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Safety Management And Accident Prevention

by B.K.Sadananda DGM ( Safety ), BEL (Retd) & Hon. Treasurer, NSC:KC

What is Safety?
Safety is the state of being free from bodily injury, being free from occupational diseases being free from mental tension

What is Accident?
An accident is an un-planned, unforeseen, unexpected event which may or may not result in injury to the person or damage to the material or equipment.
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Like Material

Management Finance Management Personnel Management Production Management Quality Management Marketing Management Sales Management

Safety Management is also a branch of Management in any Organization

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Safety Management The accomplishment of Safety objectives by first establishing the safety objectives and then attaining them through the process of planning, organising, staffing, executing, evaluating, controlling and directing (i.e. motivating and coordinating all efforts and organising groups of people and also innovating to improve the safety objectives for the feature)
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Objectives of Safety Management

To prevent Accidents, injuries, property damages Minimize Unsafe Act and Unsafe condition Good working condition

Providing healthful environment

Continuous vigil and improvements.

Functions of Safety management 1) Planning- Setting Safety objectives Formulation of Safety Policy Safety programmes Budgeting Determining procedures 2) Organising- Establishing formal structure 3) Staffing4) Directing5) Controlling6) Coordinating8

Factory Act 1948

Consists of
12 3

chapters having 120 Sections

schedules
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Chapters in Factory
Chap.

Act 1948
Sections

1. Preliminary 2. The Inspection Staff 3. Health. 4. Safety. 5. Welfare 6. Working Hrs. 7. Empl of young persons. 8. A.L. with wages. 9. Spl. Provisions 10. Penalties &Procedures 11. Supplements.

1 to 7 8 to 10 11 to 20 21 to 41 42 to 50 51 to 66 67 to 77 78 to 84 85 to 91 92 to 106 107 to 120

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Schedules in Factory

Act 1948

I List of Industries involving hazardous process II Permissible levels of certain chemical substances in wok environment

III List of notifiable diseases

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Chapters in Factory Act 1948 (sec 21-41)

Safety

21. Fencing of Machinery 22. Work on or near m/c in motion 23. Employment of young persons on dangerous m/c. 24. Striking gears &devices for cutting of powers 25. Self acting Machines 26. Casing of new Machines 27. prohibition of employment of woman & children near cotton openers 28. Hoists & lifts 29. Lifting m/c, Chains, ropes & lifting tackles
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Chapters in Factory Act 1948 (sec 21-41)

Safety

30. 31. 32. 33. 34. 35. 36.

Revolving Machinery Pressure plant Floors, Stairs & means of access Pits, Sumps, Openings in floors Excessive weights Protection of eyes Precautions against dangerous fumes & gases 36A. Precautions regarding use of portable electric light 37. Explosive or inflammable dust, gas etc. 38. Precautions in case of fire
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Chapters in Factory Act 1948 ( sec 21-41 )

Safety

39. Power to require spec of defective parts 40. Safety of building & m/c s 40A. Maintenance of building

40B. Safety officers

41. Power to make rules to supplement this chapter

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Implementation of Safety
I. Safety council (Apex body) as per sec. 41A of
factory act 1948. ( workers participation)

II.

Safety Engg. Dept.

Exclusively working for safety activities as an advisory body Small groups formed in various Dept. to take care of safety aspects of their Dept ./ Section
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III.

Safety committee

Safety council as per sec. 41A of factory act 1948. ( workers participation)

Comprising - Chairman (G.M. grade) - Secretary ( Head of Safety) - Mangt. Reps (5 AGM/DGM ) - NTU. Reps (5 Members)
Meet at least 3 months once as per statutory requirement To take care of Safety Mangt. Issues
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Objectives of Safety council To work as a part of Management function. Help the management in specific area of Safety. To work as a group of Safety representatives for Group suggestions

Decision,
Co-operative Safety efforts Two way channel of Communication through which suggestions can flow from Employees to Management and vice versa.
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Safety Engg. Dept. Headed by Chief Safety officer Directly reporting to Unit head. Assisted by number of Safety officers & office staff. All Safety Officers should have additional qualification of Diploma in industrial
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post Safety

Functions Safety Engg. Dept.

To meet all statutory requirements Accident statistics Accident Reporting Preparation of MSDS Conduct Safety Survey, Inspection & Audit Lifting devices & pressu. vessels certification To bring Safety Awareness to all Employees / Executives.
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Safety Committees Headed by Chairperson (Sect./Dept. head ) assisted by. 2 or 3 Executives, 2 or 3 Supervisors, 2 or 3 Non Exec. along with one safety officer Number of Safety Committees depends on Number of Employees, Type of Industry Complexity of Industry
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Functions of safety Committee To maintain interest of shop floor staff & Executives to understand safety as prime concern. Periodical shop floor visits to suggest improvements In safety. To assist in investigation of accidents. Contribute ideas/ suggestions to improve Safety. Promote Safety awareness. Persuade the fellow workmen to use PPEs .
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Some misconceptions about safety

1)
2) 3)

Accidents do happen they are inevitable.

