Dr. K. R.

Balasubramanian
Associate Professor
Dept. of Mechanical Engineering
National Institute of Technology
Trichy
 How Safety Evolved?????
1900 :-
 Invention and application of new tools for mass production brought
danger.

 Fatality due to industrial accidents were more than the world war .

 Employers ignored the problem as a disabled worker could be easily

replaced and wages were low.

 Workers and managers believed that accidents were inevitable.

 Accident was considered as an "act of god”(it was a time when people

believed that sickness was the result of evil spirits or a curse of god).
 1930 :-
Accelerated the upward trend of serious
and fatal injuries. The news papers became
interested and published more details about
serious cases which made public interest
grew on safety.
1940 :-
productivity
Safety and productivity was looked as two
sides of the same coin.
Safety
• 1941 :-
Organization called American Conference
of Governmental Industrial Hygienists was
formed.
• 1944:-
The Threshold Limit Values for Chemical
Substances (TLV®-CS) Committee was
established.
• 1948:-
Indian full factories act was passed and
came into force from 1st April,1949.
 1980:-
Awareness to eliminate or reduce the occupational diseases was
evolved.

PRODUCTIVITY
 1996:-
ISO 14001 environment management system was evolved.
 1999:-
The OHSAS 18001 standard was developed to bridge the gap
where no international standard existed for occupational health
and safety.
2010 onwards….
Now, Safety is looked as an integral part of business.
More focus has been made in implementing successful
Safety Management Safety and to improve safety culture
LOOK AT THE MAN CROSSING THE ROAD!
Bad Day 2.mpg
 ACCIDENT
AS PER IS 3786/1966

IT IS AN UNINTENDED, UNEXPECTED AND

UNPLANNED EVENT WHICH MAY OR
MAY NOT CAUSE AN INJURY
 FACTS ABOUT ACCIDENT
Humans are responsible for most Accidents
5000 accidental deaths annually
4 million disabling injuries annually
Staggering costs to organizations
Health of workers is harmed by toxic chemicals
and Workplace conditions
Accidents are the primary cause of death on the job and
murder is only second
ACCIDENT DATA

UNSAFE CONDITION-10%

UNSAFE ACT -88%

SOCIAL ENVIRONMENT-2%
 Unsafe condition
Unsafe condition is one in which the tools,
work environment and machine is in full of
hazards leading to accidents .

Example
•Oily floor
•work platform without hand rail
•Unguarded machinery
 UNSAFE ACT
Unsafe act is the violation to commonly
accepted safe work practices i.e breaking
of safety rules.
Example
•Smoking in flammable area,
•Over speed - rash driving?
•Tampering with safety device
•Not using PPE
•Unauthorized working
It is comparatively easy to eliminate unsafe conditions. But it
is difficult to control unsafe acts, for, this involves people. A
large number of unsafe acts are due to:

1. Ignorance of a hazard

2. A physical deficiency for the job

3. Lack of sufficient skill to work in the safe way

4. Wrong attitudes
Safety Education

- the only answer to wrong attitudes

But wrong attitude are the most difficult to be cured.

These include:

• Negligence to use Safety appliances, absent mindedness,

overconfidence, haste, impatience, urge to take chances, lack of interest in
job, disregard for safety of others and fatalistic attitudes.

• Safeguards and Safety appliances do not give protection against wrong

attitudes

• Unsafe acts springing from these could only be checked by instituting

suitable programmes of Safety Education.
Safety Education (Contd…)
Then there are hazards which cannot be guarded by providing
any Safety device

Case study
A man walking under a suspended load. No Safety
device can stop him from doing it. He must stop
himself. This is true also about reaching into a
running machine. No written Rule or Safety Switch
can prevent a person from putting his hand into the
machine before it has come to a standstill.
Foundation of a major injury:

In the year 1939, Heinrich analysis proves that, in the average case,
for every mishap resulting in an injury, there are many other similar
accidents that cause no injuries whatsoever.

As per Heinrich analysis, in a Unit-group of 330 accidents of the same

kind and involving the same person, 300 results in no injury, 29 result
in minor injury and 1 result in major injury.

