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1. INDUSTRIAL SAFETY MCN401 ARJUN P K

2. MODULE 1 Need for safety. Safety and productivity. Definitions: Accident, Injury, Unsafe act, Unsafe Condition, Dangerous Occurrence, Reportable accidents. Theories of accident causation. Safety organization- objectives, types, functions, Role of management, supervisors, workmen, unions, government and voluntary agencies in safety. Safety policy. Safety Officer-responsibilities, authority. Safety committee-need, types, advantages.

3. INTRODUCTION As the name suggests, industrial safety refers to the safety management practices that apply to the industrial sector. Those processes aim to protect industrial workers, machinery, facilities, structures, and the environment. Industrial safety is overseen by federal, state and local laws and regulations. The Occupational Safety and Health Association (OSHA) is the primary regulatory body in the United States dedicated to workplace safety, including the industrial sector. ARJUN P K

4. Industrial safety is a broad area of workplace safety, covering a number of issues and topics, including: General safety (issues and concerns that are common across all industries) Site-specific safety issues Process and production safety Material safety Fire safety Electrical safety Building and structural safety (including temporary installations) Environmental safety ARJUN P K

5. NEED FOR SAFETY Workers who sustain lost time injuries can be difficult to replace. Because of this, injuries can have significant effects on a company's production output , shipping schedules , fulfillment and customer satisfaction . Good safety practices, then, not only keep workers safe but also help maintain employee, vendor, and client satisfaction. ARJUN P K

6. 1. Social Need The accident causes social loss in great magnitude in form of suffering, loss of earning capacity and cost due to disturbance to economic efficiency. 2. Management Need Management bear huge loss due to accident. Cost of accident is two Types Direct & Indirect cost. Indirect cost is several times more than Direct Cost. Direct cost include medical expenses, compensation to the injured or their families. ARJUN P K

7. 3. Legal Need As per The Building & other construction Act 1996, Factories Act 1948 and several other related Acts & rules the general duty of the employer is to ensure Health & Safety of his employee & protect the Environment. 4. Humanitarian Need The Humanitarian reason for prevention of accidents is based on notion that it is duty of every person to ensure safety of his fellow men ARJUN P K

8. OBJECTIVES Preventing work-related fatalities, disabling injuries, illness, and damage to machinery or materials Ensuring continued production by preventing disruptive incidents Reducing workers compensation costs, maintaining lower insurance rates, and minimizing indirect costs associated with accidents Strengthening safety culture and increasing employee morale Meeting vendor and client expectations ARJUN P K

9. ACCIDENT An accident is an undesirable Event that arises to injury, fatality, ill health, property damage or combination of these . Accidents which take place in the work place are referred to as work place accidents or occupational accidents . Work place accidents include events that damage property, inhibit a particular workplace function, or cause harm to a person located in the workplace. ARJUN P K

10. INJURY An injury is any physiological damage to the human body caused by immediate physical stress. An industrial injury is defined as “ a personal injury to an employee which has been caused by an accident or an occupational disease and which arises out of or in the course of employment and which could entitle such employee to compensation under Workers ' ARJUN P K

11. An injury can occur intentionally or unintentionally and may be caused by blunt trauma, penetrating trauma, burning, toxic exposure, asphyxiation, or overexertion. Injuries can occur in any part of the body, and different symptoms are associated with different injuries. Treatment of an injury is typically carried out by a health professional and varies greatly depending on the nature of the injury. ARJUN P K

12. UNSAFE ACT Working without wearing safety helmet & safety Shoes Working at height without wearing full body harness. Taking Rest in working Areas working or Taking rest below Hanging Load Over speeding Operating equipment without qualification or authorization. Lack of/or improper use of PPE Operating equipment at unsafe speeds Failure to warn Bypass or removal of safety devices Using defective equipment Committing mistake by person or Any act that may lead to accident is known as unsafe act. ARJUN P K

13. To prevent unsafe act type accidents: Think about how to do the task safely prior to engaging in the work. Warn co-workers of hazards. If you are not trained to use a piece of equipment, don’t use it. Don’t rush your work or take shortcuts. Use all equipment, tools, and material in the appropriate and intended manner. Don’t use a chair as a ladder. Use proper lifting technique, a lifting device, or get assistance. Use appropriate personal protective equipment. Stop and mentor employees engaged in unsafe acts. ARJUN P K

14. UNSAFE CONDITION Damage welding Cable Mechanical guard not Provided on rotating parts Defective sling or lifting equipment. Defective work platform Floor or platform Opening, Pits Poor housekeeping Defective tools, equipment or supplies Inadequate supports or guards Congestion in the workplace Inadequate warning systems Hazardous atmospheric conditions etc. Any sources or situation or condition that have potential to create accident is known as unsafe condition. ARJUN P K

15. To prevent unsafe condition type accidents Think about how to do the task safely prior to engaging in the work. Ensure that you have all appropriate equipment, tools and material to safely do the job. Inspect all equipment, tools and material before use. Make certain the item is in good working condition and is appropriate for the task. Make certain that you have enough space to complete the job. Many injuries are caused because employees didn’t have sufficient room to do a job. Injuries occur everyday because employees choose not to say anything about known hazards. Employees identifying unsafe conditions should cease their activity and report the condition to their immediate supervisor for corrective action. ARJUN P K

