safety excellence -...

MY HOME INDUSTRIES PVT LIMITEDSRINAGAR, MELLACHERUVU

Safety Excellence

2nd Edition of Cement Conclave Award Presentation 2018

My Home Industries Pvt Limited (MHIPL) – At a Glance

MCW (3.2 Mtpa)

VGU (2.0 Mtpa)

SJCL (3.2 Mtpa)

TGU (1.2 Mtpa)

1998 – MCW 1

2002 – MCW 2

2006 – CPP 1

2007 – MCW 3

2008

2009 VGU 1, RMC 1

2012 VGU 2, CPP 2, RMC 2

2013 SJCL

2016 Solar Power

10.0 mtpa capacity

5,000+ dealers sales network

87 MW Captive power plant incl. WHR

1 MW solar power plant

Export to Sri Lanka and Bangladesh

Highlights Head QuarterIntegrated Plant

Grinding units

2017 TGU, WHR,

Work force of 4431 people

▪ Employees 1359

▪ Contractor 3072

5 Major project completed : > 150 m €

CRH & My Home - 50:50 Joint venture

Information about Factory - MCW

1.1 Name of Industry : My Home Industries Pvt Ltd

1.2 Full address : Srinagar, Mellacheruvu (Village & Mandal), Suryapet Dist., Telangana State, Pin - 508246

1.3 Name, designation, contact phone : Shri. M. Laxmaiah, Vice President (Works)no & address Mob: +91 9100444710

Srinagar, Mellacheruvu (Village & Mandal), Suryapet Dist., Telangana State, Pin - 508246

Work Force & Man hours

2.1 Average no of workers in Factory.

Sl. No Type of Workers 2016-17 2017-18

1 Regular 415 406

2 Contract 1745 1334

3 Total 2160 1740

2.2 Man hours worked by all workers including over time.

Sl. No Type of Workers 2016-17 2017-18

1 Regular 923288 904016

2 Contract 4289944 3225160

3 Total 5213232 4129176

Reportable Incident and F.R

Type 2016-17 2017-18

Near-miss 224 227

High Potential Near miss Nil 2

First – aid cases 36 27

LTI ( Lost Time Incident ) 2 4

Fatality Nil Nil

Man hours lost due to

LTI

808 2088

Severity Rate 1.93 6.32

Frequency Rate 0.038 0.096

No of Dangerous

occurrences as per

factory act

Nil Nil

0

10

20

30

40

50

0

50

100

150

200

250

2010 2011 2012 2013 2014 2015 2016 2017

# Near Misses # First Aid Incidents

5,000

15,000

25,000

35,000

45,000

55,000

2009 2010 2011 2012 2013 2014 2015 2016 2017

Safety Training Hours - Demos

The longest accident free period (Continuous covering the three years, assessment period)

I. During the assessment period only i.e. 2016-2018

From Period To Period No of Days Accident Free Million Man Hours

26.04.16 05.03.17 314 4.53

3 3 3

4

10

11

13

14

17

2 0 0 9 2 0 1 0 2 0 1 1 2 0 1 2 2 0 1 3 2 0 1 4 2 0 1 5 2 0 1 6 2 0 1 7

5

7

9

10

9 9

14 14

15

2 0 0 9 2 0 1 0 2 0 1 1 2 0 1 2 2 0 1 3 2 0 1 4 2 0 1 5 2 0 1 6 2 0 1 7

Avg. Training Hours per Employee Avg. Training Hours per Contractor

HSE Policy & Safety Objectives

5.1. Does the Organization / Facility have Written H&S policy? If yes attachcopy.Yes

5.2. Level at which policy has been in force.The policy has been signed and in force at the level fromManaging Director

5.3. Describe how the objective of H&S policy achieved.The objectives are achieved Pro- actively as mentioned below:• Training the Workforce• Inspection and Audit by Cross Fictional Team• Counselling the workforce through BBS Approach• Senior Leadership Interaction• Motivation through awards

5.4. Explain how the policy is made know to employees of your employeesPolicy boards are displayed at all the prominent locations in the plant andtraining on the policy is conducted to all the employees and contractworkers & refreshing through gate meetings ,awareness programs

Review of HSE Performance by Top Management

6.1. Is your organization certified OHSMS under Indian Standards. Attach copies of relevant certificates.

Yes , Certified as per the OSHAS 18001:2007, ISO 9001: 2015 & ISO 14001:2015

6.2. Does the top management receive periodic report on H&S performance?IF Yes, What is the periodicity? Submit copy.

Yes, the H&S performance reports are received once in a month.

