Basic Industrial Safety Induction Training 2024 .pptx

# Industrial Safety Education , # Safety Induction, # New Joinees Induction, # Basic Safety Awareness in Industry

1. TVS SFL Induction Training For New Employees

2. Customize Your Company Details Company Location & Details Company Policy Manufacturing Process Customer Details Manufacturing Location

3. Safety The condition of being safe; freedom from danger, risk (or) injury. Accident Unplanned Event, leads to ill health, ijury , human body parts damaged Reason for Accident a.Unsafe Act (88%) Unsafe act are any actions (or) behaviors that put ourselves (or) others at risk of harm . b.Unsafe Condition(10%) Unsafe condition are any factors in the workplace that increase the risk of accidents or injuries. Hazards A hazard is a source (or) a situation with the potential for harm in terms of human injury (or) ill-health, damage to property, damage to the environment, (or) a combination of these. Introduction

4. HAZARDS

5. HAZARDS

6. HAZARDS

7. TYPE HAZARD HAZARD CHEMICAL Solvents Oil and lubricants Hydrocarbon Acid, Alkali Solutions ERGONOMICS Layout and Design Reach Fixing Projectiles Lubrication Interlocking MECHANICAL Tapping Impact Projectiles Entanglement Contact Nipping Stability ORGANISATIONAL Fatigue Shiftwork Workload Lack of safety culture ELECTRICAL Shock Electromagnetic EMF Radiation Earthing & Bonding Fuse Lightning OCCUPATIONAL HEALTH HAZARDS Noise Dust –Powder Fumes Radiation Heat Vibration Biological Fine Fibers OTHER HAZARD Confined Space(Oxygen Deficiency) High pressure (Air, Nitrogen, Water, Steam,Chemicals ) Stored Energy (Electrical, Mechanical) HAZARDS

8. MECHANICAL HAZARDS TRANSMISSION MACHINERY Transmission machinery takes energy from a prime mover to the part of a machine where it is used. Every part of any transmission machinery should be securely fenced unless, because of its position (or) construction, it is safe. Figure shows some ways operators can be injured by this type of machinery . Transmission machinery can include gears, shafts, pulleys and belts, chains and sprockets, or friction drives. All transmission machinery should have a device in every room or workplace to cut the power to the machinery. Examples of where operators can be injured by unguarded transmission machinery Solid red arrows  = where a part of the body could be drawn into a nip-point White (or) grey arrows = movement of machine parts

9. MECHANICAL HAZARDS Drawing-in hazards between counter-rotating parts DRAWING-IN (or) TRAPPING HAZARDS Injuries can be caused when a part of the body is drawn into a ‘nip-point ’. Figure shows some ways operators can be injured by drawing in and trapping hazards, such as: In-running nips between two counter-rotating parts (like meshing gears, rolling mills, mixing rolls, press rolls) In-running nips between a rotating surface and another surface moving along it (such as a power transmission belt and its pulley, a chain and its chain wheel, a rack and its pinion) Running nips between a rotating surface and another surface moving along it where material (like metal, paper, cable, rope) runs onto a reel, drum or shaft Nips between rotating and fixed parts, which can shear, crush (or) abrade, such as spoke hand-wheels, flywheels and screw conveyors. Solid red arrows  = where a part of the body could be drawn into a nip-point White (or) grey arrows = movement of machine parts

10. MECHANICAL HAZARDS Examples of impact hazards IMPACT HAZARDS Impact hazards are caused by objects that strike the body, but do not enter it . Figure shows some ways operator can be injured by impact hazards. Examples include the rotating arm of a robot, the reciprocating bed of a metal planning machine and the arms of a shaping machine. Impact hazards are different from crush hazards even though the machines involved may be the same. Impact hazards involve the inertia of the body while crush hazards involve trapping the body between two machine parts (or) between a machine part and a fixed structure. Solid red arrows  = Direction of machine moment

