Safety surveys

► A safety survey is a systematic evaluation to check safe

operations and practices are in place in workplaces and
facilities. It is an opportunity to suggest improvements on safety
issues and confirm intended safety regulations are being complied
with. It is an integral part of the safety management system.
► Surveys are conducted regularly to detect unsafe conditions due to
malpractices, mishandling of equipment, improper stowage of
materials, poor housekeeping, workplace hazards, fire hazards,
machine wear and tear, unsafe and unauthorized activities, and no or
improper use of personal protective equipment.
► Safety surveys reduce accidental exposure and make employees
more aware of standard operation procedures. They are also an
effective way of obtaining a complete picture of day-to-day work and
safety practices.
Safety surveys may include the
following points:

• Building Conditions: Structural safety, housekeeping, unobstructed

exits, fire protection, and electrical items
• Equipment: Machine guarding, wear-and-tear on joints and
connections
• Health Conditions: Sufficiency of light and air, temperature and
humidity levels, noise pollution, ergonomics, and the presence of slip,
trip and fall hazards
• Procedures and Practices: Standard operating procedure is in place,
safety practices are adhered to, personal protective equipment is
used, and procedures for preventing exposure to harmful substances
are followed
• Personal Acts: The presence of unsafe and unauthorized activity,
talking while working, mindlessness, etc.
► Personal protection in the work environment, Types of PPEs,
Personal protective equipment respiratory and non respiratory
equipment. Standards related to PPEs. Monitoring Safety
Performance: Frequency rate, severity rate, incidence rate,
activity rate. Cost of accidents Computation of Costs- Utility of Cost
data. Plant safety inspection, types, inspection procedure. Safety
sampling techniques. Job safety analysis (JSA), Safety surveys, and
Safety audits. Safety Inventory Technique.
Plant safety inspection, types,
inspection procedure
► Periodic
► Continous
► Inermittent
► Special -

Eg: inspection of new building

Accident investigation purpose

► To prevent recurrence of accident

► Identify and locate source of accident
► Disclose unsafe practices
► Disclose the nature and size of accident in the dept& among employees
► **
Cost of accidents

✔ COST TO INJURED WORKER

Loss of wage
Cost due to medical expence

✔ COAST TO MNAGEMENT--=====- DIRECT-- INSURED,

INDIRECT--UNINSURED
✔ COST TO SOCIETY
 Safety audits

► SYSTAMATIC CRITICAL EXAMINATION OF SAFETY

ACTIVITIES

► MAIN OBJECTIVES
❑ Review operating and maintance procedures
❑ Review training
❑ Review fire protection arrangement and safety system
❑ Review design defficiencies
Safety audits---- steps

► Select the audit area

► Audit time frame

► Doing the audit----- check list

► msds
► Organising the findings
References:

► 1. Krishnan, N.V. Safety management in Industry. Jaico Publishing House, New

Delhi.(1997).
► 2. John V. Grimaldi and Rollin H.Simonds Safety management. All India
Traveller Book Seller, Delhi. (1989).
► 3. Ronald P. Blake Industrial safety. Prentice Hall, New Delhi. (1973).
► 4. Ted S. Ferry Modern accident investigation and analysis, John Wiley & Sons,
Hoboken, N.J. (1988).
► 5. Alan Waring Safety management system. Chapman & Hall, England. (1996).
6. National Safety Council Accident prevention manual for industrial
operations. Chicago. (1982).
►
 Fatal - It is capable of causing death.
Non-fatal - It is not resulting in or capable of causing death
Incident -Incident is dangerous occurrence without injury or
damage.
Death - Fatality resulting from an accident.
Injury - An injury is an external damage to the human body.
 COMPUTATION OF
THE INDICES
OF INDUSTRIAL ACCIDENTS
• Man-hours worked:- The total number of
employee-hours worked by all employees
working in the industrial premises. It includes
managerial, supervisory, professional,
technical, clerical and other workers including
contractors’ labour.
• Scheduled charge:- Charges in days of earning
capacity lost due to permanent disability and
death ( see Appendix-A of IS 3786).
 Indices of safety
performance?
• To quantify the level of safety in numbers
• Safety is an abstract thing. High level
of abstraction is involved.
• Can be sensed/felt, but cannot be seen
• Not amenable to direct measurement
• Measured indirectly through some man-made
indices [Ref: IS 3786 : 1983 (Reaffirmed in 1997)]
• Important indices are: frequency rate,
severity rate, incidence rate
20
Calculate frequency rate ,weighted frequency rate and
severity rate for the factories A and B having following
details.
Factory A Factory B
Total man hours worked 42,00,000 26,400,000
No.of fatal accidents 10 2
Non fatal accidents 12 37
First aid cases 170 85
Mandays lost due to non fatal accidents 460 1820

Also state which factory’s safety performance is better.