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18. DANGEROUS OCCURANCE These are incidents with a high potential to cause death or serious injury , but which happen relatively infrequently . Dangerous occurrence means any occurrence that does not result in, but could (if the situation was different) cause the death of a worker or will require a worker to be admitted to a hospital as an in-patient for a period of 72 hours or more ARJUN P K

19. It also includes,…. The structural failure or collapse of a structure, scaffold, temporary falsework or any part of a tunnel, trench or excavation; The failure of a crane or hoist or the overturning of a crane or unit of powered mobile equipment An accidental contact with an energized electrical conductor The bursting of a grinding wheel An uncontrolled spill or escape of a toxic, corrosive or explosive substance; A premature detonation or accidental detonation of explosives; The failure of an elevated or suspended platform ARJUN P K

20. REPORTABLE ACCIDENTS It includes the category of accidents which is little complicated than of minor accidents. Here the injuries caused to the worker prevent him from working for the period of 48 hours or more. Here supervisor is responsible to report to the higher management and arrange another worker so that the production could not be affected. ARJUN P K

21. THEORIES OF ACCIDENT CAUSATION There are several major theories concerning accident causation. The domino theory Human Factors Theory Accident/Incident Theory Epidemiological Theory Systems Theory The energy release theory Behavior Theory ARJUN P K

22. 1. THE DOMINO THEORY The domino theory was developed by H. W. Heinrich, a safety engineer and pioneer in the field of industrial accident safety. According to Heinrich, an "accident" is one factor in a sequence that may lead to an injury. ARJUN P K

23. The factors can be visualized as a series of dominoes standing on edge; When one falls, the linkage required for a chain reaction is completed. Each of the factors is dependent on the preceding factor. ARJUN P K

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25. The process….. A personal injury (the final domino) occurs only as a result of an accident. An accident occurs only as a result of a personal or mechanical hazard. Personal and mechanical hazards exist only through the fault of careless persons or poorly designed or improperly maintained equipment. Faults of persons are inherited or acquired as a result of their social environment or acquired by ancestry. The environment is where and how a person was raised and educated. ARJUN P K

26. The factor preceding the accident (the unsafe act or the mechanical or physical hazard) should receive the most attention. Heinrich felt that the person responsible at a company for loss control should be interested in all five factors, but be concerned primarily with accidents and the proximate causes of those accidents. Heinrich also emphasized that accidents, not injuries or property damage, should be the point of attack. An accident is any unplanned, uncontrolled event that could result in personal injury or property damage. For example, if a person slips and falls, an injury may or may not result, but an accident has taken place. ARJUN P K

27. Corrective action sequence Engineering Control hazards through product design or process change Education Train workers regarding all facets of safety Impose on management that attention to safety pays off Enforcement Insure that internal and external rules, regulations, and standard operating procedures are followed by workers as well as management. ARJUN P K

28. 2. HUMAN FACTORS THEORY Heinrich posed his model in terms of a single domino leading to an accident. The assumption here is that human errors cause accidents . These errors are categorized broadly as: Overload Inappropriate worker response Inappropriate activities ARJUN P K

29. i . Overload Overload defines the imbalance between a person’s capacity at any given time and the load that person is carrying in a given state. A person’s capacity is the product of such factors as his or her natural ability, training, state of mind, fatigue, stress, and physical condition. The load that a person is carrying consists of tasks for which he or she is responsible and added burdens resulting from environmental factors (noise, distractions, and so on), internal factors (personal problems, emotional stress, and worry), and situational factors (level of risk, unclear instructions, and so on). ARJUN P K

30. ii. Inappropriate Response and Incompatibility How a person responds in a given situation can cause or prevent an accident. If a person detects a hazardous condition but does nothing to correct it, he or she has responded inappropriately. If a person removes a safeguard from a machine in an effort to increase output, he or she has responded inappropriately. In addition to inappropriate responses , this component includes workstation incompatibility . The incompatibility of a person’s workstation with regard to size, force, reach, feel, and similar factors can lead to accidents and injuries. ARJUN P K

31. iii. Inappropriate activities Human error can be the result of inappropriate activities. An example of an inappropriate activity is a person who undertakes a task that he or she doesn’t know how to do. Another example is a person who misjudges the degree of risk involved in a given task and proceeds based on that misjudgment. Such inappropriate activities can lead to accidents and injuries. ARJUN P K

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33. 3. ACCIDENT/INCIDENT THEORY Extension of the human factors theory. Developed by Dan Petersen. Introduced such new elements as ergonomic traps, the decision to err and systems failure. In this model, overload, ergonomic traps and decision to err lead to human error. The system failure is an important contribution of Petersen's theory. ARJUN P K

34. Basic elements Ergonomic traps These are incompatible work stations, tools (management failure) Decision to err Unconscious or conscious human errors on making decisions, which could subsequently lead to the occurrence of accidents Systems failure Management failure (policy, training, etc.) ARJUN P K

35. SOME WAYS THAT SYSTEMS FAIL - Management does not establish a comprehensive safety policy. Responsibility and authority with regard to safety are not clearly defined. Safety procedures such as measurement, inspection, correction and investigation are ignored or given insufficient attention. Employees do not receive proper orientation. Employees are not given sufficient safety training. ARJUN P K