11. MECHANICAL HAZARDS Friction and abrasion hazards FRICTION AND ABRASION HAZARDS Friction burns can be caused by smooth parts operating at high speed. Figure shows some ways operator can be injured by friction and abrasion hazards . Examples of friction or abrasion hazards include: The sides of a grinding wheel The belt of a belt sanding /polishing machine Material running onto a band saw (or) shaft A conveyor belt and its drums Pulleys and fast-moving belts. Solid red arrows  = where a part of the body could be drawn into a nip-point White (or) grey arrows = movement of machine parts

12. MECHANICAL HAZARDS Contact with single rotating surface ENTANGLEMENT HAZARDS Entanglement is when someone is caught in a machine by loose items (such as clothing, gloves, bangle, hand rope, Jewelry, long hair, cleaning rags, (or) rough material being fed in to the machine). Figures show some ways operators can be injured by entanglement with machinery. Contact that can lead to entanglement includes: Touching a single rotating surface (such as plain shafting, couplings, spindles, chucks, screws, mandrels (or) rotating work pieces including plain bar material) Solid red arrows  = where a part of the body could be drawn into a nip-point White (or) grey arrows = movement of machine parts

13. MECHANICAL HAZARDS ENTANGLEMENT HAZARDS C atching on projections or in gaps. Belt fasteners and other projecting items (such as keys, set screws and cotter pins) are typical projection hazards. Fan blades, spoked wheels (such as pulleys, sprockets, gear wheels and flywheels), mixer and beater arms and spiked cylinders create gap-related hazards Catching on projections or in gaps Solid red arrows  = where a part of the body could be drawn into a nip-point White (or) grey arrows = movement of machine parts

14. MECHANICAL HAZARDS ENTANGLEMENT HAZARDS Touching moving materials in motion (such as in centrifuges, oiling drum, driers and dough mixers) Reaching between counter rotating parts (such as gear wheels, rolling mills) Reaching between a rotating part and another part moving along it (such as a power transmission belt and its pulley, a chain and chain wheel, a rack and pinion, a conveyor belt and any of its pulleys, a rope and its storage reel) Reaching between rotating and fixed parts (such as flywheels and the machinery bed, screw or worm conveyors and their casings, mixers, extruder screw and barrel, the edge of an abrasive wheel, or an incorrectly adjusted work rest). Catching between rotating and fixed parts Solid red arrows  = where a part of the body could be drawn into a nip-point White (or) grey arrows = movement of machine parts

15. MECHANICAL HAZARDS SHEARING HAZARDS Shearing trims or shears metal (or other material) with a powered knife or slide. Shear points are found where stock is inserted, held and withdrawn. Figures show some ways operators can be injured by shearing hazards. Parts of the human body can be sheared: between two machine parts, such as: the table of a metal planning machine (shaper) and its bed the table and blade of a guillotine or power press nip-points between connecting rods or links and rotating wheels or between parts that move back and forth) between a machine part and a work piece, such as the tool of a broaching machine and the part being broached. Shear hazards between two machine parts Solid red arrows  = where a part of the body could be drawn into a nip-point White (or) grey arrows = movement of machine parts

16. MECHANICAL HAZARDS CUTTING HAZARDS Cutting hazards exist at the point where wood, metal or other materials are cut. shows some ways operators can be injured by shearing hazards. Many kinds of tools create cutting hazards: band and circular saws boring or drilling machines planning and tenoning machines milling machines cutting edges of milling tools water jet cutting high energy lasers moving sheet material in a machine abrasive wheels cutting edges of endless-band cutting machines reciprocating knives and saws revolving cutting tools. Shear hazards between a machinery part and a work piece Solid red arrows  = where a part of the body could be drawn into a nip-point White (or) grey arrows = movement of machine parts

