04/19/09 1

SAFETY

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04/19/09 2Slide 2 of 18

1. Accident

3. Accident Elimination

4. Elements of a good Accident Report

• Sharing of Best practices

TOPICS

04/19/09 3Slide 3 of 18

Accident Gets commonly defined as a “Mishap involving a Person”

ACCIDENT

Accident should be defined as a “Mishap” involving

• Man• Machine, • Product, • Company Property• Environment

04/19/09 4Slide 4 of 18

1 Anticipate the Accident

ACCIDENT ELIMINATION

2 Eliminate the Root cause

3 Isolate the Root cause

4 Provide Poka Yoke

5 Provide PPE

6 Provide Visual / Audible Warning

9 Horizontal Deployment of CAPA

7 Mark the Accident Prone spot

8 Provide Awareness & Training

10 Involvement of the Masses

10 Steps

04/19/09 5Slide 5 of 18

1 Anticipate the Accident

ACCIDENT ELIMINATION

2 Eliminate the Root cause

3 Isolate the Root cause

4 Provide Poka Yoke

5 Provide PPE

6 Provide A/V Warning

9 Horizontal Deployment of CAPA

7 Mark the Accident Prone spot

8 Provide Awareness & Training

10 Involvement of the Masses

Machine User Safety Manuals

MSDS of Raw Material

Safety Standards – Govt / Industry

Common Knowledge / History

Plain Common Sense

04/19/09 6Slide 6 of 18

1 Anticipate the Accident

ACCIDENT ELIMINATION

2 Eliminate the Root cause

3 Isolate the Root cause

4 Provide Poka Yoke

5 Provide PPE

6 Provide A/V Warning

9 Horizontal Deployment of CAPA

7 Mark the Accident Prone spot

8 Provide Awareness & Training

10 Involvement of the Masses

Meth. Chloride is a harmful chemical

Can Meth.Chloride be replaced by Hot Water?

Operator risks heat injury while heat sealing 5mm pleat

Can the adhesive be changed to non-curing type?

Boxes upon boxes of Large ORs piled on shopfloorCan ORs be made online on JIT basis?

04/19/09 7Slide 7 of 18

1 Anticipate the Accident

ACCIDENT ELIMINATION

2 Eliminate the Root cause

3 Isolate the Root cause

4 Provide Poka Yoke

5 Provide PPE

6 Provide A/V Warning

9 Horizontal Deployment of CAPA

7 Mark the Accident Prone spot

8 Provide Awareness & Training

10 Involvement of the Masses

Provision of •Railing•Guard

Make the RC inaccessible by•Shifting beyond easy reach• Digitally Secured Doors

04/19/09 8Slide 9 of 18

1 Anticipate the Accident

ACCIDENT ELIMINATION

2 Eliminate the Root cause

3 Isolate the Root cause

4 Provide Poka Yoke

5 Provide PPE

6 Provide A/V Warning

9 Horizontal Deployment of CAPA

7 Mark the Accident Prone spot

8 Provide Awareness & Training

10 Involvement of the Masses

Machine inoperable if RC Isolator removed•LDR / Laser sensors in Presses•Sensors linked to Doors of Dangerous areas•Interlocking to prevent accidental situation

04/19/09 9Slide 10 of 18

1 Anticipate the Accident

ACCIDENT ELIMINATION

2 Eliminate the Root cause

3 Isolate the Root cause

4 Provide Poka Yoke

5 Provide PPE

6 Provide A/V Warning

9 Horizontal Deployment of CAPA

7 Mark the Accident Prone spot

8 Provide Awareness & Training

10 Involvement of the Masses

Next Line of Defense!

•Gloves•Goggles•Aprons•Safety Shoes•Masks•Material Handling devices

04/19/09 10Slide 11 of 18

1 Anticipate the Accident

ACCIDENT ELIMINATION

2 Eliminate the Root cause

3 Isolate the Root cause

4 Provide Poka Yoke

5 Provide PPE

6 Provide A/V Warning

9 Horizontal Deployment of CAPA

7 Mark the Accident Prone spot

8 Provide Awareness & Training

10 Involvement of the Masses

Mfree Line Packing machineThere is an audio alarm & a glowing Light when Line restarts

Centralised Control PanelsFor easy monitoring / direct view

Airplane Cockpit Meters Principle•Color coding•Direction of Needle

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1 Anticipate the Accident

ACCIDENT ELIMINATION

2 Eliminate the Root cause

3 Isolate the Root cause

4 Provide Poka Yoke

5 Provide PPE

6 Provide A/V Warning

9 Horizontal Deployment of CAPA

7 Mark the Accident Prone spot

8 Provide Awareness & Training

10 Involvement of the Masses

Caution Boards affixed in 12Accident Prone areas to alert operators .

04/19/09 12Slide 13 of 18

1 Anticipate the Accident

ACCIDENT ELIMINATION

2 Eliminate the Root cause

3 Isolate the Root cause

4 Provide Poka Yoke

5 Provide PPE

6 Provide A/V Warning

9 Horizontal Deployment of CAPA

7 Mark the Accident Prone spot

8 Provide Awareness & Training

10 Involvement of the Masses

Offline Training Cell•Accident history of Plant•Accident History of Cell•Accident History of Machine / Process

Evacuation Plans•Roles & responsibilities

Practice / Exercise•Mock drills for •Mass Food Poisoning•Earthquake•Fire•Electrical shock•Chemical ingestion

04/19/09 13Slide 14 of 18

1 Anticipate the Accident

ACCIDENT ELIMINATION

2 Eliminate the Root cause

3 Isolate the Root cause

4 Provide Poka Yoke

5 Provide PPE

6 Provide A/V Warning

9 Horizontal Deployment of CAPA

7 Mark the Accident Prone spot

8 Provide Awareness & Training

10 Involvement of the Masses

Standard Accident ReportIncluding a HD column identifying areasTo be closed after HD is completed

04/19/09 14Slide 15 of 18

1 Anticipate the Accident

ACCIDENT ELIMINATION

2 Eliminate the Root cause

3 Isolate the Root cause

4 Provide Poka Yoke

5 Provide PPE

6 Provide A/V Warning

9 Horizontal Deployment of CAPA

7 Mark the Accident Prone spot

8 Provide Awareness & Training

10 Involvement of the Masses

Safety Week •Declamations, •Skits, •Poems, •Slogans“Work Safely…..We are waiting for you”

Sharing of Best practices Groupwide

Safety Board•Accident History & CAPA•Common precautions•Whom to contact if…..• Evacuation Procedure• Shock value of Visuals

04/19/09 15

THANKS

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