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37. 4. EPIDEMIOLOGICAL THEORY Traditionally, safety theories and programs have focused on accidents and the resulting injuries. However, the current trend is toward a broader perspective that also encompasses the issue of industrial hygiene. Industrial hygiene concerns environmental factors that can lead to sickness, disease, or other forms of impaired health. This trend has, in turn, led to the development of an epidemiological theory of accident causation. ARJUN P K

38. Epidemiology is the study of causal relationships between environmental factors and disease. The epidemiological theory holds that the models used for studying and determining these relationships. It can also be used to study causal relationships between environmental factors and accidents or diseases. ARJUN P K

39. Key components ARJUN P K

40. The key components are pre-dispositional characteristics and situational characteristics . These characteristics, taken together, can either result in or prevent conditions that may result in an accident. For example, if an employee who is particularly susceptible to peer pressure (pre-dispositional characteristic) is pressured by his coworkers (situational characteristic) to speed up his operation, the result will be an increased probability of an accident. ARJUN P K

41. 5. SYSTEMS THEORY A system is a group of regularly interacting and interrelated components that together form a unified whole. This definition is the basis for the systems theory of accident causation. This theory views a situation in which an accident may occur as a system comprised of the following components: person (host), machine (agency), and environment . The likelihood of an accident occurring is determined by how these components interact. Changes in the patterns of interaction can increase or reduce the probability of an accident. ARJUN P K

42. For example, an experienced employee who operates a complex machining center in a shop environment may take a two-week vacation. Her temporary replacement may be less experienced. This change in one component of the system (person/host) increases the probability of an accident. ARJUN P K

43. ARJUN P K Feedback loop

44. As the model shows, even as a person interacts with a machine within an environment, three activities take place between the system and the task to be performed. Every time a task must be performed, there is the risk that an accident may occur. Sometimes the risks are great; at other times, they are small. This is where information collection and decision making come in. Based on the information that has been collected by observing and mentally noting the current circumstances, the person weighs the risks and decides whether to perform the task under existing circumstances. ARJUN P K

45. five factors should be considered before beginning the process of collecting information, weighing risks, and making a decision: Job requirements The workers’ abilities and limitations The gain if the task is successfully accomplished The loss if the task is attempted but fails The loss if the task is not attempted ARJUN P K

46. 6. ENERGY RELEASE THEORY This theory compares the rate of release of energy and relates to the kind of and severity of injuries. It focuses on the prevention of allowing energy to stores up in an uncontrolled way The first step is to prevent the accumulation of energy by reducing the amount needed and/or providing vent release mechanisms. The next step would be to install control methods that modify the release rate which can be accomplished with the use of space (distance) and time. ARJUN P K

47. For example, a fixed barrier guard separates space by not allowing workers or machinery to reach a point of operation. This is a separation by space. Other control techniques include strengthen the object that may release the energy to prevent such release. For example, slings used in hoisting operations are strength tested to withstand 2 times there working load. ARJUN P K

48. 7. BEHAVIOUR THEORY The behavioral theory of accident causation and prevention is often referred to as behavior-based safety (BBS) . One of the most prominent proponents of BBS is E. Scott Geller , a senior partner of Safety Performance Solutions, Inc., and a professor of psychology According to Geller, there are seven basic principles of BBS : ARJUN P K

49. The behavior intersession should be visible and transparent. Determine external factors that can help understand and improve behaviors. Activators should be used to direct behaviors while consequences should be used to motivate behavior. Highlight positive consequences to reinforce favorable behaviors. Make sure that the BBS program is measurable and objective. Don’t limit possibilities, create hypotheses and combine information gathered from the BBS program. Create a BBS program that considers employees’ feelings and attitudes. ARJUN P K

50. Behavior-based safety trainers and consultants teach the ABC model as a framework to understand and analyze behavior or to develop interventions for improving behavior. As given in BBS principle, the “A” stands for activators or antecedent events that precede behavior. “B” and “C” refers to the consequences following behavior or produced by it. Activators direct behavior, whereas consequences motivate behavior. ARJUN P K

51. SAFETY ORGANIZATION Safety organization can be defined as the structure and process by which groups of people (employees) are divided into sections or departments, each section or department is assigned specific safety function or duty. Authority and responsibility of everybody is clearly defined and interrelationship between them is specified for the accomplishment of organizational safety goals. A large unit may have safety department which may have groups of people for division of such safety function and responsibilities. ARJUN P K

52. But in a small unit (majority) if such division is not possible and only a few persons are available for safety work They will be assigned specific duty and other departmental heads (production, purchase, personnel etc.) will be explained their role and responsibility towards safety goals. All supervisors shall be integrated with safety as part of their duty. ‘ Safety is everybody’s duty ’ will be explained to all with their safety duty given in writing or by displaying at their workplaces. ARJUN P K

53. Objectives of safety organization To prevent accidents in future To provide safe work environment Safety consciousness Integrate safety policies with job process Compliance of rules as per factory act Ensure and modify on identified risk Training to ensure safety Invite cooperation and suggestions from the employees To take measures after accident ARJUN P K