17. MECHANICAL HAZARDS STABBING AND PUNCTURING HAZARDS The human body can be pierced by flying objects. Figure shows some ways operators can be injured by stabbing and puncturing hazards. For example: a loose tool in a lathe broken tooling on a press an abrasive wheel breaking up swarf timber from a bench saw molten metal from a die-casting machine sparks from welding a bolt from an explosive powered tool debris thrown by rotary mowers and hedge cutters. The human body can also be pierced by rapidly moving parts of machinery or pieces of material. For example: the needle of a sewing machine the drill of a drilling machine the arm of a robot. Injection of fluids through the skin can cause tissue damage similar to stabbing. Examples of stabbing and puncture hazards by flying objects or moving parts of machinery

18. TYPES OF GUARDS THAT ISOLATE THE HAZARD FIXED GUARDS Example of a fixed guard

19. TYPES OF GUARDS THAT ISOLATE THE HAZARD FIXED GUARDS Fixed guards are physical barriers that keep people out of dangerous areas during normal use, maintenance or cleaning. The need to adjust drive belts and transmission chains, other machinery parts, can affect guard design. Fixed guards can be: permanent – welded into or part of the body of the machine removable – but they can only be removed when the machine is stopped with a special tool that is not easily available to operators. Do not use wing nuts, wedge inserts or anything that can be undone with the fingers. Barriers or fences held securely in place with fasteners or other suitable devices can stop access to dangerous areas. Machine guards should be made of substantial materials (such as sheet steel, wire mesh) that cannot be easily damaged. Example of a fixed guard

20. TYPES OF GUARDS THAT ISOLATE THE HAZARD INTERLOCKED GUARDS Interlocked guards work by cutting power to the machine when the guard is opened. They are a good guard to use when a machine needs to be accessed often. If parts keep moving when the machine is not working, you must use a type of guard that cannot be opened until all parts have stopped moving, or fit devices that stop the machinery. Any brakes fitted to machinery must be well maintained. Example of a Interlocked guard

21. TYPES OF GUARDS THAT ISOLATE THE HAZARD TWO-HAND CONTROLS Figure Example of a two-hand control Only use this method to isolate people from machinery hazards. Even when used properly, two-hand controls only protect the machine operator, not other people who may be near. Example of a two-hand control Two-hand controls should: need to be turned on together (so people cannot tape one control down) need to be held to run, so the machine stops immediately when the control is released be spaced well apart and shrouded so one arm cannot run both controls. The rear and sides of the machine should be guarded by fixed guards to prevent stop access by other people.

22. TYPES OF GUARDS THAT ISOLATE THE HAZARD PHOTOELECTRIC SAFETY DEVICES Photoelectric safety devices use light beams that stop machines working when the light beam is broken. Example of a photoelectric light curtain used as a trip guard

23. TYPES OF GUARDS THAT ISOLATE THE HAZARD Lockout/ Tagout Lockout/ Tagout  (LOTO) is a set of procedures that are used to ensure that equipment or systems are shut down, inoperable, and (where relevant) de-energized prior to any maintenance or repair work. It is a protection system against unintentional exposure to hazardous energy so that work can be performed safely. Shows various types of tag-out and lock out devices that can be used

24. ELECTRICAL HAZARDS ELECTRIC SHOCK Electric shock refers to the electricity passing through the human body, affecting the normal function of the heart, lungs and nervous system. Ventricular fibrillation caused by electricity is the main reason for death from electric shocks. Electric shocks may indirectly lead to accidents, e.g. falling from heights and bruising due to body trauma etc. Electric shock refers to the electricity passing through the human body, affecting the normal function of the heart, lungs and nervous system. Ventricular fibrillation caused by electricity is the main reason for death from electric shocks. Electric shocks may indirectly lead to accidents, e.g. falling from heights and bruising due to body trauma etc.

25. ELECTRICAL HAZARDS The effect of currents passing through various parts of the body Respiratory Failure Electric shock may affect normal brain function and stop respiration . Heartbeat Failure If current passes through the heart, it will disrupt the rhythmic pumping action and eventually stop the heart beat. Suffocation Most accidents due to electric shocks are caused by current passing through the chest.When such accidents occur, chest muscles cramp, leading to suffocation and death. Unable to get free after an electric shock An electric shock causes continuous contraction of the forearm muscles, thus stopping the victim getting free from the electric source.

