UltraTech Cement Limited Aditya Cement Works

QCFI best practice competition 2016

Safety

QCFI best practice competition 2016

Safety

GENERAL INFORMATION

1.Name of Industry / Applicant :

UltraTech Cement Limited (Unit: Aditya Cement Works)

2. Full address:

Sawa-Shambhupura, Adityapuram, Distt.- Chittorgarh,

Rajasthan-312622

3. Name, designation, contact phone no & address:

Abhishek Pandey

SH-WCM & ISO

Technical Services, Aditya Cement Works

Sawa-Shambhupura, Adityapuram, Distt.- Chittorgarh,

Rajasthan-312622

2. Workforce & Man hours Worked.

Sl. No Type of Workers 2014-15 2015-16

1 Regular 820 876

2 Contract 1161 1297

3 Others (AJST) 32 32

4 Total 2013 2205

2.1 Average no of workers in Factory.

2.2 Man hours worked by all workers including over time worked

Sl. No Type of Workers 2014-15 2015-16

1 Regular 16,44,408 17,86,200

2 Contract 1,32,54,528 95,25,634

3 Total 1,48,98,936 1,13,11,834

3.Reportable incident and F.R.

Type 2014-15 2015-16

Near-miss 4741 4906

High Potential Near miss Nil 02

First – aid cases 35 19

LTI ( Lost Time Incident ) 7 1

Fatality 0 0

Man hours lost due to LTI 2368 432

Severity Rate 18.05 4.77

Frequency Rate 0.47 0.09Frequency Rate 0.47 0.09

No of Dangerous occurrences as per

factory act0 2

4. The longest accident free period (Continuous covering the three years, assessment period)•During the assessment period only i.e. 2013-2015

From Period To Period No of DaysAccident Free Million

Man Hours

15.02.15 13.09.15 209 10.70 Million Man hrs

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

Yes, we have Safety & Health policy

5. HSE Policy

5.2. Level at which policy has been in force.

Policy is applicable from top to bottom – covering all employees of all Ultratech Units.

5.3. Describe how the objective of H&S policy achieved.

A World Class Occupational Health & Safety Management System OHSAS-18001 is implemented since 2001

to identify risk, their evaluation and implementation of proactive measures. Other than this, there is a

Safety Management System in consultation with DuPont, which is looked after by Corporate Safety and Unit

head is accountable for the implementation of the system. All line managers are responsible for the smooth

implementation of the safety system in the plant. 19 numbers of Standards and procedures have been

developed for covering the entire activities of the plant in such a way that no incidents happened.

The functioning of these 5 sub committees are monitored by Apex Safety Committee which is chaired by

Unit Head of the plant.

Safety Observation Process which is a effective management tool for behavioral change is well in place and

safety Observation are conducted by the trained leaders to bring in behavioral change among the workers

of all category.

Safety helmets, Reflective Jackets, Goggles and shoes are mandatory for all employees from the main gate

itself. Other safety appliances are provided to workmen as per the job requirements. Safety kit containing

general safety equipments have been distributed to all employees as best practice.

The other activities for maintaining a sustained Safety culture are as follows:

1. A three-tier safety review mechanism is in place to review safety related issues & ensure continual

improvement in OH&S implementation.

1. A three-tier safety review mechanism is in place to review safety related issues & ensure continual

improvement in OH&S implementation.

2. A three-tier safety audit/Inspection procedure is implemented to identify and eliminate unsafe practices

and conditions.

3. Safety Training is a regular feature throughout the year. This includes classroom trainings, on the job

trainings and practical demonstration.

4. Occupational health and safety has been made key & important measurable of performance

measurement system for all employees.

5. Safety Motivational and Promotional activities are regularly organized to enhance safety awareness

amongst employees.

5.4. Explain how the policy is made known to employees.

Policy is made available through display at prominent locations, printed pocket copy

distribution to all, E-Mail and intranet portal.

6. Review of HSE performance by top management

6.1 Is your organization certified OHSMS under

Indian Standards. Attach copies of relevant certificates.