54. Functions & duties of safety organization Safety committees can serve a variety of functions. Some of the more common functions for safety committees include: Being a cooperative group between employees and management Increasing awareness of safety at the facility Identifying workplace risks and creating a plan (or making recommendations) to reduce risks Integrating safety and health priorities into corporate culture Encouraging safety training for employees and management Conducting and evaluating audits Performing routine safety inspections ARJUN P K

55. Role of management in safety Design, safe and healthy systems of work Exhibit strong management commitment Inspect workplace for health and safety problems Establish procedures and controls for dealing with health and safety issues Develop training programs Set up health and safety committees Monitor safety policies Draw up action plan and checklist ARJUN P K

56. Timely payment of compensation Following specific rules and regulations Appointment of medical, welfare and safety officers Formation of committee(safety, welfare, pollution control, canteen..) Education and training employees Promote coverage of employee under act ARJUN P K

57. Role of supervisors in safety Conduct Orientation and Training of Employees: Train and instruct employees so they can perform their work safely. Know what personal protective equipment is needed for each task and how this equipment must be properly used, stored and maintained. When there are mandated safety training courses, ensure that your employees take them and that they are appropriately documented. Enforce Safe Work Practices: It's the supervisors responsibility to enforce safe work practices and procedures; failure to do so is an invitation for accidents to occur. Workers must be encouraged to identify unsafe or unhealthful workplace conditions and/or hazards. ARJUN P K

58. Correct Unsafe Conditions: Supervisors' must take immediate steps to correct unsafe or unhealthful workplace conditions or hazards within their authority and ability to do so. When an unsafe or unhealthful workplace condition or hazard cannot be immediately corrected, the supervisor must take temporary precautionary measures. Supervisors must follow-up to ensure that corrective measures are completed in a timely manner to address the hazard. ARJUN P K

59. Investigate Workplace Accidents: Supervisors are responsible for conducting accident investigations and for ensuring that all occupationally injured employees report to the Occupational Medical Service (OMS) immediately. Promote Quick Return to Work: Employees must be encouraged to return to work as soon as possible. The longer an employee is away from work, the less likely he or she will actually return. When possible, light or limited duties should be identified and considered, to assist in returning the employee to work. ARJUN P K

60. Workers are responsible for their own safety on the job. This means that they have the right to refuse to do any act or operate any tool, appliance, or equipment when they have reasonable cause to believe that to do so would put them in danger. ARJUN P K Role of workers in safety

61. The employer must ensure that: All work is carried out without risk of injury or industrial disease Machinery and equipment are capable of safely performing the functions for which they are used All permanent and temporary buildings and structures are capable of withstanding any stresses likely to be imposed on them All buildings, excavation structures, machinery, equipment, tools, and places of employment are maintained in good condition. ARJUN P K

62. Regular inspections are made to prevent structures, grounds, excavations, tools, equipment, machinery, and work from becoming unsafe Any unsafe conditions are corrected without delay Each worker is supplied, at no cost, with all protective safety equipment required for the work An accident prevention program is set up There is a safe means of entry to and exit from the work area Firefighting equipment is provided and maintained ARJUN P K The employer must ensure that:

63. As a worker, you should keep the following personal responsibilities in mind: You must not remove any safety equipment from machines or equipment, including shields from grinders, mixers, etc. You must have had adequate instruction about a piece of machinery or equipment before you use it. You must make sure that no machine, equipment, or tool is used in a way that would cause injury to someone else. ARJUN P K

64. You must make sure that there are safe entrances to and exits from the workplace. You must make sure that the work area is safe for the movement of workers, equipment, and materials. You must wear protective eyewear when using grinders and other equipment that may be hazardous to the eyes. ARJUN P K

65. Today, labour unions have huge sway over workplace safety standards, for unionized and nonunionized workers alike. There are many theories as to why unions help promote workplace safety. Under the wing of labour unions, workers are free to speak up about safety hazards without fear of retaliation. And because unions can put pressure on employers to fix safety problems, employers are incentivized to fix and prevent problems – or face significant productivity losses. ARJUN P K Role of unions in safety

66. One of the biggest advantages unions have is the power of collective bargaining. An individual worker can often feel that they don’t have a voice, or that if they speak up alone, they won’t have much power to affect change. By joining a union, workers agree to bargain for their rights as a collective entity. This gives them far greater leverage to bargain for things like better safety conditions, improved wages, and reasonable work hours. The fact that they cover an entire group forces employers to come to the table. ARJUN P K

67. Unions can influence the safety of all workers because of two things: 1. Restriction of labour supply 2. Increase in labour demand Companies need workers. But workers have the right to a safe and fair working environment. Unions leverage this by increasing the demand for union laborers, which in turn forces companies to negotiate with them to access union workers. This, in turn, sets the standard for non-union workers. ARJUN P K

68. SAFETY POLICY An organization's safety policy is a recognized, written statement of its commitment to protect the health and safety of the employees, as well as the surrounding community. The safety policy also details the measures the company takes and will take to protect the life, limb, and health of their employees. The Occupational Health and Safety Act requires employers to develop and implement a safety policy. To succeed, a safety policy requires both a commitment and approval from the employer and support from the employees. ARJUN P K