26. ELECTRICAL HAZARDS Burns During an electric shock, the current passing through the body may lead to burns on the skin, muscles or internal organs. As electric shocks and burns are closely related, preventative measures should be considered together. Fires and explosions High temperatures caused by currents under abnormal conditions, may result in accidental fires and explosions. The common causes leading to high temperatures include: Overloading of electricity Insulator breakdowns or short circuits Improper contact of electrical circuit Improper maintenance of electrical appliances or wiring Poor ventilation, etc. If flames, sparks or metallic solutions due to electric arc welding are not controlled, hazardous fires or explosions can occur.

27. GHS Hazard Classes Globally Harmonized System

28. PICTOGRAM HAZARD CLASS CATEGORY DESCRIPTION CORROSION Skin corrosion Category 1A, 1B, 1C Irreversible skin damage Serious eye damage Category 1 Irreversible eye damage SKULL AND CROSSBONES Acute toxicity, oral Category 1, 2, 3 Highly toxic in small amounts, serious health effects or death Acute toxicity, dermal Category 1, 2, 3 Acute toxicity, inhalation Category 1, 2, 3 HEALTH HAZARD Aspiration Hazard Category 1, 2 May be fatal if aspirated Sensitization, respiratory Category 1, 1A, 1B Induces hypersensitivity of the airways Germ cell mutagenicity Category 1A, 1B, 2 May cause genetic defects Carcinogenicity Category 1A, 1B, 2 May cause cancer Reproductive Toxicity Category 1A, 1B, 2 May damage fertility; may damage the unborn child Specific target organ toxicity, single exposure Category 1, 2 Causes damage to organs Specific target organ toxicity, repeated exposure Category 1, 2 Causes damage to organs through prolonged or repeated exposure Health Hazards

29. PICTOGRAM HAZARD CLASS CATEGORY DESCRIPTION EXCLAMATION MARK Eye irritation Category 2A Causes serious eye irritation Skin irritation Category 2 Causes skin irritation Acute Toxicity, oral Category 4 Harmful if swallowed Sensitization, skin Category 1 May cause an allergic skin reaction Acute toxicity, dermal Category 4 Harmful in contact with skin Specific target organ toxicity, single exposure, Respiratory tract irritation Category 3 May cause respiratory irritation Specific target organ toxicity, single exposure, Narcotic effects Category 3 May cause drowsiness or dizziness Hazardous to the ozone layer Category 1 Harms public health and the environment ENVIRONMENT Hazardous to the aquatic environment, acute hazard Category 1 Environmental hazard Hazardous to the aquatic environment, long-term hazard Category 1, 2 Health Hazards

30. Physical Hazards PICTOGRAM HAZARD CLASS CATEGORY DESCRIPTION FLAME Flammable liquids Category 1, 2, 3 Flammable liquids and vapors Flammable solids Category 1, 2 Readily combustible solids Aerosols Category 1, 2 Pressurized container; may burst if heated Desensitized explosives Category 1, 2, 3, 4 Fire, blast, or projection hazard if the desensitizing agent is reduced Flammable gases Category 1, Pyrophoric gas Flammable compressed gas Flammable aerosols Category 1, 2 Flammable pressurized container Self-reactive substances and mixtures; and Organic peroxides Type A, B, C, D, E, F, G Thermally unstable liquid or solid that can undergo strongly exothermic reactions even without oxygen Pyrophoric liquids; Pyrophoric solids Category 1 Substance that can spontaneously ignite in air Self-heating substances and mixtures Category 1, 2 Materials other than pyrophoric materials that can react with air and without energy added. These will only ignite in large quantities or after long periods of time. Substances and Mixtures which, in contact with water, emit flammable gases Category 1, 2, 3 Substances that emit flammable gases when in contact with water