This ratio of 1:29:300 applies to the average case.

- H. W. Heinrich (1928)
Foundation of a major injury:
Then, Frank Bird, in the year 1966, and James Tye & Peterson, in
the Year 1974, analysed the accidents. Their findings are given
below:

- Frank Bird (1966)

Foundation of a major injury:

- James Tye & Petersan (1974)

MINOR ACCIDENT

MINOR ACCIDENTS:

SUCH AS PAPER CUTS TO FINGERS OR

DROPPING A BOX OF MATERIALS
MAJOR ACCIDENT

MAJOR ACCIDENT

SUCH AS A FORKLIFT DROPPING A LOAD OR

SOMEONE FALLING OFF FROM ROOFTOP
OCCUPATIONAL DISEASES

ACCIDENTS THAT OCCUR OVER AN

EXTENDED TIME FRAME:

SUCH AS HEARING LOSS OR AN ILLNESS

RESULTING FROM EXPOSURE TO CHEMICALS
Fallacies about safety
1. I am too busy to give attention to safety matters

2. I have given everything to my worker. It is for him to do the work

safely and with more care.

3. Production is affected by adhering to the safety rules. The work will be

slowed down and the worker may take his own time to complete the
work safely.

4. We may say that so many safety regulations are to be followed, but, in

practice, it will not be possible to adhere to them

5. It is the responsibility of safety engineering department to ensure that

safe practices are followed in the shop by the workmen as I have to
concentrate on production
Fallacies about safety (Contd…)

6. If an accident has to happen, it will definitely happen. It is not in our

hands.

7. The workers never listen to us on safety matters. So, the Safety

Engineering department must go round and insist.

8. Devoting time to safety is not liked by my superiors as it takes away

most of the time form production work
Philosophy of Accident Prevention

“Accident prevention is both science and an art. It

represents, above all other things, control – control
of man performance, machine performance and
physical environment.

The word CONTROL is used advisedly because it

represents prevention as well as correction of
unsafe conditions and circumstances”

- H. W. Heinrich
Philosophy of Accident Prevention (Contd…)

The elimination of accidents is vital in the nation’s

progress.

Accidents produce economics and social loss,

impair individual and group. Productivity, cause
inefficiency and retard the advancement of
standards of living.
 INDUSTRIAL ACCIDENT

WITH INJURY WITHOUT INJURY

FIRST AID INJURY LOST TIME INJURY

REPORTABLE ACCIDENT NON-REPORTABLE ACCIDENT

NON-REPORTABLE ACCIDENT
Less than 48 Hrs Disablement
REPORTABLE ACCIDENT
More than 48Hrs Disablement

MINOR ACCIDENT MAJOR ACCIDENT FATAL ACCIDENT

Less than 21 Days Morethan21Days 6000 Man days Lost
Disablement Disablement
DISTRIBUTION OF FATAL ACCIDENTS
IN CONSTRUCTION SITE
• Fall of person 74%
• Lifting equipment 7.4%
• Fall of material 5.4%
• Electrical 3.3%
• Transport 3.1%
• Machinery 1.5%
• Excavation 1.3%
• Fire and explosion 0.8%
• Poisoning and gassing 0.8%
• Others 2.4%
 CHANGING NATURE OF
HAZARDS
Accidents increase as excavations go
deeper or walls grow higher, so what
was safe yesterday may no longer be
safe today.
 COST OF AN ACCIDENT
To the victim
 pain
 worry
 no recreation
 loss of wages
 loss of limb or life
 medical expenses
 inability to perform normal work
 TO THE MANAGEMENT
Direct cost

 medical expenses
 compensation to the worker
 time lost by employees
 reduction in productivity
 TO THE MANAGEMENT
Indirect cost

 production delay
 loss of morale
 cost of training another employee
 repair cost
 loss of prestige
Accident Causation Models
1. Domino Theory
2. Revised Domino Theory
3. Energy Release Model
4. Accident Proneness
5. Epidemiological Model
6. Multilinear Sequencing
7. Ergonomic Models
8. Swiss Cheese Model
9. Universal Model
Domino
Theory
Revised Domino
Theory
 ANALYSIS
GROUP
1.NATURE OF INJURY
CUT, FRACTURE,BURN,CONTUSION,SPRAIN ETC