69. There are generally three sections in a safety policy, which include: Statement of the policy - The employer’s commitment to managing health and safety and the goal of the policy Responsibility - Stating who is responsible for implementing, enacting, and tracking each element of the policy Arrangements or procedures - Outlines the details of procedures including the reduction of hazard policy ARJUN P K

70. It may also include details about the following: Employee training Use of administrative controls, hazard isolation, locking, warnings, signs and symbols marking hazards, etc. Use of personal protective equipment (PPE) Removing hazardous materials or replacing them with less harmful alternatives Improved lighting and working environment Prevention of slip, trip, and fall incidents ARJUN P K

71. SAFETY OFFICER A hundred things happen at once in an organization. And each of these activities needs to take place in a safe environment. So it’s crucial to have a person in your company who can recognize what could go wrong, act when something goes wrong, and be willing to take ownership of the situation. This is where the role of a safety officer comes in. The safety officer is an internal employee who is assigned to prevent accidents, respond to emergencies and evaluate the effectiveness of the company’s safety programs. ARJUN P K

72. The safety officer…..! A safety officer identifies safety hazards, investigates them thoroughly, and controls them before someone gets hurt. The safety officer is the ‘head’ of the safety department and, in most organizations, reports to the Chief Operations Officer. The safety officer also checks if the safety program is working effectively and efficiently to meet all requirements. ARJUN P K

73. The role of a safety officer can vary from company to company, but they all have one thing in common — ensuring the safety of everyone in the workplace. They verify that everyone on the site is following safe work practices and doing their jobs safely. In general, safety officers have three main roles : ARJUN P K

74. 1. Planning Safety officers must create a safe environment by making sure they have all the necessary equipment for their team. They also have to ensure that they have all the required things for their team. An example of this would be ensuring they have shoring equipment at hand that they can use to shore up an unstable wall. Making sure that the employees have all the necessary tools to finish their work safely is also a part of the responsibility. ARJUN P K

75. 2. Organizing Safety officers are also responsible for organizing their workload so that no harm will come to them or anyone else during their work activities. They have to make sure that employees can complete the tasks without causing any damage to the workplace or anyone else. ARJUN P K

76. 3. Supervising Finally, safety officers are responsible for supervising everyone who works under them to ensure that they are doing their work safely. When supervising, they need to make sure that each person knows their role in the process and where they fit in. ARJUN P K

77. Irrespective of their specific role or position in the organization, all safety officers should follow a set of responsibilities. ARJUN P K

78. Responsibilities of a safety officer Identify and assess hazards, risks and control measures for a specific operation or process. Conduct ongoing review of operations and processes to identify potential hazards, risks and control measures that should be implemented to reduce these risks Assess and document hazards, risks and controls in a manner consistent with established procedures and practices. Set up and supervising temporary work areas. Supervise the safe handling, storage & disposal of hazardous materials. ARJUN P K

79. Supervise the operation of any potential hazards in the workplace. Improve workplace safety and employee productivity by transitioning from manual safety procedures to digital safety management systems. Ensure that all company employees meet all OSHA requirements. Provide OSHA training if necessary. Ensure that health, safety, and environmental policies are followed. Investigate workplace accidents and injuries and refer them to the proper authorities. ARJUN P K Responsibilities of a safety officer

80. SAFETY COMMITTEE A safety committee is an organization group that operates within a workplace and is composed of members from its various departments, including management, frontline workers, and office staff. Safety committees bring together workers and employers through regularly scheduled meetings where safety issues are addressed. The goal of a safety committee is to create and nurture a culture of safety. The main purpose of a safety committee is to mitigate the risk of workplace injuries and illnesses. Its duties also include informing and educating employees about safety issues, setting achievable safety goals for the organization, and fostering a safety culture among the workforce ARJUN P K

81. Safety committees are typically formal arrangements that hold regular meetings, either weekly or monthly. In smaller companies, however, it is common for the safety committee to gather all staff members for a monthly or quarterly safety meeting. An effective safety committee should be large enough to broadly represent the workforce. It should include employees from all levels of the company, from the custodial staff to upper management. Safety committee best practices include making sure that everyone has the opportunity to provide input, post questions, and raise concerns. ARJUN P K

82. A safety committee serves a variety of functions, including: Developing written safety programs Promoting safe work practices Facilitating safety training Performing workplace inspections Carrying out accident investigations Acting as a point of contact between employees and management Reviewing injury and illness records Increasing awareness about workplace safety issues Identifying hazards and recommending appropriate control measures ARJUN P K

83. Safety committees help provide an overall perspective of the safety status of the organization. It serves as a visible body that can be approached for safety or health complaints, suggestions, and other types of feedback. As the committee solely deals with safety-related issues, it ensures that there are employees focused on and dedicated to coordinating safety-related activities. It also encourages and motivates employees to follow safety standards and signals to them that the organization is taking measures to protect their wellbeing ARJUN P K

84. END OF MODULE 1 ARJUN P K

85. ARJUN P K MODULE 2 Personal protection in the work environment, Types of PPEs, Personal protective equipment - respiratory and non-respiratory equipment. Standards related to PPEs. Monitoring Safety Performance: Frequency rate, severity rate, incidence rate, activity rate. Housekeeping: Responsibility of management and employees. Advantages of good housekeeping. 5 elements of housekeeping. Work permit system- objectives, hot work and cold work permits. Typical industrial models and methodology. Entry into confined spaces.

