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LOSS CONTROL AND SAFETY
MANAGEMENT IN INDUSDTRIES
BY
C.V.RAGHUNATHAN,B.TECH;DIS(HONS):MIE;MSEA
DY.CHIEF SAFETY MANAGER
THERMAL POWER STATION-INEYVELI LIGNITE CORPORATION LTD
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NEED- I
TODAYS BUSINESS SCENARIO Liberalisation
Globalisation
Open Economy
Increased Competition
Customer driven market Survival of the fittest
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NEED-II
STATUTORY COMPLIANCE FACTORIES ACT 1948 AMENDED IN 1987 Power Generation Industry comes under sec2(cb)
Applicability of Sec 41B,41C,41E,41H
Sec7A (a) Plant to be maintained safe without health risk
(b) Safe handling and usage of substances
(c) Information , instruction,training andsupervision on safety
(d) Safe access and eggress
(e) Maintenance and monitoring of work place
environment
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THE TWO MANTHRAS
QUALITY
PRODUCTIVITY
(CONTROL OF LOSS PRODUCING EVENTS,
OPTIMUM UTILISATION OF MONEY,MACHINES,
MATERIALS,METHODS,MEN)
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DEFINITIONS
HAZARD
Source/inherent property of a substance which has the
potential to cause harm to human by way of injury/ill
health,damage to property and environment
RISK
The combination of likelihood and consequence of a
hazardous event
INCIDENT
An event that has potential to cause an accident(includes
near miss)
ACCIDENT
Undesired event that causes injury, ill health,death,
damage to property and environment
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ACCIDENTS
LOSS PRODUCING EVENTS
ECONOMIC LOSS
SOCIAL LOSS
IMPAIRS INDIVIDUAL AND GROUP
PRODUCTIVITY
RETARDS ADVANCEMENT AND
STANDARD OF LIVING
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ACCIDENTS ACCIDENTS DO NOT HAPPEN; THEY
ARE CAUSED
ALL THE HUMAN ERRORS DO NOT
END UP IN ACCIDENTS
BUT MOST OF THE ACCIDENTS ARE
RESULTS OF HUMAN ERROR
ACCIDENT PREVENTION VITAL FOR
NATIONAL PROGERSS
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LOSS PREVENTION & CONTROL
MANAGEMENT
CONTROL OF MACHINE
PERFORMANCE
CONTROL OF MEN PERFORMANE
CONTROL OF PHYSICAL
ENVIRONMENT
CONTROL OF MATERIALS
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CONTROL OF MACHINE
PERFORMANCE Safety in conceptual stage
Safety in design stage
Safety in construction stage
Safety in transportation stage
Safety in operation & maintenance stage Safety in dismantling stage
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CONTROL OF MATERIALS
Inventory Control
Storage & Handling
MSDS
Antidotes
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HUMAN PERFORMANCE
ORGANISATIONAL BEHAVIOUR
INDIVIDUAL BEHAVIOUR
ATTITUDE
PERSONALITY
(AGE,SEX,EDUCATION, UPBRINGING, EXPERIENCE,
ENVIRONMENT, BELIEFS,VALUES, POSITION, SITUATION)
PERCEPTION
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CONTROL OF MEN
PERFORMANCE Recruitment
Selection
Placement
Induction
Training
Devolopment Retraining
Motivation & Discipline
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ACCIDENT COSTING
(Affected parties) Accidentee
Management
Immediate Supervisor
Government
Society
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ACCIDENTEE
Loss of life/limb
Pain,Anxiety
Loss of livelyhood,wages
Incapacity to perform normal work
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SUPERVISOR
Anxiety
Loss of prestige/Reputation
Legal implications
Loss of skill
Time and energy for the devolopment ofsubstitute
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MANAGEMENT
DIRECT COST
Cost of Compensation
Cost of medical expenses
Cost of investigation
Cost of rehabilitation
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MANAGEMENT INDIRECT COSTS
Lost time of accidentee
Lost time of fellow workmen
Lost time of Supervisors & Executives
Lost time of clearing the accident site Lost time of repairing the damaged equipments
Lost time for restarting the process/production
Reduced quality of output due to the emotional upset ofsupervisors/workmen
Blocked Capital Loss of skill and experience
Lost time for the training of the replaced workman
Lowered employee morale
Increased labour conflict
Unfavourable public image/relations
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ACCIDENT PREVENTION
INDENTIFY AND ESTABLISH
CONTROL OVER THE CAUSE OF
ACCIDENTS
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INVESTMENT FOR SAFETY
Cost of accidents are 10 times morethan the cost of accident prevention
programmes, as the indirect cost of
accidents are 10 times more than the
direct costs.