Aditya Cement Works is certified to OHSAS 18001:2007

since Dec.’2001.

6.2. Does the top management receive periodic report 6.2. Does the top management receive periodic report

on H&S performance? IF Yes, What is the periodicity?

Submit copy.

Safety performance is reviewed at three level and on

Monthly basis:

i. Apex level (Chaired by Unit Head)

ii. Function level (Chaired by Function Head)

iii. Department level (Chaired by HOD)

iv. Central Safety Committee meeting.

Safety KPI of unit level is discussed, reviewed and action

plan (MOM) prepared, again reviewed in next meeting.

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

Following action has been taken by the top management after review the reports & those are

implemented:

1. To further strengthen the near miss reporting culture, management has decided to report

one near miss per month mandatorily for staff members.

2. Four PPE have made mandatory for all employees and visitors entering in the plant.

3. 19 safety standards and procedures have been rolled out and compliance of these

standards is monitored through various sub committees.

4. Robust audit system has been developed and implemented for monitoring the compliance4. Robust audit system has been developed and implemented for monitoring the compliance

of standards.

7. HSE Organization

7.3 Does the organization have set a safety KPI for every employee in order to achieve H&S

Objective? If Yes. What is the measurable?

Yes, the organization have set a safety KPI for every employee in order to achieve H&S Objective.

The measurable are sampled below:

DH Level KPI – 2015-16

SL. No. KPI UNIT TARGET

1 Department CFSA Nos. 1/Week

2 No. of SWP reviewed Nos. 1/Week

3Compliance of Incident investigation & Black

corner notice recommendations % 100%

corner notice recommendations

4 % of Contractor upgraded above 70% % 100%

5 Repetitive SO points Nos. Zero

6 No of issues resolved through SAM Nos. 4 nos /section / month

7 No. of safety review meetings Nos. 1/Month

8 Repetitive CFSA points Nos. Zero

9Organize training of employees through T&C

sub-committeeNos. 8 Hrs /Employee/year

10 No. of Near-miss Nos. 2/Employee/Month

7.4 Safety Personal

Sl. No Name Designation Since Qualification

1R R Choudhary DGM - DH 07.10.2013

B. Sc, LLB, DISM(PU),

DME

2Bireswar Das AM - SH 21.02.2012

DEE, BA, PDIS (RLI

Kanpur)

3Deepak Sethy Sr. Engr 13.08.2008

DEE, PDIS (Asian Workers

Dev Inst (Orissa)

4 BE, PDIS (RLI Kanpur)4Pushpendra Gupta Sr. Engr 16.05.2008

BE, PDIS (RLI Kanpur)

8.0 HSE Trainings

8.1 Does the organization identify training need identification (TNI) for employees and

contractors.

Health & Safety training need of all employees is identified as per defined procedure

of Training. As per procedure, following key points are focused for OH&S training

need identification: -

•Focus groups and one-on-one meetings.

•Analyze the OH&S survey results.

•Employee’s current job description.

•Job analysis.•Job analysis.

•Health & Safety Measures needed to perform the present job.

•Skills needed to perform other roles in the organization.

•Future career aspirations.

•The identification of prior learning obtained.

•Review of implemented agreed actions of training delivery

•Health Check-up prescriptions.

•Performance Appraisal Outcomes.

•Special Safety Measures required on Technology Updating.

8.2 Does the organization have implemented training matrix for Employees & Contractors. If yes, attach.

Function wise Matrix - Safety Standards TrainingS No Safety Standards Technical TPP Mines Commercial HR