6.3. Explain the action taken by top management on those reports & its implementation.

The Monthly Review Meetings and Joint Safety Review Meetings are conducted monthly and Bi Monthly respectively. All the Key Performance Indicators are reviewed and discussed in the meeting and any such non compliance will discussed for the resources requirement and actions for implementation.

Certified in accordance to ISO 9001:2015,ISO 14001:2015 & OHSAS 18001:2007& ISO50001:2011

Certified in accordance to ISO 9001:2015,ISO 14001:2015 & OHSAS 18001:2007& ISO50001:2011

HSE Organization

7.1 Explain the organizational set up and responsibilities at various levels and arrangements for implementation of H&S policy.

The Organization have a dedicated Safety Department where HOD – Safety directly reports Unit Head and HOD – Safety and he is been supported by Corporate Safety. HOD – Safety coordinates and reviews the implementation of H&S Policy and Its requirements through communication of procedures, guidance documents, standards etc., Safety Audits, Walk Through Inspection, Safety Inspector of the Day (SID) etc.

7.2 Attach a copy of your company H&S organogram

HSE Organization

Sl. No NameRegular/

ContractDesignation Qualification

Working

Since

1 D. Ramesh Regular DGM (Safety & IMS) M.Sc. ( Applied Chemistry),DIS,NIPM April 1984

2 K. Veeresh Babu, Regular Manager B. Tech (Mech), PDIS Feb’ 2004

3 S. B. Srimannarayana Chary Regular Sr. Engineer B. Tech (Mech), ADIS Dec’ 2011

4 J. Vijay Kumar Regular Engineer Diploma in Electrical Engg, DIS April’ 2016

5 S. K. Khalandher Regular Engineer B. Tech (Mech), DIS June’ 2017

7.3 Does the organization have set a safety KPI for every employee in order to achieve H&S Objective? If Yes. What is the measurable?Safety KPI is set for each employee and compliance will be reviewed during annual appraisal. 30 % to 50 % of employee performance rating is purely is compliance to his Safety KPI. The measurable include No of near miss reported. No of BBS observations made. No of Trainings conducted etc.

7.4 H&S Personal

HSE Trainings8.1 Does the organization identify training need identification (TNI) foremployees and contractors ?TNI is been identified for employees and including contract workers.

8.2 Does the organization have implemented training matrix for Employees &Contractors. If yes, attach.Yes, Trainingmatrix for Employees & Contractors is as attached.

8.3 Does Trainings effectiveness is measured through feedback.Trainingeffectiveness is measured through feedback form by the employeeand contract workers and the effectiveness of the training is also assessedthrough training assessment form.

8.4 What is the induction method followed for employees, contract workforce,experts, Govt. Officials and otherSeparate safety induction module is prepared and all the employees andcontract workers need to undergo the safety induction before entry into theplant premises. A Visitors like Govt Officials, outside agencies, ect will beinducted through Visitors safety induction . Drivers are inducted throughInduction Module before entry into the plant premises at the main gate.

5,000

25,000

45,000

65,000

2009 2010 2011 2012 2013 2014 2015 2016 2017

8.5 Does the organization maintain individual training records? If. Yes. Attach Sample copy.

Yes, the sample copy attached.

8.6 How does the organization covers drivers (Internal& External Vehicles) training. All the internal and external vehicles drivers are trained with the job specific training and the refresher training is also covered once in 3 years. The Training will be conducted through external expertise with the practical demo.

HSE Trainings

5

7

9

10

9 9

14 14

15

2 0 0 9 2 0 1 0 2 0 1 1 2 0 1 2 2 0 1 3 2 0 1 4 2 0 1 5 2 0 1 6 2 0 1 7

Avg. Training Hours per Employee

3 3 3

4

10

11

13

14

17

2 0 0 9 2 0 1 0 2 0 1 1 2 0 1 2 2 0 1 3 2 0 1 4 2 0 1 5 2 0 1 6 2 0 1 7

Avg. Training Hours per Contractor

Sl. No. Trainings 2016-17 2017-18

1

Internal Trainings Transport safety, Work At Height ,

Training on ELCB & Confined space

lighting, Machinery safety , Practical

Rescue Procedure in emergency while

Working At Height

Behavior Based Safety

Safe Rigging And material Handling practice,

Internal and External Transport, LOTOC,

Confined Space, Machinery Safety, Electrical

Safety, Fork Lift safety, Chemical Handling,

SCBA, Site Transport

2External Trainings Defensive driving, Scaffolding training, Internal Auditors Training,