31. Physical Hazards PICTOGRAM HAZARD CLASS CATEGORY DESCRIPTION EXPLOSIVE Explosives Unstable Explosive, Div 1.1, 1.2, 1.3, 1.4, 1.5 Explosive compounds and projection hazards Self-reactive substances and mixtures; and Organic peroxides Type A, B CORROSION Corrosive to Metals Category 1 May be corrosive to metals FLAME OVER CIRCLE Oxidizing liquids; Oxidizing solids Category 1, 2, 3 Oxidizers. Are not combustible themselves, but may cause or intensify fires in other materials Oxidizing gases Category 1 GAS CYLINDER Gases under pressure Compressed gas, Liquefied gas, Dissolved gas Gases under pressure, may explode if heated Refrigerated liquefied gas May cause cryogenic burns or injury

32. Identification : Product identifier used on the label; manufacturer or distributor name, address, phone number, emergency phone number; recommended use; and restrictions on use. Hazard Identification : This section lists the GHS classification and hazard statements. Every hazard statement has a corresponding precautionary statement recommending measures to minimize or prevent adverse effects such as “Do not breathe dust.” This section may also show the label pictograms and give any other information related to known hazards of the product. Classifications by other entities such as OSHA, HMIS, or NFPA may also be given. Composition/Information on Ingredients : provides a list of all hazardous ingredients, their CAS numbers, and their concentrations or concentration ranges in the product. For each ingredient, the hazard classification is given. Depending on the concentration, the classification for each individual compound may be different than the classification of the mixture found under section 2. CONTENT OF A SAFETY DATA SHEET In compliance with the new Hazard Communication Standard, SDS are divided into 16 sections and are required to provide the following information:

33. First-Aid Measures :  describes potential symptoms and acute or delayed effects resulting from exposure. It gives information on how to respond to exposure and on appropriate medical treatment. Fire-Fighting Measures :  lists suitable extinguishing techniques and equipment as well as potential hazards arising from a fire, such as toxic fumes. Accidental Release Measures :  lists emergency procedures for responding to a spill, required protective equipment, and basic methods of containment and cleanup. Handling and Storage :   lists brief precautions for safe handling and storage. It should contain information about incompatibilities with other chemicals, but it is often not exhaustive. Refer to the DRS chemical storage guide for more detailed information. Exposure Controls/Personal Protection :  lists OSHA's Permissible Exposure Limits (PELs) and Threshold Limit Values (TLVs) for each ingredient. This section should also give information on personal protective equipment (PPE); e.g., appropriate respirators and gloves, and engineering controls.

34. Physical and Chemical Properties  : lists the characteristics of the product such as color, boiling point, pH, and density etc. Stability and Reactivity:   lists chemical stability, possibility of hazardous reactions, conditions to avoid, incompatible materials, and hazardous decomposition products. Toxicological Information:  describes possible routes of exposure; symptoms related to physical, chemical and toxicological characteristics; acute and chronic effects; and numerical measures of toxicity such as LD50 values if available. Ecological information:   includes available information on Eco toxicity, degradability, bioaccumulation, and other adverse effects on the environment. Disposal considerations :  is relevant for professional waste disposal services. Refer to the DRS chemical waste guide for disposal practices. Transport information :  lists DOT UN number, proper shipping name, and class. Regulatory information:  includes other applicable local regulations on safety, health, and environment. Other information :  includes the date of preparation of the SDS or its last revision.