► Frequency Rate,
► A- FATAL= 2.3 , -Non Fatal =2.85
► B Fatal= 0.07 , -Non Fatal =1.401
► Severity Rate,
► A= 109.52
► B=68.93
► WEIGHED FREQUENCY RATE = FREQ.RATE FOR FATAL
ACCIDENT+ FREQ.RATE FOR NON FATAL ACCIDENT
► A -5.2 , B -1.4
► RESULT ??
 COMPUTATION OF
THE INDICES
OF INDUSTRIAL ACCIDENTS
 Objectives of this
assessment?
✔ To quantify the level of safety in numbers
✔ To compare the performance of one factory
with another
✔ To compare the safety performance with a policy or
a benchmark
✔ To study the trend of safety performance of an
industry over years so that improvements can be
made
Notes:
Periodicity: may be half-yearly or annual, generally
 Frequency Rate
(number of lost time injuries per million man-hours
worked)
The frequency rate shall be calculated both for lost
time injuries and reportable lost time injuries as
follows:
FA = (Number of lost time injury/
Man-hours worked) × 1 000 000

FB = (Number of reportable lost time injury/

Man-hours worked) × 1 000 000
• If the injury does not cause loss of time in the
period in which it occurs but in a subsequent
period, the injury should be included in the
frequency rate of the period in which the loss
of time begins.
• If an injury causes intermittent loss of time, it
should only be included in the frequency rate
once, that is, when the first loss of time
occurs.

Note:- Since frequency rate FB is based on the lost time

injuries reportable to the statutory authorities, it may
be used for official purposes only. In all other cases,
frequency rate FA should be used for comparison
purposes.
 Severity Rate
(man-days lost per million man-hours worked)
The severity rate shall be calculated from man-days lost both
of lost time injury and reportable lost time injury as follows:

SA = (Man-days lost due to lost time injury/Man-hours

worked) × 1 000 000

SB = (Man-days lost due to reportable lost time injury/Man-

hours worked) × 1 000 000

Note:- Since severity rate SB is based on the lost time injuries reportable to
the statutory authorities, it should be used for official purposes only. In all
other cases severity rate SA should be used for comparison purposes.
 How to calculate the man-days lost
1. Man-days lost due to temporary total disability.
2. Man-days lost according to schedule of charges for
death and permanent disabilities as given in
Appendix A. In case of multiple injury, the sum of
schedule charges shall not be taken to exceed
100% (6 000 man-days).
3. Man-days lost in the period under review due to
injuries from accident(s) which occurred in
previous period shall be included in the period
under review.
4. In the case of intermittent loss of time, each
period should be included in the severity rate
for the period in which the time is lost.
5. If any injury is treated as a lost time injury in
one statistical period and subsequently turns
out to be a permanent disability; the man-
days charged to the injury shall be subtracted
from the schedule charge for the injury when
permanent disability becomes known.
 Incidence Rates
(Number of injuries per 1000 persons employed)
Lost-time injury incidence rate =
(Number of lost-time injuries/Average number of persons
employed) × 1 000

Reportable lost-time injury incidence rate = (Number of

reportable lost-time injuries/Average number of persons
employed) × 1 000

Note: Since reportable lost-time injury incidence rate is based

on the lost time injuries reportable to the statutory authorities,
it should be used for official purposes only. In all other cases
lost- time injury incidence rate should be used.
Frequency-severity index
(FSI)
 SCHEDULED CHARGES FOR
S. InjuryDISABILITIES
description (Ref: IS Loss
3786)
of Equiv.
No. earning man- days
Part-A: Total disablement
capacity (%) lost
1 Death 100 6000
2 Loss of both hands or amputation 100 6000
at higher sites
3 Loss of a hand and a foot
4 Double amputation through leg or thigh, or 100 6000
amputation through leg or thigh on one side
and loss of other foot
5 Loss of sight to such an extent as 100 6 000 100 6000
to render the claimant unable to perform any
work for which eyesight is essential
6 Very severe facial disfigurement 100 6000
7 Absolute deafness 100 6000
30
 Exercise
S. No. Data description Factory-A Factory-B
1 No. of workers- 1st shift , 1000 1500
other two shifts and sundays 500 750
2 No. of deaths 1 -
3 No. of disabling injuries other 5 100
than deaths
4 Man-days lost due to disabling 100 2000
injuries other than deaths
5 Total man-hours worked
 How to calculate total man-hours worked?