Safety In Power plants, 3 Training Participants Company 374 385

4 Training Participants Contractors 1483 1214

5 Total Training Hours 23142 Hrs 44209 Hrs

6Training Hr. individual per

employee per annum

16.16 Hrs 26.49 Hrs

7Training Hr. Contractor individual

per employee per annum

9.41 Hrs 25.07 Hrs

8 % covered Employees 90 % 94 %

9 % Covered Contract workforce 86 % 90 %

8.7 Training Particulars.

HSE Trainings

Mock Drills

Sl.

NoDescription 2016-17 2017-18

1Simulated fire mock drill near

Wagon Loading Area

The Mock drill was conducted on

20/04/2016


Choutapalli Mines

The Mock drill was conducted on

12/10/2016

3

LPG Gas leakage in residential

colony

It was the real scenario which happened

on 01/02/2017. The LPG Gas Leakage was

successfully arrested by the emergency

team.

4

AFL leak from the tanker The AFL leak was observed from the tanker

which was parked in the parking yard on

25/08/2018 and the leak was arrested

successfully by the team


Old Coal Yard

The Mock drill was conducted on 30/11/2017

Provide Mock drill details as per Factories Act / Law.The Details of Mock Drill conducted in the respective year is as mentioned below:

Accident/Incidents Reporting

10.1 What is the method of reporting system in your organization? All the Accidents and Incidents will be reported in the standard attached Incident Reporting Format and based upon the type of the incident, it will be escalated up to Managing Director

10.2 Reporting will escalate up to what level in your organization &what is the path?Based upon the type of the incident, it will be escalated up to Managing DirectorThe escalation matrix and the path is as mentioned below:

Type of Incident

Escalated up to

Near Miss Unit Head

First Aid Unit Head

MT / RWD UH / CSH

HPLE UH /CSH / Director (Operations)

LTI UH / CSH / Director ( O ) Managing Director

Escalation Matrix

Incident Witness

Section Head

HOD - Safety Dept HOD

Unit Head Corp Safety HeadDirector

Operations

Managing Director

WTD

Accident/Incidents Reporting

10.3 Does the organization conduct RCA on all incidents such as ,property damage, Loss of product, H&S related .

Yes, the RCA will be conducted for all the incidents like Near Miss,First Aid, HPLE, Property Damage and other H & S related.

10.4 Who leads the RCA process?The RCA will be lead by Department HOD’s with the support ofHOD – Safety. The RCA will be reviewed by Unit Head .

10.5 If CAPA points does not get closed as per target datesprovide, what is the method you adapt for extension.The RCA CAPA points will be discussed and reviewed in theMonthly Review Meeting and Joint Safety Review Meeting. Anypoints which are not closed will be discussed for the constrainsand resources required if any will be provided and actions will becomplied.

HIRAC & SOP

11.1 Does the organization conducted HIRAC for the plant and its critical maintenances.

Yes, the HIRA will be conducted for all the routine Operation andmaintenance Activities. Sample copy of Mechanical Dept HIRA is attached

11.2 Does Standard Operating Procedures exist for all critical and regular activities?SOP are been prepared for all the Operation and Maintenance activitiesand the SOP’s are been trained for all the related employees and workers.Sample SOP of HP Motor Preventive Maintenance is attached

11.3 Does the company have Job Safety Analysis (JSA)& Job SafetyObservation (JSO) system. If Yes. Attach one sample copy.

The organization fallows the HIRA for all the routine and Risk assessmentfor all the non routine jobs and all the elements of JSA are covered . job Safety Observation (JSO) are been covered through Safety Inspector ofthe Day (SID), Walk Through Inspection (WTI) and Group Safety Inspection

C = Consequence of Occurrence L = Likelihood of Occurrence

RR = Risk Rating

Category Consequence Severity Likelihood

5 Fatality, Public Hospitalization, or Severe

Health Effects Frequent

4 Permanent Disability, Multiple

Hospitalizations, or Major Health Effects Probable

3 One or More Lost Time Workday Cases or

Significant Health Effects Rare

2 Medical Treatment with Restricted Duty or

Medium Health Effects Remote

1 Medical Treatment, Minor Health Effects,

First Aid Case, or Less Improbable

LIK

EL

IH

OO

D

5 II II III IV IV

4 I II III III IV

3 I II II III III

2 I I II II II

1 I I I I II

1 2 3 4 5

CONSEQUENCE

Risk Categories

IV 17-25

High Mitigate with highest priority

III 12-16

Significant

Mitigate with Priority

II 5-10

Medium Controls Verified -

I 1-4

Low No Mitigation Required

MY HOME INDUSTRIES LTD.