86. Employers have duties concerning the provision and use of personal protective equipment (PPE) at work - Article 16 - Occupational Safety and Health Convention, 1981 (No. 155) ARJUN P K

87. Personal protection in the work environment, Personal safety in the workplace depends on your own awareness of potential threats and risks as well as your employer's safety policies and procedures. Employers may have different priorities to consider besides your personal safety. By giving some thought to managing the risks, you can make yourself safer on the job. Personal protective equipment (PPE) is protective clothing, helmets, goggles, or other garments or equipment designed to protect the wearer's body from injury or infection. ARJUN P K

88. PPE is needed when there are hazards present. PPE has the serious limitation that it does not eliminate the hazard at the source and may result in employees being exposed to the hazard if the equipment fails. Any item of PPE imposes a barrier between the wearer/user and the working environment. This can create additional strains on the wearer, impair their ability to carry out their work and create significant levels of discomfort. Any of these can discourage wearers from using PPE correctly, therefore placing them at risk of injury, ill-health or, under extreme circumstances, death. Good ergonomic design can help to minimise these barriers and can therefore help to ensure safe and healthy working conditions through the correct use of PPE . ARJUN P K

89. PERSONAL PROTECTIVE EQUIPMENTS PPE is equipment that will protect the user against the risk of accidents or of adverse effects on health. It can include items such as; Safety helmets Gloves Eye protection goggles High-visibility clothing Safety footwear Safety harnesses Respiratory protective equipment (RPE). ARJUN P K

90. Why is PPE important? Even where engineering controls and safe systems of work have been applied, some hazards might remain. These include injuries to: The lungs, e.g. From breathing in contaminated air; The head and feet, e.g. From falling materials; The eyes, e.g. From flying particles or splashes of corrosive liquids; The skin, e.g. From contact with corrosive materials; The body, e.g. From extremes of heat or cold. PPE is needed in these cases to reduce the risk. ARJUN P K

91. When selecting and using PPE Choose products which are suitable to the residual risk and are the required standard, suppliers can advise you. Choose equipment that suits the user – consider the size, fit and weight of the PPE. If the users help choose it, they will be more likely to use it. If more than one item of PPE is worn at the same time, make sure they can be used together, e.g. wearing safety glasses may disturb the seal of a respirator, causing air leaks. Instruct and train people how to use it, e.g. train people to remove gloves without contaminating their skin. PPE must be properly looked after and stored when not in use, e.g. in a dry, clean cupboard. If it is reusable it must be cleaned and kept in good condition. ARJUN P K

92. Types of PPE There are two types of PPE Simple personal protective equipment – this refers to equipment that has a basic design model, it protects against lower risk hazards. Complex personal protective equipment – this refers to equipment that it more of a technical design and provides protection against fatal or serious risk. ARJUN P K

93. Types of PPE that can be used Eyes Hazards Chemical or metal splash, dust, projectiles, gas, welding light, vapour , radiation, sparks Options Safety spectacles, goggles, face screens, face shields, and visors Make sure the eye protection chosen has the right combination of impact/dust/ splash/molten metal eye protection for the task and fits the user properly. ARJUN P K

94. Types of PPE that can be used Head and neck Hazards Impact from falling or flying objects, risk of head bumping, hair getting tangled in machinery, chemical drips or splash, climate or temperature Options Industrial safety helmets, bump caps, hairnets and firefighters’ helmets Some safety helmets incorporate or can be fitted with specially-designed eye or hearing protection. Don’t forget neck protection, e.g. scarves for use during welding. ARJUN P K

95. Types of PPE that can be used Ears Hazards Noise – a combination of sound level and duration of exposure, very high-level sounds are a hazard even with short duration Options Earplugs, earmuffs, semi-insert/canal caps Provide the right hearing protectors for the type of work, and make sure workers know how to fit them. Choose protectors that reduce noise to an acceptable level, while allowing for safety and communication. ARJUN P K

96. Types of PPE that can be used Hands and Arms Hazards Abrasion, temperature extremes, cuts and punctures, impact, chemicals, electric shock, radiation, biological agents and prolonged immersion in water Options Gloves, gloves with a cuff, gauntlets and sleeving that covers part or all of the arm Some materials are quickly penetrated by chemicals – take care in selection Wearing gloves for long periods can make the skin hot and sweaty, leading to skin problems. Using separate cotton inner gloves can help prevent this ARJUN P K

97. Types of PPE that can be used Feet and Legs Hazards Wet, hot and cold conditions, electrostatic build-up, slipping, cuts and punctures, falling objects, heavy loads, metal and chemical splash, vehicles Options Safety boots and shoes with protective toecaps and penetration-resistant, mid-sole wellington boots and specific footwear, e.g. foundry boots and chainsaw boots Footwear can have a variety of sole patterns and materials to help prevent slips in different conditions, including oil- or chemical-resistant soles. It can also be anti-static, electrically or thermally non-conductive. ARJUN P K

