Chanderia Cement Works

Action Plan- GAP ANALYSIS ON SAFETY MANAGEMENT SYSTEM - M/s Chola MS Report
S. Safety Management Element
Major Recommendations Responsibility Target Date
No. System Element Score
The objective for the safety needs to be clearly defined and the commitment
towards the objective by the management needs to be visibly felt. CCW may Safety & All HODs 31/12/2019
prepare a safety strategy plan for next 3 years.
HSE Leadership
1 43% Structured Safety Management Manual to be developed in line with ISO 45001
and Commitment All HODs and Safety 31/03/2020
for effective implementation of existing SMS
It is recommended to establish Safety Leadership KPIs and a company wide
Safety 31/03/2020
tracking of lead indicators for safety performance
The safety committee members shall be trained on hazard identification techniques
Safety and HR 31/12/2019
and shall carry out structured safety inspection every month.
Workforce
2 31% Consider preparing a responsibility chart for all employees at every level. Safety
Involvement
responsibility to be defined across the organization – Safety as a line function Safety and All HOD's 31/03/2020
concept to be emphasized.
Exhaustive legal register to be developed defining administrative, technical
ISO MR, HR, ISD 30/11/2019
Statutory compliance with field level responsibility defined.
Compliance and Escalation Matrix to be developed ISO MR and ISD 30/11/2019
3 65%
Standards Consider identifying list of Indian / International standards on safety applicable for
Benchmarking Safety 31/10/2019
the operations
Reports / notification issued by statutory authority to be tracked for effective closure ISO MR and IT Head 30/11/2019
A guided HIRA session shall be conducted for the engineers from various teams Safety and Core team
30/11/2019
Hazard Identification, and develop HIRA for the entire facility. members of Depts.
4 Risk Assessment & 22% Develop a comprehensive risk register and update the same on periodical basis. Safety & All HODs 30/11/2019
Risk Control Life critical elements with respect to cement plants are to be identified and OCP
Safety & All HODs 30/11/2019
shall be made available
It is recommended to carry out occupational health mapping. It is also
MO and HR 30/11/2019
recommended to develop occupational health matrix.
Occupational
5 45% A comprehensive PPE survey to be carried out for entire operations. Based on the
Health & Safety
survey, the PPE required for the various sections may be standardized, according Safety and All HODs 30/11/2019
to hazards.
Develop a pre-requisite required during the selection of contractor Safety and All HOD's 30/11/2019
Purchase, Safety &All
Structured approach for rating of contractors yearly 31/12/2019
HODs
Contractor Safety
6 35% Move towards skill-based training. HR
Management
Technology enabled skill improvement program to be developed HR and Safety 31/12/2019
Role based specific trainings to be provided. HR and Safety
Rewards and recognition program to be introduced. HR
Procedure to be developed for Work Permit system Safety Done
 Chanderia Cement Works
Action Plan- GAP ANALYSIS ON SAFETY MANAGEMENT SYSTEM - M/s Chola MS Report
S. Safety Management Element
Major Recommendations Responsibility Target Date
No. System Element Score

A Training Manual on PTW system to be developed, covering details like who is

the issuer/ who is the receiver/ Role of contractors / checklists and flow charts
Safety Done
for PTW. Supervisor and executing team have to be skilled and received specific
training on PTW.

7 Work Permit System 20% System of training and certification to be established for permit issuer, receiver
Safety Done
and approving authorities.
Work Permit Authorization Card shall be issued for personnel attending the
Safety 31/12/2019
training and clearing the written examination.
From Dec
Develop permit to work audit system in order to review the effectiveness Safety and All HOD's
2019
Risk assessment to be carried out for all critical jobs prior to issuing permit. From Nov
All HODs
Permit shall be issued with copy of updated risk assessment. 2019
ISO MR Done
CCW shall introduce Management of Change system on priority to ensure that
(Procedure)/Safety
all major modifications (including capacity additions/process modifications
31/10/19
/replacement/ Upgradation/by-passing of interlocks of equipment) are
Implementation - Project &
subjected to EHS review so that overall safety philosophy is not altered
Management of All HODs
8 0%
Change Comprehensive training programs on management of change to be conducted for
All HODs, HR & ISO MR 31/12/2019
line managers / key personnel having significant role in implementing MOC.
A list of all HSE critical equipment (where an equipment malfunction or failure could
have a significant, adverse HSE impact) shall be prepared. Develop a procedure All HOD's and Safety 30/11/2019
for bypassing, including the categories and levels of approvals.
It shall be ensured that operating procedures are prepared for all type of operations
– routine and non-routine operations /activities and especially for critical jobs in Safety and HOD's 30/11/2019
process area at the earliest.
Operational controls are a layer of protection in managing risks - HIRA findings to
Safety and ISD 31/01/2020
be linked with SOP.
Operating
9 29%
Procedures 31/12/2019
Training needs to include training on SOP. Safety and ISD
31/01/2020

