Responsible Care

‘A Tool to
Change Safety Culture’
By R M Desai
NOCIL LIMITED
Mission Responsible Care in Gujarat 18.05.2018
Ahmedabad
 NOCIL - Company History / Milestones

1973 : Incorporated as “ Mindia Chemicals ” (MONSANTO IN INDIA)

1976 : Production of Rubber Chemicals commenced.
1981 : Merger with erstwhile “ Polyolefins Industries Limited ”(PIL)
1994 : NOCIL – PIL merger
1995 : ISO 9001
2001-2004 : ISO 14001 , ISO 9001- 2000 , OHSAS 18001
2009 : ISO /IEC 17025 – NABL Accredetation
2010 : REACH registration for 6 products
2012 : Dahej plant commissioned
2012 : TS – 16949 Certification
2017 : Chemicals Weapons Convention (CWC)
Site inspection by OPCW
2018 : Awarded „Responsible Care‟ Logo by ICC
 NOCIL LTD
INTRODUCTION
NOCIL‘s involvement in the Rubber chemicals
business spans over 4 decades. We are one of the
few players in this business to offer wide range of
rubber chemicals to suit the customer needs. Due to
our rich experience and offering a one stop shop to
customers, NOCIL is today acknowledged as a
dependable supplier of rubber chemicals. Globally
we are recognised for our technical capabilities and
on this aspect alone, NOCIL enjoys an edge over
other players in this business.

NOCIL has set up new manufacturing facility at Dahej

in Gujarat, with a much improved process technology
to strengthen our position in the field of Rubber
Chemicals. The said facility has started its commercial
operations in FY 2012-13.
 NOCIL - VISION AND MISSION

Vision
• We at NOCIL Limited are
committed to be a World Class,
Customer Focused, Innovative
Organization in the field of
Rubber Chemicals and partner
of choice to all our customers
across the globe.

Mission
• To innovate, build and operate
chemical plants in the most safe
and environment friendly
manner.

• NOCIL has very strong belief in

“Ethics of Excellence” which is
the Arvind Mafatlal Group’s
(AMG) business philosophy.
 NOCIL : LOCATIONS

Head Office / Mafatlal House , Backbay Reclamation,

Registered Office H T Parekh Marg
Churchgate,
Mumbai – 400020
Tel – 91-22-66364062
Plant 1 – Navi Mumbai C-37, TTC Industrial Area, Pawne Village,
Off Thane Belapur Road,
Navi Mumbai – 400705
Tel – 91-22-66730551
Plant 2 - Dahej Plot No 12-A-1, GIDC Industrial Area.
Dahej, Taluka Vagra, Bharuch,
Gujarat – 392130.
Tel – 91-2642-399201
 NOCIL : HIGHLIGHTS
Rubber Chemicals

 LARGEST MANUFACTURER OF RUBBER CHEMICALS IN INDIA

 ANNUAL TURNOVER – APP. 1000 CR

 EMPLOYS ABOUT 1000 PERSONS

 MAJOR RC SUPPLIER TO TYRE AND NON TYRE SECTOR

 SIGNIFICANT PRESENCE IN EXPORTS MARKET

 NOCIL : Product Range
Rubber Chemicals

 ANTIOZONANTS.

 ANTIOXIDANTS.

 ACCELERATORS.

 PRE VULCANIZATION INHIBITOR.

POST VULCANIZATION STABILIZER.