98. Types of PPE that can be used Lungs Hazards Oxygen-deficient atmospheres, dusts, gases and vapours Options respiratory protective equipment (RPE) Some respirators rely on filtering contaminants from workplace air. These include simple filtering facepieces and respirators Wearers must ensure the RPE fits properly, e.g. for tight-fitting respirators (filtering facepieces, half and full masks). There are also types of breathing apparatus which give an independent supply of breathable air, e.g. fresh-air hose, compressed airline and self-contained breathing apparatus . ARJUN P K

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102. Types of PPE that can be used Whole body Hazards Heat, chemical or metal splash, spray from pressure leaks or spray guns, contaminated dust, impact or penetration, excessive wear or entanglement of own clothing Options Conventional or disposable overalls, boiler suits, aprons, chemical suits The choice of materials includes flame-retardant, anti-static, chain mail, chemically impermeable, and high-visibility. Don’t forget other protection, like safety harnesses or life jackets. ARJUN P K

103. PPE Standards 29 CFR 1910.133 Eye and Face Protection: “The employer shall ensure that each employee uses appropriate eye or face protection when exposed to eye or face hazards from flying particles, molten metal, liquid chemicals, acids or caustic liquids, chemical gases or vapors, or potentially injurious light radiation.” ARJUN P K

104. 29 CFR 1910.134 Respiratory protection: “The employer shall provide a respirator to each employee when such equipment is necessary to protect the health of such employee. The employer shall provide the respirators which are applicable and suitable for the purpose intended. The employer shall be responsible for the establishment and maintenance of a respiratory protection program ARJUN P K PPE Standards

105. 29 CFR 1910.135 Head protection “The employer shall ensure that each affected employee wears a protective helmet when working in areas where there is a potential for injury to the head from falling objects. The employer shall ensure that a protective helmet designed to reduce electrical shock hazard is worn by each such affected employee when near exposed electrical conductors which could contact the head. ARJUN P K PPE Standards

106. 29 CFR 1910.136 Occupational foot protection: “The employer shall ensure that each affected employee uses protective footwear when working in areas where there is a danger of foot injuries due to falling or rolling objects, or objects piercing the sole, and where such employee's feet are exposed to electrical hazards.” ARJUN P K PPE Standards

107. 29 CFR 1910.137 Electrical protective equipment: details the design requirements for specific types of electrical protective equipment—rubber insulating blankets, rubber insulating matting, rubber insulating covers, rubber insulating line hose, rubber insulating gloves, and rubber insulating sleeves used for the primary insulation of employees from energized circuit parts. ARJUN P K PPE Standards

108. 29 CFR 1910.140 Hand protection: “Employers shall select and require employees to use appropriate hand protection when employees' hands are exposed to hazards such as those from skin absorption of harmful substances; severe cuts or lacerations; severe abrasions; punctures; chemical burns; thermal burns; and harmful temperature extremes.” ARJUN P K PPE Standards

109. 29 CFR 1910.140 Personal Fall Protection Systems: “Employers shall ensure that each personal fall protection system used to comply with this part must meet all applicable requirements of this section. This section establishes performance, care, and use criteria for all personal fall protection systems such as personal fall arrest systems and positioning systems.” ARJUN P K PPE Standards

110. 29 CFR 1910.132 General requirements: says that all PPE has to meet these minimum requirements: Provide adequate protection against the particular hazards for which they are designed Be of safe design and construction for the work to be performed Be reasonably comfortable when worn under the designated conditions Fit snugly and not unduly interfere with the movements of the wearer Be durable Be capable of being disinfected Be easily cleanable Be distinctly marked to facilitate identification only of the manufacturer ARJUN P K PPE Standards

111. IS Standards related to PPEs HEAD PROTECTION IS CODE 2745 : 1983 – Specification for non-metal helmet for firemen and civil defence personnel. IS CODE 2925 : 1984 – Specification Industrial safety helmet. IS CODE 4151 : 1993 – Specification for protective helmets for scooter and motorcycle riders. ARJUN P K

112. IS Standards related to PPEs BODY PROTECTION IS CODE 3521 : 1999 – Industrial safety belt and harness. IS CODE 4501 : 1981 – Specification for aprons. IS CODE 6153 : 1971 – Protective leather clothing. IS CODE 7352 : 1974 – X-ray lead protective aprons. IS CODE 8519 : 1977 – Guide for selection industrial safety equipment for the body. IS CODE 8990 : 1978 – Code of practice for care and maintenance of industrial safety clothing. ARJUN P K

113. IS Standards related to PPEs EAR PROTECTION IS CODE 6229 : 1980 – Methods for measurement of real-ear protection of hearing protectors and physical attenuation of ear muffs. IS CODE 8520 : 1977 – Guide for selection of industrial safety equipment for eye, face and ear protection. IS CODE 9167 : 1779 – Specification for ear protectors ARJUN P K

114. IS Standards related to PPEs EYE AND FACE PROTECTION IS CODE 1179 : 1967 – Equipment for eye and face protection during welding . IS CODE 5983 : 1980 – Eye Protector. IS CODE 7524 : 1980 – Method of test for eye protectors: -non optical tests. (part -1) IS CODE 2521 : 1977 – Industrial safety face shield with plastic visor (part – 1) IS CODE 2521 : 1994 – Industrial safety face shield with wire mesh visor (part – 2) ARJUN P K

