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HOW TO ACHIEVE ZERO ACCIDENT

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TOOLS TO BE ADOPTED
SAFETY AUDIT
SAFETY TRAINING
TESTING OF CRITICAL EQUIPMENTS
CONTRACTORS REGULATION
PRE-COMMISSIONING INSPECTION
MOTIVATION
ACCIDENT INVESTIGATION
FREQUENCY RATE / SEVERITY RATE
LAYOUT
EMPLOYEE PARTICIPATION
EMERGENCY PREPAREDNESS
LEGAL REQUIREMENTS
FIRE SAFETY
CHEMICAL HANDLING
COMMUNICATION
PERFORMANCE MEASUREMENT
COMMITTEE MEETING
ACCIDENT REPORTING
WORK PERMIT SYSTEM
ELECTRICAL SAFETY
WORK PLACE HYGEINE 2
FAMILY PARTICIPATION
ACHIEVING ZERO ACCIDENT THROUGH
SAFETY AUDIT

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SAFETY AUDIT
Foreword :

Safety audit is a very vital tool among all others


where the performance of all other tools can be checked

Purpose :

•To identify unsafe conditions / unsafe practices


•To find out ways and means to implement preventive measure
•To ensure employee participation in accident prevention
•To evaluate& compare the safety performance level within
departments
•To register the upward communication on safety issues
•To create a safe work place 4
SAFETY AUDIT
Methodology

• Prepare checklist for conducting audit


• Identify key persons to conduct the conduct the audit
• Adequately train them
• Select a department / unit
• Conduct the audit once in month comprehensively
• Record the findings in the format
• Present them in the Safety committee meeting
• Suggest countermeasure and preventive measure
• Send minutes of meeting to the concerned HODs
• Follow the progress of action
• Re-audit the same if the non-conformities existing
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SAFETY AUDIT
Methodology
Prepare checklist for conducting audit comprising :
•Machine guarding
•Safety switches
•Layout of machines
•Material handling equipments
•Electrical safety
•Fire fighting equipments
•Training and knowledge of operators
•Chemical handling
•Safety communication
•Storage of materials
•Work environment hazards
•Contractors regulation
•Accident reporting
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SAFETY AUDIT
Methodology

• Prepare checklist for conducting audit comprising :


•Work environment hazards
•Contractors regulation

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SAFETY AUDIT
Evaluation of Safety performance :
•Overall checklist may not have the details
•Specific area (eg., material handling ) must have
detailed checkpoints
•Auditors with overall checklist with broad headings
should be trained in as a whole
•Auditors should rate the department in 1 to 10 scale
where 1 is poor and 10 is excellent.
•Scores may be displayed in a board in the unit to
propogate
•Record of non-conformities observed must be
discussed in the committee meeting to arrive at a
solution
•Re-audit should start with the status of the previous8
audit non-conformities
SAFETY AUDIT
Methodology

•Key persons who can be an auditor


•Safety Officer
•Group of Managers / Supervisor
•Group of Safety committee members
• Group of Cross functional experts

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SAFETY AUDIT
Methodology

•Quality required for an auditor


•Well experienced in any one of the field of audit criteria
• Trained in the hazard identification techniques
• Should find the facts not the faults
• Un-biassed
• Seek for an objective evidence
• Good listener

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SAFETY AUDIT
Machine guarding checklist should contain the following :
• Is there any mechanical damage to the guarding ?
• Is machine running without guard exposing any potential
hazards ?
• Is guard designed and fixed inadequately ?
• Are doors and panels open ?
• Observed any guards placed on unwanted locations ?
• Are the trip guards functioning well ?
• Are the automatic guard limit switches functioning ?
•Are there any guards intentionally removed from m/c ?

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Furnace lid guarded 12
Additional / accurate Stopper to avoid over-ride of tilting furnace
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Base of the furnace tilting furnace tied with chains to avoid toppling
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Rigid guard provided to avoid injury to the abdomen 15
Pedestal fans provided with mesh 16
Machine guard removed from machine
Large gap between guards which gives access for burr flying
Large gap in between moving parts which will cause sever finger injur
Evidence of operating the drilling machine with gloves in hands,
which will lead serious hand injury
Protrusion of allen screw in revolving spindle,
which will cause for hand injury
Open rear side of a machine
Properly guarded ( painted in zebra, and interlocked)machine
Point of operation provided with a fixed guard,
to prevent finger injury
One of the doors open while operation due to malfunction
of trip switches
Evidence of poor maintenance of safe switches - Gear shift rod
tied with string
Large gap in between moving parts which will cause sever finger injur
Heavy tool on the loader which may slip while high rotating speed
Machine provided with guard but not adhered
Accumulation of loose cloth near revolving machine
Evidence of poor maintenance of safe switches - Gear shift rod
tied with string
SAFETY AUDIT