 NOCIL : RESPONSIBLE CARE JOURNEY
JOURNEY

2018

2010

2005
2004

2001

1995

QMS EMS OSHA NABL IMS RESPONSIBLE CARE

 NOCIL : RESPONSIBLE CARE JOURNEY

RESPONSIBLE CARE JOURNEY

1. „RC Undertaking „ signed on 23rd February 2015
2. Top Management Team meeting held on 9th June 2015
3. Code owners nominated.
4. 1st GAP audit in July 2016
5. 2nd GAP audit in August 2017
6. Application to ICC inviting for RC audit - 8th September 2017
7. Final RC audit on 20th to 23rd November 2017
8. RC Logo Awarded – January 2018
 NOCIL : RESPONSIBLE CARE JOURNEY

RESPONSIBLE CARE - CODE AND OWNERS

1 Process Safety – Asst. V P - Technology
2 Employee Health & Safety – V P – Operations, Corporate HR
3 Emergency Response – D G M - EHS
4 Pollution Prevention – V P – R & D
5 Product Stewardship – V P – Quality Assurance
6 Distribution – Asst. V P – Purchase and A V P - Sales
 EMPLOYEE HEALTH AND SAFETY CODE

SAFETY
 HSE Policy.
 Department and Central Safety Committees.
 Permit and other Safety Procedures.
 Job Safety Analysis – ‘Do Minute Ki Soch’.
 Safety Audits.
 Incident Investigations.
 Weekly Mock Drills.
 Safety Training.
 EMPLOYEE HEALTH AND SAFETY CODE

HEALTH
 Pre-employment Medical Check.
 Periodic Medical Check-ups.
 Health Trend Analysis.
 Employee Counselling.
 Factory Medical Officer / Nurses.
 Awareness Training Programs.
 EMPLOYEE HEALTH & SAFETY CODE
Daily safety Oath in all departments.

12.07.2017 15
 EMPLOYEE HEALTH & SAFETY CODE

Daily safety oath & safety Talk to contract

employee.
• Daily safety oath and safety talk is
administered to contract employee
near contractor shed.
• Everyday different Contract labor is
called to administer safety oath.
• Every day safety talk on identified
topics like PPE, Use of ladder,
Electrical equipments etc.
• Recent Incidents are communicated
by person involved in the
incident/officer.
• Communication of type of
emergency sirens and actions to be
taken on hearing of siren.
12.07.2017 16
 EMPLOYEE HEALTH & SAFETY CODE

In-Plant Safety Rally

Safety rally is undertaken every year to

boost safety awareness among
employee.

Salient features of the rally

1.All employees including contract
employees participate in the rally.
2. Safety slogans are enchanted.
3.Cut outs showing safety messages are
displayed.
4.Rally covers entire plant area..
 EMPLOYEE HEALTH & SAFETY CODE
Safety in Gatherings.
Annual gatherings safety is ensured through pre
checkups by admin dept. as per formulated
checklists.
Salient features
• Transport arrangement after the celebrations to
ensure no drunk & drive.
• Arrangement to drop lady members to their
respective locations.
• Suitable & clearly marked night glow exits for
the place of celebrations.
• Fire fighting equipments in place, etc.
• Control on alcohol.
NOCIL LTD, NAVI MUMAI
CHECKLIST FOR GATHERINGS
(To be filled in by Admin dept. where expected participants are more than twenty five)
Date: -----------------------
General information
Name of Event: ---------------------------------------------------------------------------------------------------
Event Date: ---------------------------Place of event: ---------------------------------------------------------
Approximate no. of people gathering for the event: ----------------------------------------------------
Approximate number of cars expected at the events:…………………………………………………………
Description. YES/NO/NA
1 Is necessary permissions from local police station are obtained by operator/organiser for
Public announcement system for off the site programmes?
2 Is necessary communication to traffic department made by place owner/organisers?
3
4
5
Adequate barricades are provided for no entry for general public.
Adequate security arrangements have been made.
Adequate Parking arrangement/ restrictions on vehicle entry.
6 Parking bay connected with separate PA system to call drivers during emergency.
7 The making of pandal, stage/desk has been carried out by reputed vendor to ensure its
stability.
8 Adequate railings are provided for stage/staircase if height is more than 1.8m.
9 1m wide walkways are kept at the middle and both sides of seating arrangement.
10 Row of maximum 10 chairs is maintained between two walkways. Additional walkway shall
be considered for wider places
11
12
Distance of 1.5 feet is maintained from front chair for swift movement during an
emergency.
Row of maximum 10 chairs is maintained between two walkways. Additional walkway shall
13
be considered for wider places
At least two EXIT ways are available and clearly marked with nightglow stickers(for
programme extending after sunset)
14 The staircase, walkways, passages are free from obstacles.
15
16
Arrangement for adequate illumination made for programmes extending after the sunset.
Electrical installations in the area are as per the electrical standards (E.g. use of pins sockets,
no open ends/naked joints of electrical wire, no freely layed wires on the ground etc.).
17 Transport arrangement after the celebrations to ensure no drunk & drive.
18 Arrangement to drop lady members to their respective locations.
19
20
Control on alcohol ensured by nominating of observer volunteers.
Availability of wiremen having knowledge of electrical isolation switches throughout the
programme.
21 Power back up arrangement with DG set.
22 Type of emergency communication and actions to be taken in case of emergency shall be
made known through announcement prior to beginning of programme.
23 Adequate emergency squad members available at plant if event location is away from
site.
Checked by Officer- Employee welfare and P&A
 EMPLOYEE HEALTH & SAFETY CODE