2.PART OF BODY
HEAD,EYES,BODY,HANDS,LEGS,ETC

3.TYPE OF ACCIDENT
STRUCKBY, STRUCK WITH, FALL OF PERSON, FALL OF OBJECT, CONTACT
WITH ,ETC

4.AGENCY OF ACCIDENT
CHEMICALS,MACHINES, TOOLS,EQMTS, FLOOR,AREA ETC
 ACCIDENT REPORTING
SN TYPE OF FORM USED PERIOD SEND
O ACCIDENT TO

1 ALL TYPE ACCIDENT 24 HRS SAFETY

REPORT DEPT

2 REPORTABLE FORM 18 60 HRS SD-IF

ACCIDENT

3 DANGEROUS FORM 18-A 12 HRS SD-IF-

OCCURANCE CIF

4 FATAL FORM 18 12 HRS SD-IF-

CIF
 ACCIDENT PREVENTION
METHODS- 4 ES
•ENGINEERING REVISIONS
• 1.APPLICATION OF MODERN TECHNOLOGY
• 2.NEW TECHNICAL DEVELOPMENT
• 3.MODIFICATION OF SYSTEMS
• 4.MECHANISATION

•EDUCATION &TRAINING
• 1.BASIC TRAINING
• 2.SPECIAL TRAINING
• 3.REFRESHER TRAINING
 ACCIDENT PREVENTION
METHODS- 4 ES
•ENTHUSIASM&ENCOURAGEME
NT
• 1.SAFETY AWARD SCHEME
• 2.SAFETY INCENTIVE
• 3.SAFETY COMPETITION
• 4.RISK ALLOWANCES
•ENFORCEMENT & DISCIPLINE
• 1.PUNISHMENT
• 2.MEMO & CHARGE SHEET
• 3.WARNING LETTERS
 FACTORS INFLUENCING
SAFETY AT WORK-PLACES
– Material Factors
– Policies & Practices
– Safety Related Conditions
– Behavioural & Attitudinal
– Level of Concern for Safety & Welfare
– Others
FACTORS INFLUENCING SAFETY AT WORK-PLACES

• Material Factors:
•Plant Design
•Production Equipment
•PPE

• Policies & Practices:

•Safety Priorities
•Safety Training
•Enforcement
•Daily Routines
•House keeping
FACTORS INFLUENCING SAFETY AT WORK-PLACES

• Safety Related Conditions:

•Work Stress
•Social Relations

• Behavioural & Attitudinal:

•Personal motivation
•Safety Knowledge
•Optimism
•Risk Justification
•Fatalism
•Apathy
FACTORS INFLUENCING SAFETY AT WORK-PLACES

• Level of Concern for Safety & Welfare

• Management
• Supervisors
• Safety Specialists
• Government Inspectors
• Safety Committee
• Workers Themselves

• Others
• Age
• Experience
• Qualification
• Job Category
Measures for Safety in an Organization
• Management Commitment To Safety
• Safety Communication
• Safety Training
• Safety Promotion Policies
• Safety Rules & Procedures
• Workers’ Involvement
• Work Environment
• Safety Knowledge
• Safety Attitude
• Safety Priority Over Production
• Safety Compliance
• Safety Participation
• Emergency Preparedness
 HOUSE KEEPING
• A place for everything and everything in
its proper place
• House keeping day
• Daily cleaning after the work
• Protruding nails
• obstruction,
• Lighting
• approaches
 PERSONAL PROTECTIVE
EQUIPMENT
• Safety belt
• Hard hat
• Safety shoes
• Gum boots
• Goggles and gloves
• Ear protection
And
• Respiratory protective equipment
RESPIRATORY PROTECTIVE
EQUIPMENT
• SCBA
• Dust mask
• Canister mask
• Air line apparatus
 Successful accident
prevention program
• Depends on
– Leadership by the employer
– Safe and healthy working conditions
– Safe work practices by employees - sop
Thank you