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ACCIDENT CAUSES
PROXIMATE CAUSE
CONTRIBUTING CAUSE
IDETIFY AND ATTACK THE ROOT
(CONTRIBUTING) CAUSES
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PROXIMATE CAUSE
UNSAFE PHYSICAL CONDITION
UNSAFE WORK PRACTICES
COMBINATION OF BOTH
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CONTRIBUTING CAUSE
Inadequate knowledge and skill
Anatomical /Physiological unsuitability
Improper Psychological charecteristics
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ROOT CAUSE
FROM THE PART OF SUPERVISOR
Inadequate leadership
Inadequate motivation
Inadequate instruction(No instruction,Incomplete
instruction,Erroneous instruction)
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ROOT CAUSE
FROM THE PART OF WORKMAN
ANATOMICAL/PHYSIOLOGICAL UNSUITABILITY
Loss of limbs Shortage of limbs
Poor eye sight
Poor hearing(THL/PHL) Astigmatism
Epileptic
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ROOT CAUSE FROM THE PART OF WORKMAN
PSYCHOLOGICAL
Over confidence
Lack of confidence
Haste
Short cut practices
Chance taking
Inattention
Absent minded
Thoughtlessness
Fatalistic attitude
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ROOT CAUSES
FROM THE PART OF WORKMAN
DISCIPLINE
Disobedience Disregard to instructions
PHYSICAL CONDITION
Sick/Weak/Fatigued
KNOWLEDGE/SKILL
Inexperienced
Ignorant
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CLASSIFICATION OF INDUSTRIAL
ACCIDENTS AS PER IS 3786 CLASSIFICATION ACCORDING TO
B1 AGENCY
B2 UNSAFE PHYSICAL CONDITION B3 UNSAFE ACT
B4 UNSAFE PERSONAL FACTOR
B5 TYPE OF ACCIDENT B6 NATURE OF INJURY
B7 LOCATION OF INJURY
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B1 AGENCY
MACHINES(Prime movers,Transmission
machineries,metal/wood/agricultural,mining
machineries) TRANSPORTATION/MOVING
EQUIPMENT(Lifting
machines,Road,Rail,Air,Water transportation
OTHER EQUIPMENTS(Pressure
vessels,Electrical installations,Electric hand tools)
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B2 UNSAFE PHYSICAL CONDITION
Inadequately Guarded machinery
Inadequate Ventilation
Inadequate illumination
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B3 UNSAFE ACT
Operating without authority
Failure to warn
Operating at unsafe speed
Making safety devices inoperative
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B4 UNSAFE PERSONAL FACTORS
Inadequate knowledge and skill
Anatomical /Physiological unsuitability
Improper psychological charecteristics
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B5 TYPE OF ACCIDENTS
Fall of persons
Fall of objects
Striking against objects
Struck by objects
Caught in between objects
Exposure to extra temperature
Exposure to electric current
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B6 LOCATION OF INJURY
Head
Neck
Trunk
Upper limb
Lower limb
Multiple locations
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B7 NATURE OF INJURY
Fractures
Dislocations
Sprains
Concussions
Burns
Acute poisoning
Asphyxia
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ACCIDENT INVESTIGATION
COLLECTION OF PRELIMINARY DATA
SPOT VISIT AND COLLECTION OF
OBJECTIVE EVIDENCES INTERACTION AND RECORDING
ANALYSIS AND CONCLUSION
RECURRENCE AVOIDANCE MEASURES PREPARATION OF REPORT
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ACCIDENT INVESTIGATOR
KNOWLEDGEABLE
EXPERIENCED
PROMPT
UNBIASED
FACT FINDING
SOUND IN JUDGEMENT
DIPLOMATIC
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REPORTING
SYSTEM OF REPORTING
(INCIDENTS,NEAR MISSES,ACCIDENTS)
STATUTORY REPORTING
FACTORIES ACT
SECTION 88- NOTICE OF ACCIDENTS
SECTION 88A-NOTICE OF DANGEROUSOCCURENCES
SECTION 89-NOTICE OF DISEASES
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REPORTING
TNFR/RULE 96
(FATAL,SERIOUS,DANGEROUS OCCURRENCE)
Immediate information to CIF/DCIF/IF through telephone/Fax,District
Magistrate,Inspector of Police Form 18/18A within 12 Hrs.