List of Surveys done under Health and

Safety

List of Surveys Done

• Illumination survey is
carried out in the factory
once in a year.
• Ventilation survey has been
carried out in the factory.
• Noise survey is being
carried out in the factory on
quarterly basis.
 EMPLOYEE HEALTH & SAFETY CODE
Safe Attitude Encouragement Rounds

Salient features of SAE.

SAFE ATTITUDE ENCOURAGEMENT (SAE) S&E:F:13 09/17

Name of Observers : Date of observation : Time of observation :

1. Unsafe act is captured and corrected on 1.

2.
-------------
------------

the spot by counselling. Locati

on.
ITE
M OBSERVATIONS Tick appropriate Unsafe Act

2. Politely enquire his name and

No.
Working without authority/ Permit
Failure to lock out.
Failure to secure

department. Explained him with Operating at improper speed/haste/hurry.

Making safety devices inoperable

consequences of unsafe acts.

Removing safety devices
Using defective equipment
Failure to use PPE
Improper placement on the job.

3. Get assurance by oath that he will not Improper lifting

Improper position for task
Horseplay

repeat the unsafe act.

Under influence of alcohol and/or other substances
Other (specify)

4. Ask & record his three colleagues name

Guidelines for observations during SAE rounds

 PARIKRAMA : Take an observation round of the plant/unit.


to whom he will tell about unsafe act
PRASHNA : Ask the question to observe whether he is safe.
 PRASHANSA : Praise for his safe behavior to reinforce.
 PARIVARTAN : Unsafe acts during the ongoing jobs to be captured and corrected on the spot


and consequences.
by counselling.
 PRASHIKSHAN: Educate importance of safe behavior & awareness w.r.t.
 Identification / segregation / collection of scrap / waste in the designated containers of
scrap / waste items.

5. Explain him details of emergency sirens  Mitigation actions to be taken for leakages / spillages.
 Use / conditions of PPE being worn ( helmet, goggles, shoes , mask etc )
 Type of sirens

, location of nearby MCP and actions to  Action to be taken during the emergency situations.
 Location of nearest manual call point.
 Location of nearest extinguisher.

be taken on hearing of siren. 

 Location of assembly points.
 Location of wind soaks.
PRATIGYA : Take a oath from him that he will not repeat the unsafe act.
 PRACHAR : Ask observe to tell his three colleagues about the unsafe act and consequences..
 note down names of his three colleagues.
 PRARTHANA: Repeatedly request for safe behavior.
12.07.2017
 EMPLOYEE HEALTH & SAFETY CODE

Safe Attitude Encouragement Rounds

Guidelines for observations during SAE rounds

• PARIKRAMA : Observation round of the plant/unit.