MELLACHERUVU

RISK ASSESMENT

Name: PV Ranga Rao Mgr(E) P.Srikanth, D.M(E) , Narsimha Rao €, N.Srinivas Reddy (E) , Rigger batch Mr.Srinivasa Reddy

Unit/Location/Operation/Equipment: workshop new shed , - Electrical

Task :HT Motors Shifting and storing

Major equipment: Slings, Ropes, Chain pulleys. Hydra Date: 29/05/2014

S.no Activity Hazard Risk Level Safety Recommendations Responsibility Remarks.

Low, Medium,

High

1

2

Approach to work area

Lifting and shifting of HT

motors into new shed

a.) Slips & falls at floor

level

b.)fall of person while

working at height.

a) falling of object

b) Failure of wire ropes

Medium

High

High

High

Good Housekeeping & clear

path ways.

Approach to be made clear

Ensure proper approach like,

ladder , scaffolding and proper

anchoring of safety belt to be

ensured

1. Use certified tools (reputed

make) ,Slings, chain blocks, wire

ropes etc

2. Ensure supervision by

Manager(E)_/Dy.Manager(E)

throughout complete monitoring

till completion of job.

3. The HT motors 7to 10T

capacity are done by lifting

one or 2 inches and moving

over small lengths

Team :

P.V.Ranga

Rao,

P.Srikanth

D.N.Rao

N.Srinivas

Reddy (E) ,

Rigger batch

Mr.Srinivasa

Reddy

Contractors Safety Management12.1 Does the organization has evaluation of contractors method. If Yes. What is the process?Yes, the organization follows the Contractor Pre Qualification. The Contract will be awarded based on the requirements fulfilled and safety performance in the pervious works carried. The sample Contractor Pre Qualification is been attached.

12.2 What is the frequency of contractor’s safety performance monitoring? The contractor’s safety performance will be reviewed twice in a year at the plant level and once in a year at the Corporate level.

12.3 Does the contractor deploy qualified safety person on board as per 50:1?Yes, we have the clause no: 3.4 of Contractor safety Rules which will be issued at the time of contractor issue and as per the clause, one safety Officer/ Engineer need to be deputed for every 50 Workers and this is been complied.12.4 How frequently contractor will get involved in safety meetings.Weekly, all the Contractors are involved in Weekly safety gate meeting

Contractors Safety Management

12.5 What is the method adapted to encourage contractors safetyperformance?The methods adapted to encourage contractor s safetyperformance are:

• Implementation of workers to workers interactionprogramme in which we used to award the contract workers

for imparting the trainingfor his co-workers.• Contractors who have successfully completed the projectswill be awarded for his best safety performance.• Contractors get together will be arranged for safe andsuccessful completion of the project.• Contractor will be awarded annually for the Best SafetyContractor.• Quarterly get together will be arranged for the contract

workers for the best safety performance as per locationwise in the quarter.

Safety Audits

Sl. No. Audits 2016-17 2017-18

1 Internal

No of Observation 4855 4224

Compliance % 100 % 98 %

Variance 0% 2 %

2 External

No of Observation 68 172

Compliance % 100 % 91%

Variance 0% 9 %

Safety Audits

Occupational Health14.1 Does the factory have dedicated OHC & Dedicated Staff? Provide Names with designations.Yes, the dedicated OHC with staff are available round the clock and the details of the staff are mentioned below:

14.2 What is the pre-medical check procedure for employees followed? All the employees before joining the organization need to under gothe Pre Medical Examination. After verifying the medical reports, theResident Medical Officer certifies the fitness of the employees. Theformat of Pre Medical Examination is been attached.

Sl.No Name Designation

01 Dr. K. Phani Bhushan Resident Medical Officer

02 Mr. N. Srinu Male Nurse

03 K. Madhusudhan Naidu Male Nurse

04 V. Yashodha Lakshmi Female nurse

05 K. Saidulu Ambulance Driver

Occupational Health

14.3 What is the frequency of re-medical checkup for employees?

The re – medical examination will be conducted once in a year and the results of the examination will be reviewed by Medical Officer. The sample copy of the Medical Examination is attached.