1 Contractor Safety Management FH, DH, SH, PF

2 Incident Investigation FH, DH, SH, PF, Staff

3 Permit To Work FH, DH, SH, PF, Staff, WB, CL

4 Road Safety FH, DH, SH, PF, Staff, WB, CL

5 Safety Observation FH, DH, SH, PF, Staff

6 Working at Height FH, DH, SH, PF, Staff, WB, CL

7 Electrical Safety FH, DH, SH, PF, Staff, WB, CL FH, DH, SH, PF, Staff

8 Excavation FH, DH, SH, PF, Staff, WB, CL FH, DH, SH, PF, Staff

9 HIRA-JSA FH, DH, SH, PF, Staff, WB, CL FH, DH, SH, PF, Staff

10 HEMM FH, DH, SH, PF, Staff, WB, CL FH, DH, SH

11 Hot Work FH, DH, SH, PF, Staff, WB, CL FH, DH, SH

12 LOTOTO FH, DH, SH, PF, Staff, WB, CL FH, DH, SH

13 Machine Guarding FH, DH, SH, PF, Staff, WB, CL FH, DH, SH, PF

14 Lifting and Supporting of Loads FH, DH, SH, PF, Staff, WB, CL FH, DH, SH, PF, Staff

15 Confined Space Entry FH, DH, SH, PF, Staff, WB, CL FH, DH, SH

16 Scaffolding FH, DH, SH, PF, Staff, WB, CL FH, DH, SH, PF

17 Rail Safety FH, DH, SH, PF, Staff, CL FH, DH, SH, PF

18 Mines Safety FH, DH, SH FH, DH, SH, PF, Staff FH, DH, SH

8.3 Does Trainings effectiveness is measured through feedback.

Yes is measured through feedback from pre and post evaluation sheet and then from

verbal feedback from department

8.4 What is the induction method followed for employees, contract workforce, experts, Govt.

Officials and others.

Induction training for all employees ,contractor workmen and visitors has been carried

out before preparation of gate pass. The SOP of the gate pass such that withoutout before preparation of gate pass. The SOP of the gate pass such that without

induction training it can not be made. So nobody can enter without safety induction

training

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

All the Training records are maintained.

Own EmployeeTraining Topic /Module

Participants Training Topic /Module Participants

Awareness Session on Near Miss 39 One month specialised certificate

course in safety & health for supervisory

personnel working in hazardous

process

1

Confined Space Entry 122 Organising & motivating for safety &

accident Analysis 1

Contractor Safety Management 13 PTW / Online PTW 577Contractor Safety Management (On Line

Course) 12 Rail Safety Standard 62

Course)

Electrical Safety 63 Revised HIRA/JSA 735Employees' Action in Improving Safety (EAIS) 335 Road Safety 78

Excavation, Shoring and Sloping 84 Safety Behavioural Observation & Audit 82

Fire Fighting Equipment 29 Safety leadership skills training

programme for FLEs by DuPont

Consultant

45

Heavy Earth Moving Equipments 42 Safety Practices & Initiatives at Aditya

Cement111

Hot Work 46 Safety Standards Videos 6Incident Investigation 61 Scaffolding Standards 132Lifting and Supporting of Loads 96 Training on Workmens Inspector 2

LOTOTO Standard 74 Visible Felt Leadership 378Machine Guarding 79 Working at Height 196One month specialised certificate course in

Safety & Health 1 Workmen"s Inspectors trg. 2

Grand Total = 3504

S.N Safety KPI's Location Description Apr'16 May'16

1

Incidences/fatalities

reported and timeliness

of reporting

Inside PlantNear Miss 4 2

Accident/Fatality 0 0

Outside PlantNear Miss 0 0

Accident/Fatality 0 0

Declarations from

TransporterTotal No 20 22

Declaration received From 17 20

8.6 How does the organization covers drivers (Internal & External Vehicles) training.

Training are being imparted to all the drivers who ever enters into plant at main gate