Other cases of reportable accidents within 72 Hrs in Form 18
Electrical accidents in Power Generation, Transmission,Distribution
systems involving injury to human or animal to be reported to the
Electrical inspector by telephone within 24 Hrs and in FORM as perANNEXURE XIII within 48 Hrs.(as per Rule 44A of IER 1956)
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MANAGEMENT OF INTOLERABLE RISKS
Reduce the risk level by reducing the likelihood &consequence THROUGH
Introduction of New Technology
Modification of Existing Technology
Substitution
Separation
Administration Training
PPE
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FEASIBILITY STUDIES
TECHNICAL VIABILITY
ECONOMIC VIABILITY
OPERATIONAL VIABILITY
LEGAL REQUIREMENTS
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AREAS OF OSH AUDIT AS PER IS 14489
Health & Safety Policy
Safety Organisation (Safety
Dept/Committee/Safety Budjet
Accident Reporting,Investigation & Analysis
Safety Inspections
Safety Education & Training
First Aid Occupational Health Centre
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OSH AUDIT AS PER IS14489
General Working Condition(House
Keeping,Noise,Illumination,Ventilation)
Hazard Identification & Control
Safe Operating Procedures
Work Permit System
Waste Disposal System
Personal Protective Equipment
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OSH AUDIT AS PER IS 14489
Fire Protection
Emergency Preparedness
Plant Layout and Area Classification
Static Electricity
Pressure Vessels(Fired & Unfired)
New Equipment Review
Lifting Machines & Tackles
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OSH AUDIT AS PER IS 14489
Mobile Equipment & Vehicular Traffic
Safe Access
Material Handling Pressure Vessels/Tanks Safety
ON SITE Gas Cylinder Storage Area
Plant Communication System Transportation of Hazardous Materials
(Road/Rail/Pipelines)
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SAFETY PERFORMANCE INDICES
FREQUENCY RATE
(Number of accidents x10,00,000)/Man
Hours worked
SEVERITY RATE
(Total mandays lost x10,00,000)/Man
Hours worked
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DETERMINATION OF RISK LIKELIHOOD
Highly Unlikely1
Full control over the identified hazardby way of Technology, Operational
Control,measurement and
monitoring,Competence(NO GAP)
Unlikely
2
Minor Gap exits over the control of
identified hazard
Likely
3
Major Gap exits in control over the
identified hazard
Very Likely
4
No Control over the identified hazard
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CRITERIA FOR RISK ASSESSMENT
LIKELIHOD(L) COSEQUENCE( C ) RISK=LxC
Highly Unlikely(1)
Slightly Harmful(2)
Trivial(2)
Unlikely
(2)
Harmful
(4)
Moderate/
Tolerable(4-8)
Likely
(3)
Very Harmful
(6)
Substantial
(12-18)Very Likely
(4)
Extremely Harmful
(8)
Intolerable
(24-32)
DETERMINATION OF RISK CONSEQUENCE LEVEL
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DETERMINATION OF RISK CONSEQUENCE LEVEL
RANKING HUMAN PROPERTY
Slightly Harmful2
MomentaryDiscomfort No Damage
Harmful
4
First Aid./Non
Reportable
injuries
Minor Damage
Very Harmful
6
Reportable
Minor/Major
injuries(Temp
disability)
Severe Damage
Extremely Harmful
8
Fatal/Perm.
Disability(Incide
nts involving
large number of
Complete
Distruction