If a worker is destined to meet with an accident no effort can save him. When there is huge machineries and fast moving production line, accidents are inevitable. Production and safety do not go together. We can have high production only at the cost of safety Safety rules are for new comers.
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4)

5)

Some misconceptions about safety

(Cont.)

6) 7)

8) 9)

A willing worker will meet with accidents, not an idler Only the man who works sincerely gets injured A lazy worker is always safe
Maintaining safety is only a managerial function, employees have nothing to do with it.

10) It is cowardly to be afraid of accidents hide yourself behind safety appliances guards.

and and
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Accident Ratio
Un preventable = 2% Preventable = 98%

Henrich theory Based on 75000 cases

Major Injury

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Minor Injury

300

Near Miss cases

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ACCIDENT CAUSATION Many theorists and psychologists have conducted in-depth studies in the field of industrial safety. Those studies prove that

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Accidents do not occur

but

They are caused

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ACCIDENT CAUSATION - (cont)

Dr.H.W.Heinrich, One of the pioneer researchers in safety management, after analyzing 75,000 accidents, came to the conclusion that 98% are Preventable and 2% are Unpreventable. Further, he classified the causes into twoi.e. Unsafe actions (88%) and Unsafe conditions (10%) All such accidents are found to be due to human failure.
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ACCIDENT CAUSATION:- (cont)

Dr. Heinrich further explained that the process of accident causation is a chain of events.

This sequence of accident causation process is termed Five Domino Theory, with each Domino appearing one after another viz.
1) Faulty social environment 2) Fault of persons 3) Unsafe actions / Unsafe condition 4) Accidents 5) Injury / Losses
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ACCIDENT CAUSATION:- (cont)

Frank E Bird has gone further to identify exact causes of accidents. Lack of control by the management would be the primary link in the chain of accidents causation. i.e. the root or basic cause of accidents is The lack of control by the management.

Wherever substandard practices and conditions are permitted to exist, the accidents do mostly occur.
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ACCIDENT CAUSATION - (cont)

Edward Adam confirms that the unsafe actions and unsafe conditions are arising out of operational errors made by the Managers or Supervisors. In other words the interest taken by the top management will reflect on the Safety of the company as a whole.
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ACCIDENT CAUSATION - (cont)

D.A.Weaver has updated the Domino Theory of Heinrich and concluded that the unsafe action or unsafe condition are only proximate causes ascribed to an accident . Where as management practices in Policy, Priorities, Organizational structure, Decision making, Evaluation, Control and Administration are the root causes behind them.
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(Used to predict accidents)

Accident Causation Model

Threshold limit

Lack of Control

Immediate Basic Causes Causes

Unsafe act

Incident

Loss Unintended Harm and/or Damage

Inadequate: Personal System factors System Stds. or Compliance System/Job to Std factors

event
unsafe condition

Loss Control Model

(used to analyze accidents)
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Causes of Accidents
Simple care Inexperience Failure to follow Instruction Poor engineering Equipment Bad House keeping Bad Lighting & Ventilation Improper Chemical handling Unsafe Loading Improper Attitudes
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Causes of accidents: Direct causes

Unsafe practices Unsafe conditions
* Indirect causes Supervisory safety performance Mental condition of persons Physical condition of persons
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DIRECT CAUSES:

UNSAFE CONDITION

UNSAFE ACT

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UNSAFE CONDITIONS
* Unguarded * Unsafe Dresses * Unsafe tools
* Slippery Floors, Hazard Material Storage

* Bad Housekeeping * Bad Illumination and Ventilation * Over crowding, Obstructions * Unsafe methods & Procedures * Noise & Vibration * Improper Storage of Chemicals * Defective conditions

hours 8 6 4 3 2 1.5 1 . 75 0. 5 0. 25

dBA 90 92 95 97 100 102 105 107 110 * 115

* No exposure to continuous noise in excess of 115 dBA

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UNSAFE ACTS
* * * * * * * Operating without authority Operating at Unsafe Speed Making Safety Devices Inoperative Using unsafe Equipment Unsafe Loading, Placing & Mixing Taking unsafe Position / Posture Distracting, Teasing, Abusing & Startling

* Failure to use Personal Protective equipment

* Removing Guards of Machines
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RESULTS

Injury / Fatality
Minor injury / Disabling Production delay

Reduced quality
Spoilage
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Economics of Accidents
Rs 1000 Insurance Costs
Covering injury, ill health & damage

Hidden Costs
Rs. 8,000-36,000 Plant & Building Damage Legal Costs Clearing Site Overtime Working Investigation Time Clerical Effort Loss of Expertise 39

Product & Material Damage Tool & Eqpt Damage Emergency Supplies Production Delays Temporary Labour Supervisors Time

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Prevention of accidents (4Es) Engineering Education Encouragement Enforcement

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Engineering : By designing and providing guards, Good ventilation, Good illumination, Changing processes Eg. Dry process to wet process, Manual handling to Mechanical handling, Enclosing and isolating process.
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Education: Educating employees and training them in different safety aspects. E.g.: pre-employment training, On the job training , Periodical training.
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Encouragement: Safety competitions, Safety education, Safety exhibitions, Safety films and video shows, Seminars and debates, Safety awards etc.
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Enforcement: By implementing safety rules and to have administrative controls and following the same. E.g. Pre-medical exam
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TYPES OF HAZARDS: CHEMICAL PHYSICAL