• PRASHNA : Ask the question
• PRASHANSA : Praise for safe behavior
• PARIVARTAN : Counselling and Correction
• PRASHIKSHAN: Educate importance of safe behavior
• PRATIGYA : Take a oath
• PRACHAR : Ask to tell three colleagues
• PRARTHANA : Repeatedly request for safe behavior.
12.07.2017 21
 EMPLOYEE HEALTH & SAFETY CODE

Cardinal safety Rules

Cardinal Safety Rule: The cardinal safety rules are those
that, if violated, present an immediate risk to life
safety. These include:

• Confined Space Entry procedure

• Lock-out/Tag-out procedure CARDINAL SAFETY
• Hot Work Permit procedure RULES
• Elevated Work / Fall Protection Requirements Formulated By
• Overriding of safety interlocks or critical to safety Corporate HSE

equipment
• Non attending of weekly drills/emergencies by squad
member
• Failure to enforce the cardinal safety rules listed above
• Failure to report a violation of the cardinal safety rules listed
above.
12.07.2017
 EMPLOYEE HEALTH & SAFETY CODE

Other Policies developed under the

umbrella of Safety and Health

Following policies are developed

• No Smoking Policy

• Alcohol Policy
ASBESTOS POLICY
Formulated By

Corporate HSE

• HIV policy.

• Asbestos policy.
 EMPLOYEE HEALTH & SAFETY CODE
Safety Committee Formation and Agenda
Safety Committee
Central safety committee formed once in two years by
selection.
Central safety committee is chaired by Factory Manager
and Safety officer is designated secretary of the
committee.
Equal members from management and non management
staffs.
Factory medical officer is member of the committee and
acts as alternate secretary to safety officer.
Central Safety committee meets every quarter to review
safety status and discuss safety issues.
Department safety committees meets six times a year.
12.07.2017 24
 EMPLOYEE HEALTH & SAFETY CODE

Safety Publications

Monthly safety bulletin

12.07.2017 25
 EMPLOYEE HEALTH & SAFETY CODE

Safety and Health Literature

List of Pamphlets
• Guidelines for pre monsoon
checkups.

• Diwali crackers Safety.

• Fire service day bulletin.

• HSE diaries containing information

on safety
 EMPLOYEE HEALTH & SAFETY CODE

Safety Week Celebration

Safety Week Celebrations

• Various competitions are organized as follows.

 Safety Quiz.
 Fire Hose Drill competition.
 Safety slogan. (In English, Hindi and Marathi).
 Safety Poster.
 Use of Chlorine kit by Breathing Apparatus Set (BA
Set) Donning Competition.
 Stage play (Skit) on HSE
 EMPLOYEE HEALTH AND SAFETYCODE

OHC Infrastructure
OHC Infrastructure
The OHC is spread over 450 square feet with
walls made up of smooth and impervious
surface with adequate illumination and
ventilation.

OHC comprises of:-

• Factory Medical Officer‟s consulting room –

90 sq feet.
• Nursing Station & Pathology Lab – 170 sq
feet.
• Treatment & Observation room – 155 sq
feet.
• Rest room & Shower - 1
22/05/2018
 EMPLOYEE HEALTH AND SAFETY CODE
Key Health Initiatives
Sr. No. HEALTH INITIATIVES

1 Hepatitis B Immunisation of Health care providers

2 Malaria Chemoprophylaxis of security guards
3 De-worming of regular contract employees
Awareness program on de-addiction of Alcohol/ Tobacco /Smoking / Drug
4
Abuse
5 Awareness talk on personal hygiene for canteen workers
6 Heat Stress awareness talk for boiler operators

7 3D stereo optic vision and Glaucoma test of fork lift drivers

8 Eye check of company drivers.

22/05/2018
9 Tetanus Toxoid (TT) for garden employees
 EMPLOYEE HEALTH AND SAFETY CODE