Safety switches :
1. Two hand switches
2. Trip switches
3. Emergency switches
4. Automatic guard limit switches
5. On / Off switches
6. Hand control valves (Air / Hydraulic
7. Foot pedal switches
8. Pull - cord switches
9. Proximity switches

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SAFETY AUDIT
Safety Switches checklist should contain the following :

•Are the two hand switches giving access for


one hand operation ?
•Any switch made inoperative ?
• Any safety switches shorted electrically ?
• Is the location of various switches and the valves
give access for accidental operation ?
• Is the emergency switch is of mushroom headed type?
•Are the other switches are flush type of switches ?
•Is the foot pedal switch fixed rigidly ?
•Are the proximity / limit switches functioning always
•Are the panel board located at hip level of operator ?
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Wrong design of
Two hand switch
And no guard

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Correct design of
Two hand switch
And guard

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Wrong method of
Operation posing fo
injury

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Correct method of
Operation with
Two hand switches

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Properly located flush type switch for cycle-on and mushroom
headed switch for emergency stop
Unsafe locations of valves which may cause hand injury
due to running spindles
Mushroom headed switches gives access for accidental touch
which may cause fro hand injury
Wrong method of operation under a tilting loader 41
Correct method away from the loader 42
Two hand switch in the core making machine
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Not only the front side but also the rear side gap will cause
finger injuries
Collar provided to avoid rear side finger injury 45
Safe Limit Switch damaged
Unsafe locations of valves which may cause hand injury
due to accidental touch
Two-hand switches gap giving access to operate by thumb
and little fingers of one hand
Unsafe locations of valves which may cause hand injury
due to running spindles
Mushroom headed switches gives access for accidental touch
which may cause fro hand injury
SAFETY AUDIT
Layout of work place checklist should contain following :

•Are the machines located with atleast one foot gap ?


•Any part of the machine protruding to the gangway ?
•Is the foundation of the machine is adequate, if the
machine is of reciprocating / or tilting type ?
•Is there any clearance for the operator to escape in case
of emergency
•Are the gangways marked with proper clearance for
material handling equipments movement ?
•Is adequate ventilation provided ?
•Is the exhaust system functioning ?

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Adequate space around the machine
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Adequate space around the machine
Caution display provided
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A see-through spacing before all Electrical panels 54
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Ladder with all safety parameters – rails / treads / angle / footing
Good gangway marking and locators but unsafe stacking
SAFETY AUDIT
Material handling equipments checklist should contain
the following :

•Are the machines operated by trained and certified


operators?
•Is the forklift provided with rear horn / zebra painting
Flasher lamp ?
• Are the cranes / forklifts duly certified by Govt. Officer
•Are the brakes and hydraulic system functioning well ?
•Overall condition of the material handling equipment ?
•Is the design of the MHE is safe ?
•Are the wheels the handles are in good condition ?
•Is the MH trolleys and stands are provided with the
toe-boards to avoid falling of components ? 57
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Trained and qualified forklift operator with badge in pocket
Height reduced trolley to avoid toppling 59
Rigorous forklift driver training 60
Rigorous forklift driver training 61
Rigorous forklift driver training
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No toe-board to avoid falling of components in the trolleys
Forklift with rear
Horn and flasher ligh

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High pressure air line connected to the fragile FRL unit which
leads to explosion
Extractor screw broken and not reconditioned
No toe-board to avoid falling of components in the trolleys
SAFETY AUDIT
Fire fighting equipment checklist should contain
the following :

•Are there adequate number of FFE in place ?


•Are they located within the reach of the operator (45 feet
•Are they maintained properly and labelled ?
•Are the FFEs appropriate to the nature of operation ?
•Are the FFEs are located in an easily approachable
location machines given with temporary connection ?
•Are the fire hoses and stand pipes are maintained well ?
•Are the nearby operators trained in operating the FFEs ?
•Whether the locations are legibly marked and indicated ?