14.4 How you ensure contractor workforce medical prior to deployment on job. Attach pre-medical check format.

Its Mandatory for all the Contract Workers to undergo thePre Medical Examination and the gate pass are only issuedafter conforming by the Medical Officer for the fitness of the workers. The Copy of the Contract Pre Medical Checkformat is been attached.

Safety Promotional Activities 2016

15.1 How does the factory encourages employees and workforce to follow safety practices. List is not limited to…

Sl.

No.List of promotional activities-2016

01 27th National Road Safety Week

02 45th National safety Week Celebrations

03 Annual Safety Campaign - Focus 1 -Machinery safety & Safety TrainingsFocus 2 - Transport safetyFocus 4 – Process Safety

04 National Fire Service Week Observation

05 Electrical Safety Week

06 Mines Safety Week Celebrations

Visit to Local Site Tour by the Award winners with spouses during CRH Awards Function


Safety Promotional Activities 2016CRH India Awards – 2016 for the Best Safety Performers


SDG Exhibit, CSI – WBCSD

Sharing the Best Practices on safety - Directors of Mangalam & Tancem


Sl.

No.List of promotional activities-2017

01 28th National Road Safety Week

02 46th National safety Week Celebrations

03 Annual Safety Campaign - Mobile plant safety & Energy Isolation, Internal and External Transportation

04 National Fire Service Week Observation

05 Electrical Safety Week

06 Mines Safety Week Celebrations


Safety Campaigns 2017, Energy Isolation & Internal and External Transport 08.05.2017 to 10.06.2017


15.2 Does the organization participate in external events, if yes, provide data

• We have participated in Mines Sustainability Exhibition by IBM at Hyderabad, 09.06.2016

• Mines Initiatives Exhibition at Nalgonda 20.06.2016 Vikas Parv Celebrations • Hosted 2nd workshop on the Best Practices in cement sector on 7th & 8th

July 2016 under Knowledge Exchange Platform

• Sharing the Best Practices on safety - Officials of TAN CEM Ltd Visit on 16th March 2017

• Sharing the Best Practices on safety - Directors of Mangalam Team Visit on July – 2017

• Participated in Best Safety Practice Meet at Dublin on 09.10.2017• Brief on SDG Exhibit, CSI – WBCSD 11th CSI Forum - 26th & 27th Sep’ 2017,

New Delhi • Hosted Work shop on “Proactive Safety Management in Cement

Manufacturing” on 07.09.2018 in collaboration with National safety Council, Hyderabad and Director of Factories, Telangana Govt

BEST SAFETY PRACTICE MEET AT DUBLIN

“Proactive Safety Management in Cement Manufacturing”

Awards & Rewards 2016 -17

Sl. No. Awards Achieved / Awarded by 2016-17 2017-18

1May Day Award – Best Management Award Awarded by Labor Dept, Telangana Govt

May’ 2016

2 3 Star EHS National Award from CII Aug’ 2016

3

CCQC Hyderabad Chapter, 5 Nos Gold and 1

Silver award –

Awarded by Quality Circle forum of India

Sep’ 2016

4

NCQC 1 Platinum and 1 Gold award received

at Raipur

Awarded by Quality Circle forum of India

Dec’ 2016

5

Overall First Prize during Mines Safety Week

(MS & PC – 2016)

Awarded by DGMS, Hyderabad

Dec’ 2016

6

CRH India Safety Award for Best Safety

Performance

Awarded by CRH India

Dec’ 2016

Golden Peacock Award for Sustainability

Sl. No. Awards Achieved / Awarded by 2016-17 2017-18

1 Facilitation award for implementing

OSHAS 18001:2007

Awarded by National Safety Council,

Hyderabad Chapter

April’ 2017

2

Quality Circle Awards - 04 Gold Rating

Awarded by Quality Circle forum of

India, Hyderabad Chapter Sep’ 2017

3 Golden Peacock Award for Sustainability at LONDON GLOBAL CONVENTION, 26.10.2017

Dec’ 2017

4 First Runner up Trophy for Safety Best Practices by CII Aug 2018

5 Best performed Mines for 2017 by MC & ME Sept 2018

Awards & Rewards 2017 -18

Mines Safety Award - 2017

First Runner up Trophy for Safety Best Practices by CII

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