Antidotes

ANTIDOTE FOR

Methylene Blue Aniline

Anti Snake Venom Snake Bite

Atropine/Vitamin K Garden/Household Pesticide

 EMPLOYEE HEALTH AND SAFETY CODE

Talk on Heat Stress – Utilities Operator

22/05/2018
 EMPLOYEE HEALTH AND SAFETYCODE

Stress Management, Yoga, Proper Diet & Naturopathy

22/05/2018
 EMERGENCY RESPONSE CODE
EMERGENCY RESPONSE
 On Site Emergency Plan.
 Emergency Control Centre.
 Public Address System.
 Hydrant Network.
 Sprikler Network.
 Adequate Water / Foam Storage.
 BA / ELSA Apparatus.
 Ambulance.
 Trained First Aiders.
 Mock Drills and Training.
 Table Top Mock Drills.
 EMRGENCY RESPONSE CODE
Emergency Action flow Chart
OVERVIEW OF “ON
OVERVIEW OF SITE
ON SITE EMERGENCY
EMERGENCY CONTROL
CONTROL PLAN”
PLAN

Emergency MAIN SIREN IN THE FACTORY

Site FIRE SIREN : Wailing type with four fluctuations. Duration : approx. 30 seconds.
GAS SIREN : Continuous siren with shrill pitch. Duration - 30 seconds.

Raising The Fire Pump Monitors Hydrant/deluge Pumps

Person Discovering Alarm Utility/ Boiler Operator House and water pressure

To keep ready Emergency vehicle. Takes instructions

Control the Incident Ambulance Driver / Stand by from ECC and reports to the site of emergency,
Trained Employee Transports casualties to OHC/ outside hospital

Emergency Management
Incident Controller To be ready in respective MCC/work stations and take instructions
Emergency Squad Electrician/ Mech. from IC to Cut-off Power Supply/steam/HO of area in Danger,
Members  Area / Shift In-charge
technician provide skilled technicians to isolate the leak etc.
 Firemen/ Fire squad  Safety Officer
members
- Announce the location on the Public Address System.
 First Aiders - Assign watchmen to front and rear gate to man for selective entries.( Fire
Security
brigade, Govt. Authorities, Doctors, etc. ),to guide them to OHC or
Emergency Supervisor emergency site and to assist supervisors in cordoning of the emergency
Controller area.
 Dy/Head Ops / Call Declaration Of Major
INJURIES duty officer Hazard Situation and To inform Management Authorities and Out Side Agencies
Occupatiuonal Health Evacuation as per Directives from Emergency Controller
Takes Charge OF ECC
Centre :. 351/345
All those not directly connected in Emergency Control Operation reports to the evacuation
Dr. Trilochan Singh P&A assembly points via safe route as guided by Public Address System
(M) : 9820235077 To control Outsiders, press Assembly Point No. 1 : Lawn in front of New Administration Building
at gate. Head count assisted by Assembly Point No. 2 : Near East Security gate. Head count
Dr. Sunil Kaushik
(M) : 9821310106 respective supervisors

Jaydish Nursing Home,

ALL CLEAR
Vashi :022-27890849 On information from IC after testing and inspection of the affected area
/0637 GOVERNMENTAUTHORITIES CONTINUOUS SIREN : DURATION 60 SECONDS
1. D. I. S. H. Thane Office.
MGM Hospital,Vashi 2. M. P. C. B. Regional Office
02227824618/ 2461 3. Dist. Collector’s Office, Thane
Sterling Hospital, Vashi 4. Police Station, Turbhe. Emergency Help
02227820371/ 7007 1.Emergency Response Station (Pawne):022-27780207/27780208
18.11.2017 2.NMMC Fire Brigade :Tel. No. 02227660101
34
 EMRGENCY RESPONSE CODE

SIREN PROTOCOL

FIRE SIREN 30 seconds

6 6 6 6

2 2 2

GAS SIREN (Shrill pitch)30 seconds

ALL CLEAR SIREN 30 seconds

35
EMRGENCY RESPONSE CODE
Visitor‟s Safety Instruction card.
 EMRGENCY RESPONSE CODE
Visitor‟s Safety Instruction card.

18.11.2017 37
EMRGENCY RESPONSE CODE

PROCESS HAZARD &

EMERGENCY BOOKLET
EMRGENCY RESPONSE CODE

Tanker Emergency Kit.