115. IS Standards related to PPEs EYE AND FACE PROTECTION ( Contd …) IS CODE 8940 : 1978 – Code of practice for maintenance and care of industrial safety equipment for eyes and face protection. IS CODE 9973 : 1981 – Specification for the visor for scooter helmets. IS CODE 9995 : 1981 – Specification for the visor for non-metal police and firemen helmets. IS CODE 14352 : 1996 – Miner’s safety goggles – Specification. ARJUN P K

116. IS Standards related to PPEs FEET AND LEG PROTECTION IS CODE 1989 : 1986 – Specification for leather safety boots and shoes – for miners (part – 1). IS CODE 1989 : 1986 – Specification for leather safety boots and shoes -for heavy metal industries (part – 2) IS CODE 3737 : 1966 – Leather safety boots for workers in heavy metal industries. IS CODE 3738 : 1998 – Rubber boots – Specification. IS CODE 3976 : 2003 – Protective rubber canvas boots for miners – Specification. ARJUN P K

117. IS Standards related to PPEs FEET AND LEG PROTECTION ( Contd …) IS CODE 4128 : 1980 – Specification for fireman leather boots. IS CODE 5557 : 1999 – Safety rubber boots. IS CODE 5852 : 2004 – Steel toe safety shoes. IS CODE 6519 : 1971 – Code of practice for selection, care, and repair of safety footwear. ARJUN P K

118. IS Standards related to PPEs HANDS PROTECTION IS CODE 2573 : 1986 – Specification for leather, gauntlets and mittens. IS CODE 4770 : 1991 – Rubber Gloves – electrical purposes – specification. IS CODE 6994 : 1973 – Specification for safety gloves –leather and cotton gloves (part – 1). IS CODE 8807 : 1978 – Guide for selection of industrial safety equipment for the protection of arms and hands. ARJUN P K

119. IS Standards related to PPEs RESPIRATORY PROTECTION IS CODE 8318 : 1977 – Colour identification markings for air purifying canisters and cartridges. IS CODE 8347 : 1977 – Glossary of terms relating to respiratory protective devices. IS CODE 8522 : 1977 – Respirators chemical cartridge. IS CODE 8523 : 1977 – Respirators canister type gas masks. IS CODE 9473 : 2002 – Respiratory protective devices -filtering half masks to protect against particles – specification IS CODE 9563 : 1980 – Carbon monoxide filter self rescuers. ARJUN P K

120. IS Standards related to PPEs RESPIRATORY PROTECTION ( Contd …) IS CODE 9623 : 1980 – Recommendations for selection use and maintenance of respiratory protective devices. IS CODE 10245 : Part 1 to 46 – Breathing apparatus. IS CODE 15322 : 2003 – Particle filters used in respiratory protective equipment –Specification. IS CODE 15323 : 2003 – Gas filters and combined filters used in respiratory protective equipment -Specification. ARJUN P K

121. Monitoring Safety Performance: The primary goal of a safety system is to reduce operational risks and improve the overall process safety of a plant over its entire lifecycle. In the event of a deviation or failure of the safety system, Safety Instrumented Systems (SIS) are there to ensure that a plant is taken into a safe state, limiting the negative consequences to people, equipment and the environment. It is important that organizations in the process industry are able to react quickly under variable conditions and have the capabilities to continuously monitor and evaluate safety system performance. Lets discuss about a few factors which are useful for the statistical analysis of safety. ARJUN P K

122. 1. Frequency rate The frequency rate is the number of disabling/lost time injuries per one million man-hours worked. The frequency rate shall be calculated both for lost time injury and reportable lost time injury.   ARJUN P K

123. Note that ……! If the injury does not cause loss of time in the period in which it occurs but in a subsequent period, the injury should be included in the frequency rate of the period in which the loss of time begins. If an injury causes intermittent loss of time, it should only be included in the frequency rate once, that is, when the first loss of time occurs. Since frequency rate F B is based on the lost time injuries: reportable to the statutory authorities, it may be used for official purposes only. In all other cases, frequency rate F A should be used for comparison purposes. ARJUN P K

124. Disabling Injury ( Lost Time Injury ) - An injury causing disablement extending beyond the day of shift on which the accident occurred. Reportable Disabling Injury ( Reportable Lost Time Injury ) - An injury causing death or disablement to an extent as prescribed by the relevant statute. ARJUN P K

125. What does 1000000 mean ? No of workers in a year = 500 Daily Hour Worked = 8 hrs No. of days worked in a week = 5 days Total hours worked in a week = 8 x 5 = 40 hrs Total week in a year = 50 week So, In a year = 50 week x 40 hrs /week x 500 workers = 10 00 000 man hours ARJUN P K

126. Man-Hours Worked The total number of employee-hours worked by all employees in the industrial premises, It includes managerial, supervisory, professional, technical, clerical and other workers including contractors, labors etc. It shall be calculated from the pay roll or time clock recorded including overtime. When this is not feasible, the same shall be estimated by multiplying the total man-days worked for the period covered by the number of hours worked per day Total number of man-days is the sum of the number of men at work on each day of the period ARJUN P K

127. Example 1 Using the following data calculate the frequency rate of accident in an industrial plant. Number of workers= 500 Number of disabling injuries per year= 5 . Average number of hours worked by worker per year= 2000 . ARJUN P K