Operating procedures shall be reviewed and certified annually that they are current
Safety and All HOD's 31/12/2019
and accurate.
Maintenance philosophy shall be established – A comprehensive document
outlining the asset integrity program for the plant to be developed, identifying
All HODs
the parts to be maintained/ inspected/ calibrated- standards to be followed/
equipment to be used for calibration/ agencies which can carry out job etc.
Inspection & Maintenance deferrals shall be monitored. All HODs
 Chanderia Cement Works
Action Plan- GAP ANALYSIS ON SAFETY MANAGEMENT SYSTEM - M/s Chola MS Report
S. Safety Management Element
Major Recommendations Responsibility Target Date
No. System Element
Inspection & Score
10 51%
Maintenance MTTR for critical equipment to be defined and followed All HODs
Equipment availability data, break down analysis, etc. shall be done All HODs
Electrical maintenance program to be strengthened considerably. Electrcal
Inspection program to be developed for underground storage tanks (Petrol and
Store 31/12/2019
Diesel)
Training calendar on safety to be reviewed based on Training need analysis of
Safety & HR 31/12/2019
Training, individual employees.
A Knowledge vs Skill Mapping matrix to be prepared as part of the training
11 Awareness and 54% HR
program.
Competence Pre and post assessments for training programmes shall be carried out alongwith
HR 31/10/2019
training feedback.
Incident reporting system to be strengthened – Injuries are reported; however,
Safety 15/9/2019
incidents are not.
Incident Action tracking register on recommendations to be maintained. Safety Done
12 Investigation and 51% Lessons learning from incidents to be prepared and circulated. Safety Done
Analysis Scientific root cause analysis techniques to be adopted Safety and All HOD's 30/11/2019
Investigation team shall be trained in investigation techniques. Safety and All HOD's 30/11/2019
Determine closure period of open points and monitor as KPI. All HODs, Safety and HR

Active Fire Protection System to be provided in the unit including detection and
Security, Mech., Thermal
suppression system. Currently, CHP area has fire protection system however 31/01/2020
and Safety
found was inadequate for such operation.

Emergency Control Center to be strengthened with adequate infrastructure. Security 31/12/2019

Emergency Preparedness plan to take inputs from PHA study. Safety
Emergency Planning
13 45% Emergency lighting to conform to NBC 2016 Electrical
and Response
Safety, Electrical &
Emergency exit marking to be strengthened.
Building 31/12/2019

Security, Mech., Thermal

Passive fire protection concept to be introduced. 31/01/2020
and Safety

CCW shall define relevant safety metrics to monitor and measure the
Measurements & effectiveness of the Safety management system and its constituent elements and
14 33% Safety Done
Metrics work activities.

A system shall be established and maintained to evaluate compliance with

relevant SMS requirements periodically. Safety & All HODs 31/03/2020

CCW may consider cross functional safety audits Safety Done

 Chanderia Cement Works
Action Plan- GAP ANALYSIS ON SAFETY MANAGEMENT SYSTEM - M/s Chola MS Report
S. Safety Management Element
Major Recommendations Responsibility Target Date
No. System Element Score
Compliance The list of recommendations / actionable items arising of this Gap Analysis study
15 31%
Audits may be tabulated with target completion date and compliance of the same shall Safety & All HODs 30/09/2019
be evaluated as part of implementing Compliance Audit element.

Define the periodicity of Safety Audits / Safety Inspections / Safety walkthrough

Safety
by Senior Management.
 Remarks

Through Corporate Evaluation

Format
Bi monthly

Monthly

Training provided for WPS.

 Remarks

Issued and training provided

Training provided for WPS.

Training provided

Quaterly Audit

During Shutdown
OHS Procedure
BCL:OHSP:11

As per Training Calender

ISD to develop system for

SOP & HIRA availability on
plant PC
Trainings for SOP
ISD to develop system for
SOP & HIRA availability on
plant PC
Annualy
 Remarks

One survey conducted and

report submitted.
It is also proposed
to conduct survey through
M/s Chols-MS

DMP prepared

Done at MCC and Sub-

Station
One survey conducted and
report submitted.
It is also proposed
to conduct survey through
M/s Chols-MS
Safety metrics/performance
is monitored through leading
and lagging indicators on
monthly basis.

As per ISO 45001

 Remarks

Monthly
 Chanderia Cement Works
Discussion Points
SAFETY CULTURE SURVEY- M/s Chola MS Report
S. No. Major Recommendations Action Plan
1 CCW may prepare a safety strategy plan for next 3 years with repect to Hard ware , Software. To prepare Safety strategy plan
2 Number of recommendations open from the audits, safety observations To be closed as per target date
3 Plant inspections to be carried out by senior management team. Periodically conducted

Safety shall be line function responsibility. Every department shall set its objectives and targets for to Safety responsibility to be defined across
4 ensure continuous performance towards safety management system. the organization
Safety performance integration with
5 Safety performance not integrated with Performance appraisal in all cadres. Performance appraisal

The recommendations from the Safety committee be documented with the target date,responsibility To be closed as per target date
6 and be circulated.The outcomes recorded in MOM to be tracked for closure.