EMRGENCY RESPONSE CODE
Trainings on Emergency.

 Hose Drill Signals

 EMRGENCY RESPONSE CODE
Potential Emergencies.

Potential emergencies

Release of chlorine gas.

Fire/Explosion due to leakage of hydrogen

from pipeline/trolley

Release of H2S from MBT autoclave

glands/pipeline.

Fire at tanker during unloading of CS2

EMRGENCY RESPONSE CODE
Community

N
 EMRGENCY RESPONSE CODE

Community Awareness Trainings.

Community Awareness Trainings.

• Training programme on house

safety with special reference to
LPG was conducted for ladies of
nearby Pawne Village.

• Training programme on creating

awareness on chemical safety
and chemical hazards was
conducted for representatives of
neighboring industries.
 EMRGENCY RESPONSE CODE

Community Welfare Forum.

Community Welfare forum

• To identify & act on community

concerns.
• To undertake various community
Training programmes
• First meeting held on 11.09.2017
• Members
 Social worker.------Chairmen
 Local Corporator.- Secretary
 School principal.
 Medical officer-Pawne Arogya
Kendra.
 M/S NOCIL.
 M/S RPGLS.
EMRGENCY RESPONSE CODE

Community Awareness Trainings.

Training programme on fire safety at

Municipal school Pawne village
 EMERGENCY RESPONSE DOCE

Mutual Aid with neighbouring companies

Mutual Aid Agreement

• Mutual Aid agreement
with M/S BASF

• Mutual Aid agreement

with M/S SI in progress.

18.11.2017 46
 EMRGENCY RESPONSE CODE
MARG (Mutual Aid Respons Group)

Mutual Aid response group (MARG)

• Group members are safety professionals from nearby industries.

• Annual mock drill schedule for member industries in place.

• Jt. director DISH and MARG members are invited for mock drills.

• Sharing of incidences.

• Safety audits for member industries carrying out solvent purification by

distillation units.
 OTHER INITIATIVES

NO INITIATIVE CODE
1 Recovery and recycle of catalyst from waste water in TDQ plant PP
2 Recovery and recycle of Aniline from waste water in TDQ plant PP
3 Recovery and recycle of Butanol from waste stream in PVI plant PP
4 Phased out NH3 chiller PP
5 Replacement of Glycol chiller with self-tube cleaning type energy efficient PP
chilllers
6 Replacement of Freon based refrigerant to environment friendly refrigerant PP
in Utility.
7 Fuel changeover from LSHS to PNG in hot oil heaters PP
8 Solar Power Generation at Dahej PP
9 Solar lighting – Skytubes in warehouse. PP
10 Rain water collection system for workshop building PP
 OTHER INITIATIVES

NO INITIATIVE CODE
11 Recycle and reuse of waste paper by converting it into useful stationery (in PP
association with an NGO)
12 Contribution towards plantation of 1500 trees in Thane / Kalyan region. PP
13 Sewage Treatment Plant using Soil Bio Technology (SBT) PP
14 Convert canteen waste into manure by bio-composting EHS
15 Training of drivers / Transporters DIS
16 Separate Rest Room for Drivers/Cleaners
17 Installation GPRS based vehicle real time tracking system by 8 transporters DIS
18 Tankers / Trucks „Journey Management Plan‟ DIS
19 Developed in-house team to carry out HAZID, HAZOP & HAZAN. PS
20 Implementation of Prestart up Safety Review System (PSSR) PS
Ethics of Excellence