BIOLOGICAL
ERGONOMICAL # # Physiological Psychological
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CHEMICAL HAZARDS: CHEMECAL Explosives Corrosives Flammable Liquids Toxic Chemicals Oxidizing Materials Dangerous Gases AIRBORNE PARTICULATES Dusts Fumes Smokes Aerosols Mists Gases Vapors
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PHYSICAL HAZARDS: Noise

Vibration
Temperature Radiation # Ionizing # Non Ionizing * Infrared * Ultraviolet * Microwave * Laser
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BIOLOGICAL HAZARDS: Bacteria

Fungi
Moulds Mites Insects Plants Viruses
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ERGONOMICAL HAZARDS:PHYSIOLOGICAL
Lifting

PSYCHOLOGICAL
Monotony

Cumulative Trauma Disorders

Fatigue

Personal Relation ships

Work Rest Cycles

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Measurement of Safety performance:There are 3 types of injury rates: 1) Frequency rate 2) Severity rate 3) Incidence rate
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Frequency rate :
i.e., How often do injury occur ? -Defined as the disabling (lost time) injuries per 106 man-hours worked FA
= No. of reporable lost time injury * 106 Man hours worked
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Severity rate :
-i.e., How serious are the injuries ? -Defined as the number of days of lost time per 106 man-hours worked SA
= Man days lost due to lost time injury * 106 Man hours worked
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Incidence rate :
-i.e., How serious are the injuries ? -is the ratio of the number injuries to the number of persons during the period under review. -It is expressed as the no. of injuries per 1000 persons employed IA
= Number of lost time injuries * 1000 56 Average No. of persons employed

Three major concerns of a supervisor to prevent accidents

The Worker The work method The work area

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The Worker
Make sure that all of your team: -Know the correct & safe way of doing job -Understand the dangers they may face -Wear their PPEs -They must report faults immediately -Fire eqpts. & their usage -Maintain personal hygiene Take action to control the danger by -Train, Explain, Acceptance of safety instructions To prevent recurrence by -Stop, Correct, Retrain & Follow up
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The Work method

Ensure that -Prescribed safety procedure are maintained -Guards are secure and in good condition -Lighting is adequate for the job -Materials, tools and equipments are safe -Layout is safely maintained -Stacking of goods and equipments is safe -Dust and fume extraction works propely Take action to control the danger by -safe method of working -Watch for dangerous working practices To prevent recurrence by

-Eliminate, Guard, warn, Report

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The Work area

Check that in all working areas -Lay out and work spots are safe -Access is adequate and free from danger -Fire eqpts are ready for immediate use -Floors, gangways etc. are in good condition & free from obstruction, oil etc. -Handrails and covers for openings are secure Take action to control the danger by -Eliminate, guard, warn, Report To prevent recurrence by -Take action on potential hazards
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Proactive Measures to avoid Accidents in hazardous area

* Work permit system is to befollowed strictly * Display of MSDS (Material Safety Data Sheet) at the concerned Chemical storage / handling and process areas * Issue of Chemical / Electrical Oil resistance Shoes * Issue of job related PPEs to employees * Well organised Hazardous waste Management
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Special attention in case of the following

House keeping Fire Electicity PPE usage Guards Chemicals Tools Machines

Material handling High temperature High speed Lighting Ventilation Flooring Falling objects
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What to do in case of Accident involving an injury:

1) 2) 3) 4) 5) 6) 7) Be calm Remove the danger Attend to the injured person Call medical help if necessary Inform to the manager Investigate the cause Complete the accident report form
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4 As for Safety:
1) 2) 3) 4) First Second Third Fourth A Attitude A Awareness A Action A Accountability
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Accident Prevention

What can you do?

Do not cut corners, always use the correct equipment for the task Think of others, be observant Make sure you fully understand any instructions, if in doubt ASK NEVER ignore safety instructions

Remember accidents are preventable

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NOTIFIABLE DISEASES
1. 2. 3. 4. 5. 6. 7. 8. ANTHRAX ARESENIC POISONINGS ASBESTOSIS BENZENE POISONING BERYLLIUM POISONING BYSSINOSIS CARBON MONOXIDE CARBONBISULPHIDE 16 17 18 19 20 21 22 23 MANGANESE POISONING MERCURY POISONING NOISE INDUCED HEARING LOSS NITROUS FUMES POISONING OCCUPATIONAL CANCER OCCUPATIONAL DERMATITIS PHOSGENE POISONING PHOSPHORUS POISONING

9.

CHROMIUM ULCERATION

24 PRIMARY SKIN CANCER

25 26 27 RADIUM & X-RAY HAZARDS SILICOSIS TOXIC ANEAMIA

10. COAL MINERS PNEUMOCONIOSIS 11. DEMATITIS 12. HALOGEN POISONING

13. ISOCYANATE POISONING

14. LEAD POISINING 15. LEAD TETRAETHYL POISONING

28 TOXIC JAUNDICE
29 TOXIC NEPHRITIS
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