itself. (KPI of transport committee is tracked monthly in Apex meeting

2

Declarations from

transporters and

drivers – % covered

Declaration received From 17 20

Driver

Total No (approx no if exact no. not

available) 535 545

Declaration received From 22 32

3

No of

driver/transporter

trainings done against

targets and % coverage

TransporterTotal No 10 10

Trained in current month 2 3

Driver

Total No. (approx if exact no not

available)332 400

Trained in current month 0 18

4

Vehicle Fitness

Compliance - number of

deviations

Dedicated Total no. vehicles 155 155

8.7 Training Particulars.

Sl. No. Trainings 2014-15 2015-16

1 Internal Trainings 161 149

2 External Trainings 3 2

3 Training Participants Company 3138 2643

4 Training Participants Contractors 1988 28031988 2803

5 Total Training Hours 22973 22033

6 Training Hr. individual per employee per annum 28 25

7 Training Hr. Contractor individual per employee per annum 3 5

8 % covered Employees 100 100

9 % Covered Contract workforce 100 100

Sl. NO Description 2014-15 2015-16

1 Elect Shock 1 Nil

9.Mock Drills

Provide Mock drill details as per Factories Act / Law.

2 Fire 2 2

3 Rescue from Height 1 Nil

10 Accident/Incidents Reporting

10.1 What is the method of reporting system in your organization?

A systematic Incident Investigation procedure is in place. All incidents are reported within the shift of

incident in software called My Setu. The incident report goes to all HOD and top management automatically

and an investigation team is formed by concerned HOD determining leader as per the potential severity of

the incident within 24 hours. Then the incident is investigated within 7 days and report is submitted with

root cause, system failures and corrective and preventive recommendations. Compliance of

recommendations is monitored and the entire process is monitored through incident investigation

subcommittee

Finally the status of incidents, investigations and recommendations are reviewed in Apex Safety committee

meeting every month.

10.2 Reporting will escalate up to what level in your organization &what is the path?

10.3 Does the organization conduct RCA on all incidents such as , property damage,

Loss of product, H&S related .

The incident is investigated following 8 step procedure as mentioned

�Making Initial response & report

�Form Investigation Team

�Determine the Facts

�Determine the Kay Factors – Root Causes

�Determine Systems to be Strengthened – Gaps in the system

�Recommend Corrective & Preventive Actions

�Document & Communicate the Findings

�Follow Up �Follow Up

10.4 Who leads the RCA process?

Investigation reports are shared with all to avoid recurrence anywhere in unit.

Near Miss reporting reward scheme is established to encourage reporting of Near –Misses

because near miss incidents lead to real accidents.

Online system is available & being utilized for incident reporting and investigation. This

ensures better record keeping, analysis and CAPA follow ups.

10.5 If CAPA points does not get closed as per target dates provide, what is the

method you adapt for extension.

These points are tracked and monitored by Incident Investigation sub committee (Chaired

by FH) and pending points are discussed in the apex safety committee meeting every

month. So there is no points left, if any actions are left, it is tracked in the meeting by

senior management and implemented.

11. HIRAC & SOP

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

maintenances.

Yes….No activity is performed without risk assessment. After HIRA, SWP/SOP is prepared &

permit is not issued unless the SWP/SOP is attached with the permit.

We have established and implemented a procedure for Hazard Identification & Risk

Assessment developed by multi disciplinary senior professional and corporate safety under

the guidelines of Du pont methodology. As per the procedure, HIRA conducted by a multi

disciplinary team of all the non routine/ tentative jobs. Risk is assessed by using Kenny &

Fine method where Exposure, Severity & probability factors are considered to determine Fine method where Exposure, Severity & probability factors are considered to determine

the risk and necessary control measures are taken to mitigate the hazards or reduce the

risk level to acceptable range. The control measures are taken following the hierarchy of

control as mentioned

�Elimination

�Substitution

�Engineering Control

�Administrative control

�PPE.

In addition, a Safe Working Procedure is developed for all jobs and followed. The SWP is

reviewed periodically by an expert team to identify any gap between the written

procedure and actual practice. Accordingly necessary modification done to the SWP.

11.2.Does Standard Operating Procedures exist for all critical and regular activities?

We have standard on HIRA, as per the standard requirement, hazard identification and risk

assessment done for all the activities performed across the plant. After completing HIRA ,

SOP, SWP and SMP are prepared for all critical and regular activities.

11.3.Does the company have Job Safety Analysis (JSA)& Job Safety Observation (JSO)

system. If Yes. Attach one sample copy.