35. PPE Personal Protective Equipment (PPE) is an essential aspect of workplace safety. This Induction program aims to discuss the benefits of wearing PPE, the types available, common excuses for not wearing PPE, and the consequences of not using PPE. We will also go through specific PPE requirements for different jobs and situations. Personal protective equipment must be worn in the workplace Safety helmet Goggles Ear protection Gloves masks Safety footwear

36. Wearing appropriate PPE can greatly reduce the risk of workplace injuries and illnesses. Some of the key benefits include: Protection against physical, chemical, and biological hazards Prevention of long-term health problems Compliance with industry regulations and standards Reduction of workplace accidents and associated costs Benefits of Wearing PPE

37. There are various types of PPE designed for different job tasks and conditions. Some common examples include: Types of Personal Protective Equipment (PPE) Safety helmets Safety goggles Gloves Safety shoes Hearing protection Safety belts/harnesses Respiratory protection Specialized equipment like H2S monitors, LEL indicators, oxygen analyzers, and SCBA

38. Warning sign Prohibition sign Mandatory sign Safe Condition sign Fire Safety sign Safety signs

39. Safety signs

40. Warning sign

41. Burn Hazard Hot Surface Body Crush Tipover Hazard Arm or body entangle rollers Arm Entangle Rollers Hand Crush Force Body Crush Cutting of Fingers Electrical Shock Automatic Start-Up

42. Prohibition sign

43. Mandatory sign

44. Fire Safety sign

45. check that the machinery they use is in sound working order report immediately any problems to their supervisor report devices, guards, appliances, protective devices removed form machinery. Never leave machines unattended with parts still moving. Remember that parts may still be moving after the machine has been turned off. not wear loose clothing, jewelry, or long hair around machines Don’t use a machine or appliance that has a danger sign or tag attached to it. Never use compressed air to clean your clothes or any part of your body. Machine operators should

46. Keep floors free of sawdust, oil, grease or any other liquid. Clean up spilled liquids immediately, they are slipping hazards. Store materials in such a way that they cannot become tripping hazards. Immediately return all excess material to its proper storage place. Put tools away when not in use. This prevents loss of tools and also makes them available to others. Place all scrap in scrap containers. Stop work 10 minutes prior to the time you need to leave the shop. This will provide ample time to clean and replace tools to their homes. KEEP THE SHOP CLEAN AT ALL TIMES . It is all of our responsibility to keep the shop clean. There is no excuse for a cluttered or messy workspace. If your workspace is cluttered, then you are working too fast. Slow down. Know this: you will not anger someone if you clean up after them. In fact, they will likely do the same for you. Workplace Cleanliness Rules

47. House Keeping : 3 – Bin SYSTEM

48. 1. Yellow: Purpose: General Waste Usage: this is less common for general waste management industries 2.Green: Purpose: Recyclable Materials Usage: Green bins are often used for general recyclable materials, including: Metal Scrap: Collecting various types of metal scrap such as steel, aluminum , and iron for recycling. 3. Red: Purpose: Hazardous Waste Usage: Red bins are used for hazardous waste materials that require special handling and disposal procedures. This includes: Oil Waste: Used oils and lubricants that need to be disposed of safely. Chemical Waste: Any hazardous chemicals used in the manufacturing process. Contaminated Materials: Items like rags, gloves, or absorbent materials that have been contaminated with hazardous substances.

49. FIRE EXTINGUISHERS

50. THE FIRE TRIANGLE Oxygen  to sustain combustion Heat  to raise the material to its ignition temperature Fuel  to support the combustion Chemical reaction  between the other three elements This is The Fire Triangle. Actually, it’s a tetrahedron, because there are four elements that must be present for a fire to exist: Remove any one of the four elements to extinguish the fire. The concept of Fire Protection is based upon keeping these four elements separate. THE FIRE TRIANGLE

51. TYPES OF FIRES Class A Fires Fires in  ordinary combustibles , such as wood, paper, cloth, rubber and many plastics. Class E Fires Fires involving  energized electrical equipment , such as computers, servers, motors, transformers and appliances. Remove the power and a Class C fire becomes one of the other classes of fire. Class D Fires Fires in  combustible metals , such as magnesium, titanium, zirconium, sodium, lithium and potassium. Class B Fires Flammable liquids such as gasoline, petroleum greases, tars, oils, oil-based paints, solvents and alcohols Class C Fires Flammable gases which can be very dangerous and highly explosive. These include gases such as butane and propane in gas canisters

52. Thank You