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Arrangement of fire fire fighting equipments 69
LPG Safety – damaged hoses 70
LPG Safety – mishandled cylinders 71
Spillage of oil – potential for fire
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Layout of FFEs 74
Evidence of using paper as lighter
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Fire extinguisers placed in an inaccessible place
SAFETY AUDIT
Training and knowledge checklist should express
the following :

•Are the operators aware of the hazards involved in


• their operation ?
•Are the operators know how to react to an emergency ?
•Are the operators understand and adhere to wearing
personal protective equipments ?
• Are the new entrants duly trained in before engaged
in the operation ?
• Are the operators know about emergency preparedness

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Training

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Training
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Training- First aid – family participation 80
Training- First aid – family participation
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Training
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SAFETY AUDIT
Chemical handling checklist should express
the following :

•Are the chemicals stored in a safe place ?


•Are the chemicals handled safely with all required PPEs
•Are the operators aware of their activities related
to chemical aware of the hazards involved in
• Do they know MSDS ?
• Are there any fumes and toxic emission from chemical
•Are the operators know how to react to an emergency ?
•Are the new entrants duly trained in before engaged
in the operation ?
• Are the operators know about emergency preparedness
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Un labelled chemicals placed in the workplace which causes for fire
Unwanted / unlabelled chemical stored near unreachable location
Performance measurement – ambient air
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Testing of critical equipments – pressure vessel testing 87
SAFETY AUDIT
Safety communication checklist should contain the
following :
•Are adequate number of caution displays available ?
•Are the caution displays legible and understandable
•Are the displays appropriate to the operation ?
•Are the communication related to safety reaches
operators
•Are chemicals storage area / lab were displayed ?
•Are the new entrants instructed about the hazards
and remedies ?

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Communication 89
Communication
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Convex mirror at the intersection of roads - communication
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SAFETY AUDIT
Storage of materials checklist should express the following :
•Are the incompatible materials stored near any
flammable substances ?
•Are the materials stored unsafely beyond the height
of 6 feet ? If so, what safety measure has been taken
•Are the highly flammable liquids stored in a closed
containers ? Are they away from heat source ?
•Are the chemicals stored in non-corrossive
containers ?
•Are adequate steps taken for controlling fumes ?
•Are the gas cylinders stored in the designated place
•Are sharp edges and pin points are protected ?
•Are the trays and stands are rigidly fixed to the
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ground ?
SAFETY AUDIT
Work environment hazards identification checklist should
express the following :
•Is there any complaint of unbearable noise ?
•Is there any complaint of unbearable temparature
• Is there any toxic emission ?
•Is there any fumes from the furnaces ?
•Is there any report of unbearable skin problems due
to chemical handling ?
•Can you find out which machine / operation /
chemical creates the hazard ?
•Is there any complaint of inadequate / overlighting
•Is there any complaint of ventilation / exhaust
•Do you find any evidence of countermeasure ?
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SAFETY AUDIT
Electrical safety checklist should express
the following :

•Are the machines given with temporary connection ?


•Are all the DB s legibly marked ?
•Are loose wires found connected to the plug points ?\
•Are the panel boards free from accumulation of
materials ?
•Are the switch gears are operated by experienced and
trained personnel ?
•Is there any fans and lights hanging in an unsafe
•postur ?
•Are the switch boxes located away from water spill /
spray ? 94
Electrical cables exposed posing for shock 95
Electrical panel boards open 96
Temporery wiring taken for a high power machine
Open electrical panel boards
Loose wires plugged into sockets
ON_OFF switch does not indicate for which machine
Broken plug points
Direct contact with the coolent and operating the electrical switch
in next operation which leads to shock
Location and operation of the valve is unsafe to damage the
electrical plugin box
No obstrcution before panel boards 104
Accumulation of materials before electrical switch boxes obstructing
the emergency preparedness
SAFETY AUDIT
Contractor regulation checklist should contain the
following :

•Are the contractors instructed about the hazards


involved in the job ?
•Are the contractors are following safe work permit
system ?
•Are the contractors follow the instructions given by
the safety officer and the initiator department ?
• For example - working at height- wearing safety
belt and is it tied to a rigid support ?

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SAFETY AUDIT
Accident reporting checklist should express the
following :

•Were all the accidents including first aid injury and


near misses have been reported ?
•Are the countermeasures / preventive measures are
in place ?
•If not reported, details of the accidents ?

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