Company have a details HIRA/JSA and Safety Observation Procedure. SO submission and

tracking system is done trough online portal Mysethu.tracking system is done trough online portal Mysethu.

There is a Safety Observation process (to identify & correct at risk behaviors of employees at

shop floor) by which most of the jobs observed and corrected immediately. All management

staffs are involved in this process. Also routine plant round by safety professionals and

consequent observations help not to ignore such things.

During Safety Observation, The Observer along with area in charge follows the Six-Step

process.

1. Observe, decide, stop the unsafe act (safely).

2. Comment on safe behavior.

3. Discuss Possible consequences of unsafe act. Safer ways to do job.

4. Get agreement to work safely.

5. Discuss other safety issues.

6. Thank the employee.6. Thank the employee.

12. Contractors Safety Management.12.1 Does the organization has evaluation of contractors method. If Yes. What is the process?

“Contractor Safety Management” system plays a major role here. Six step process of CSM ensures that

Selection of contractors/suppliers only after they complete the entire requirement as per our policy as

mentioned below:-

�Pre-Qualification

�Contract Preparation

�Contract Awarding

�Orientation & Training

�Managing the work (CFSA)

�Post Contract Evaluation�Post Contract Evaluation

Before awarding contract, all the requirements related to safety is well communicated to contractors.

12.2 What is the frequency of contractor’s safety performance monitoring?

Evaluation of safety performance is done through pre scheduled CFSA (Contractor Field Safety Audit) during

the works are going on and communicated to concerned department & contractor as well.

This audit report and results are reviewed in Apex meeting. Necessary actions are decided in the apex

meeting for a specific contractor if rating goes high.

12.3 Does the contractor deploy qualified safety person on board as per 50:1?

Yes this system is in place as per CSM (Contractor Safety Management) standard .

12.4 How frequently contractor will get involved in safety meetings.

•Contractor mass communication meetings are being arranged in every month for discuss

various safety issue, theme etc.

•Contractors are also invited in different department /Functional meeting .

12.5 What is the method adapted to encourage contractors safety performance?12.5 What is the method adapted to encourage contractors safety performance?

Contractors safety performance are encouraged by issuing certificates and awarding in

different forums.

Sl.

No.Audits 2014-15 2015-16

1 Internal

No of Observation 205 265

Compliance % 94 93

Variance 6 % 7 %

13 Safety Audits.

2 External Not conducted in this period

No of Observation

Compliance %

Variance

14.Occupational Health.

14.1 Does the factory have dedicated OHC & Dedicated Staff? Provide Names with

designations. Chief Medical officer is appointed who looks after well equipped the Occupational Health Centre. Chief

Medical officer is assisted by a team consisting of a lady Medical officer, 1 Medical officer and 07

paramedical staff. First Aid boxes have been provided at various identified locations in the Plant.

Dr. Vinay Verma, Dr. Unnat Mathur

14.2 What is the pre-medical check procedure for employees followed?

Health monitoring, like spiormetry test, audiometry test, x-ray, general health check up, color blindness

etc are done and trend of employee health is maintained and monitored to take all sorts of preventive etc are done and trend of employee health is maintained and monitored to take all sorts of preventive

action. At Aditya cement, the health monitoring is not limited to permanent employees rather we extend

the service to all of our contractual manpower.

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

Yearly and half yearly as per the hazard matrix area of the plant

14.4 How you ensure contractor workforce medical prior to deployment on job.

Attach pre-medical check format.

This is a part of SOP of Gate pass, so without medical check up, nobody can work inside.

15. Safety Promotional Activities

15.1 How does the factory encourages employees and workforce to follow safety practices.15.1 How does the factory encourages employees and workforce to follow safety practices.

List is not limited to…

Sl. No. List of promotional activities-2014

National Safety week celebration

National Fire Safety week celebration

Sl. No. List of promotional activities-2015

1 Contractor monthly Mass communication meeting

2 Monthly Mass communication meeting

3 National Safety week celebration

4 National Fire Safety week celebration

5 National Road Safety week celebration