36

9

FireExplosionGas poisoningSlips, trips fallsElectrical shockElectrical flash overFall from heightsHot metal burnsBurns due to other hot objects

Hazards in VSP


10/36

10

Body part caught in moving machinery

Material handling hazard

Level crossing hazardsCold burns (frostbite)

Noise

Dust

RadiationConfined spaces

Working with chemicals

Transportation

Snake bites

Hazards in VSP


11/36

11

If hazards are not put under control, Accidentswill takes place.

Any Accident can only be caused by either/bothof the following two reasons..

-

-

Unsafe acts

Unsafe conditions

Hazards Accidents Causes


12/36

12


13/36

13

Any event that is

Unplanned

Undesired

Unexpected which results

Or has potential to cause

Death

Bodily injuryIll health

Loss of property

Damage to equipment

Damage to environment

Accident


14/36

14

X Standing below a hangingload.

X Welding / Gas cutting withouteye protection.

X Jumping over a runningconveyor.

X Operating crane withoutpermission.

X Using compressed air for

cleaning body.X Using oxygen for cooling.

X Height work without safetybelt.

X Using welding rod holderwithout proper insulation.

X Using damaged sling for

X lifting loads.

XEntering gas prone areaswithout permission.

X Throwing down material fromtop without caution.

X Running a loco at high speed

X Carrying out elect S/D jobwithout caution tag (Men-at-work) at panels.

Unsafe Acts


15/36

15

Ignorance

Negligence

Over confidence Shortcut methods

Hurry & worry

Horse play

No concentration

Communication gap

Poor co - ordination

Not trained in the job

Unauthorized person

Violation of SOP/SMP

Using Defective tools

No PPEs

Poor health conditions

No P T - W system

Giving wrong / No signals

Fatigue

Causes of Accidents-1

Unsafe Acts


16/36

16

Unguarded m/c

Floor openings

No hand rails Slippery floor

Loose elect. Cables

No body earth Working in gas areas

Working at heights

Obstructions on the path

Absence of interlock

Poor illumination Jungle growth

Water / Oil leakage and

stagnation Poor operating condition of

the equipment

Causes of Accidents 2Unsafe Conditions


17/36

17

State in which the risk of harm to persons ordamage to property is limited to a tolerable

level.

Safety ?


18/36

18

Indian Factories Act-1948

AP Factories rules-1950

Indian Electricity Rules-1956

Gas Cylinders Rules-2004

Indian Explosives Act-1884

Indian Boilers Act-1923

Calcium Carbide Rules-1987

Workmenscompsn Act - 1923

Indian Motor Vehicle Act-1988

Central MV Rules-1989

Petroleum Act1934, Rules 1976

Noise pollution Act - 2000

Chemical Accident Rules- 1996

The Static and Mobile Pressure Vessels

Rules-1981 The Environment( Protn.) Act - 1986

Statutory Acts Applicable

Many More .


19/3619

Contains XI chapters and 120 Sections

Chapter III(sec 11-20) - Health

Chapter IV(sec 21-41) - Safety

Chapter IVA(sec 41A-H) - Hazardous processes

Chapter V(sec 42 -50) - Welfare

Chapter VI(sec 51-66) - Working hours

Chapter X (sec 92-106) - Penalties for Offenses

Section 7A Duties of Occupier

Section 101Exemption of Occupier from liability

Indian Factories Act 1948


20/36

20

Sec 21Fencing of Machinery

22 - work on/near M/c in motion

23Employing young persons 28Hoists / Lifts

29Lifting M/cs, ropes, chains..

31pressure plant

33pits, sumps, floor openings 35Eye protection

36portable elet. Light cautions

37Explosve/Inflamable gases

41ASite appraisal Comittee

41BDisclosure of Info must

41COccupier responsibility

in relation to Haz. Processes

41DPower of Central Govt.

41EEmergency Standards

41Fpermissible Exposure

limits of chemical substances 41GWorkers participation in

safety management

41HRt of worker to warn

about an imminent danger

Salient features of Indian Factories Act


21/36

21

Appointing Occupier& Manager

Accident Reporting and Investigation.

Reporting of Electrical accidents to REA, Chennai

Safety audits - Internal and External agencies

Onsite and Offsite Emergency plans

Material Safety Data Sheets (MSDS)

SOP / SMPs and HIRA / Control measures Protocols - Hazardous Jobs

Fire Fighting facilities

Health CheckupsEye, Ear..

Safety Trg.Regular and Contractor Employees

Complying with the statutory provisions


22/36

22

Testing of all Pressure vessels, tools, tackles, Safety Belts .

Emergency Management Team.

Mock Drills.

Permit To Work System.

DSC and CSC Meetings.

Providing adequate Illumination.

Supply of PPEs

Interlocks

Statutory Records update.

Corrective and Preventive actions

COMPLYING WITH THE STATUTORY PROVISIONS


23/36

23

National Safety on 4thof March every year.

Fire Safety Day on 14thof April every year.

Suggestion scheme on safety. Shop floor safety talks.

Safety skits, poster, slogan, Housekeepingcompetitions.

Quality circles for improving safety standards.

Weekly review of safety activities of VSP by ED (W).

Implementations of OHSAS18001.

Nominating employees to National seminars, Workshops,

symposiums, competitions, Trg. programs on safety.

Safety promotional activities


24/3624

Ultimate aim of all these endeavours

is to achieve..

Accident prevention

The goal

Zero accidents


25/36

Mindset


26/36


27/36


28/36


29/36


30/36

Correction Techniques

Union leaders

Supervisors and managers

Total worker population

Continuous R&D

Experience sharing

Quality of PPE

Modern Technology (eg:-CCTV)


31/36

Counseling

Coaching

Mentoring

Motivation

+ve Reinforcement


32/36

Total safety culture

PDCA

RTR

Walk the talk

MWA

I-I-I

h i i it GM hi f t


33/36

she is owning it: GM chief steps

up to handle safety questions

(Business standard 20-03-14)

Past 10 years

Faulty Ignition switch

12 Fatal

1.6 m cars recalled

Mary T Barra ,CEO-GM

T t t 1 2b $ f t i


34/36

Toyota to pay 1.2b $ over safety issues(Business standard 20-03-14)

Disclosure by Toyota

Since 2009 10m cars

recalled

US-Toyota settlement


35/36


36/36

Thank You

safety- a question of mind set

Documents