Safety theme of the month be developed and all the events, discussions are campaigned around that Communication & Displayed
7 element or theme.
CCW shall ensure that employees participation is assured in activities Eg: Training, Incident reporting
8 Training already given by safety deptt.
and investigation, Work permit audit, Safety inspection and audit

9 Illumination study to be carried out. Monitoring to be carried out.

10 License needed for possession Acetylene gas cylinders exceed twenty-five at a time. To be obtained

Standard Operating Procedure shall be prepared for the Hazard Identification and Risk Assessment
11 Prepared as per ISO 45001
process.
 Chanderia Cement Works
Discussion Points
SAFETY CULTURE SURVEY- M/s Chola MS Report

12 OCP to be perpared for workind at height, Electrical Safety, Welding& cutting. Prepared as per ISO 45001

13 List of first aiders and their contact numbers to be displayed at vital areas. List to be displayed

14 The contract shall be awarded based on the safety performance of the contractor. Evaluation System to be developed

15 Nearmiss reporting, unsafe act, unsafe condition reporting to be strenghthened. Strengthening of Reporting
16 List of confined spaces to be maintained. List to be perpared
Training program or exams shall be conducted for the work permits Issuer and receiver and certify
17 Training already given by safety deptt.
them.

18 Emergency shutdown procedure not evident in CPP and other control room. Shutdown Procedure to be made

19 Permit handing over system to be implemented during shift change over. To be communicated.

20 Management of change procedure to be prepared Prepared as per ISO 45001

21 Contract employees not aware of emergency scenarios and its management. Emergency Management Training
A list of all HSE critical equipment (where an equipment malfunction or failure could have a
22 To be prepared
significant, adverse HSE impact) shall be prepared.
23 Develop a procedure for bypassing, including the categories and levels of approvals. Procedure to be developed
24 Lock out/tagout system implementation process in the facility to be expedited. Implemented in CCW & NCCW

Yearly Safety Training calender to be

25 CCW should have a safety Training Calendar in the plant. Trainings to be conducted as per the calendar prepared.
26 Emergency lighting shall be provided in the plant, To be provided at identified location.
A spare of 10% to be maintained for the fire extinguishers & other emergency equipments in the
27 To be procured
plant.
 Chanderia Cement Works
Discussion Points
SAFETY CULTURE SURVEY- M/s Chola MS Report
28 The emergency plans are to be prepared based on risk analysis. Disaster management plan prepared.

Traffic layout study shall be carried out for the facility to ensure safe movement of man and Traffic management survey to be
29 machine. conducted.

Fire hydrant system survey to be

30 Existing firefighting system to be strengthened. conducted.

31 Inspection and Maintenance procedure for each equipment to be developed and followed. Procedures to be developed

HIRA shall be discussed on the employee and contract level. Emergency Preparedness to be
32 Training has been started.
strengthened
 Target
Responsibility Remarks
Completion
Safety & All HOD 28/02/2020
Safety & All HOD As per target Continuous
Pressident With Monthly
All HOD &Safety
All HODs, HR & 31/01/2020
Safety

HR 31/03/2020

Before Next
Safety & All HOD Meeting

Safety & All HOD Quartely

Safety, HR & All Monthly

HOD

Electrical & 31/3/2020

Safety

With the help of

Store 31/03/2020 concerned mines deptt.

Safety & All HOD Done

Safety & All HOD Done

First aid training to be

MO & HR 31/12/2019 provided.
Purchase, Safety Tthrough Corporate
31/12/2019
& All HODs Evaluation Format
All HODs & 30/11/2019
Safety
Al HODs & Safety 31/10/2019

Safety Monthly

To prepare & Implement

CPP Head 31/10/2019
SOP

All HODs & 31/10/2019

Safety
OHS Procedure
Safety & All Done BCL:OHSP:11
HODs
Safety & HR 31/03/2020
Al HODs 31/12/2019
All HODs 31/12/2019
Electrical & Done
Safety
With the help of Corporate
HR & Safety 31/01/2020
Safety for external training.
Electrical 31/01/2020
Security & Safety 31/03/2020
Safety & Security Done
M/s Green Arrows Safety
management visited plant
Logistic, Security and preliminary report
31/03/2020 submitted. It is proposed
& Safety to conduct the study
through M/s Chola MS
also.
Fire hydrant system
survey has been
Security, conducted by the one
consultant and report
Mechanical & 31/01/2020
submitted. It is also
Safety proposed to conduct the
survey through M/s Chola
MS.
All HODS 31/03/2020
HR, Safety &
Core team 31/03/2020
members of the
concerned deptt.