• Factory-A
(1000x8x313)+(500x2x8x313)+(500x3x8x52) =
5,632,000 man-hours
• Factory-B
Learners may please complete…..
 Answer
S. No. Index
s Factory-A Factory-B

1 Frequency rate (F) 1.07 ( <5) 11.84 (>5)

2 Severity rate (S) 1083 237 (<300)

3 Incidence rate (I) (>300) 34.57 (>10)
3.11 (<10)
 Excercise-
2
• A factory employs on an average 800 workers
in the regular day shift and 400 each in the 2nd
and 3rd shifts, each shift being of 8 hours. The
plants operate round the clock and
throughout the year including Sundays and
holidays. The accident records of three
consecutive years are given below. Calculate
the frequency rate, severity rate and incidence
rate of each year. List out your conclusions on
the trend of injuries.
 Data
given
2013 2014 201
5
Number of deaths 3 2 2
Number of disabling
injuries other than 100 130 120
death
280 250 300
Number of
first-aid injuries
Man-days lost due to
disabling
1500 1100 1400
injuries
(excluding
death)
 Ans:
Excercise-2
• Total man-hours=[800x8+400x8+400x8] x 365 =
4,672,000 = 4.672 million man-hours

FR SR IR FSI

2013 22 4174 64 9.58

2014 28 2804 83 8.86

2015 26 2868 76 8.64

 Trend
Analysis
30
Frequency rate
25

Frequency rate 20

15
28
26
22
10

0
2013 2014 2015
 Severity Rate
4500
4174
4000

3500

Severity Rate 3000 2804 2868

2500

2000

1500

1000

500

0
2013 2014 2015
 Incidence rate
90
83
80 76

70 64
Incidence rate 60

50

40

30

20

10

0
2013 2014 2015

40
 Frequency-severity index (FSI)
9.8
9.58
9.6

Frequency-severity Index
9.4
9.2
9
8.86
8.8
8.64
8.6
8.4
8.2
8
2013 2014 2015
Merits and Demerits of the
indices
• Frequency rate and incidence rate capture the
no. of injuries but not the severity
• Severity rate captures the severity of the
injuries but ignores the factum of highly
frequent nature of injuries in the
factory, though less severe in nature
• Man-hours worked:- The total number of
employee-hours worked by all employees
working in the industrial premises. It includes
managerial, supervisory, professional,
technical, clerical and other workers including
contractors’ labour.
• Scheduled charge:- Charges in days of earning
capacity lost due to permanent disability and
death ( see Appendix-A of IS 3786).
 Indices of safety
performance?
• To quantify the level of safety in numbers
• Safety is an abstract thing. High level
of abstraction is involved.
• Can be sensed/felt, but cannot be seen
• Not amenable to direct measurement
• Measured indirectly through some man-made
indices [Ref: IS 3786 : 1983 (Reaffirmed in 1997)]
• Important indices are: frequency rate,
severity rate, incidence rate
20
Merits and Demerits of the
indices
• Frequency rate and incidence rate capture the
no. of injuries but not the severity
• Severity rate captures the severity of the
injuries but ignores the factum of highly
frequent nature of injuries in the
factory, though less severe in nature
Frequency Rate - It is define as number of
disabling accidents per million man-hours worked
by factory, in a year
► ❖.
► Purpose - To know how often disabling accidents occur.
► Formula –
► FA = (Number of lost time injury/ Man-hours worked) × 1 000 000

FB = (Number of reportable lost time injury/ Man-hours

worked) × 1 000 000
Frequency Rate = 3.8428 Indices
► (Per million man-hours worked)
Sr.No. Year (1 April To 31 March) Severity of Accident Types of Accident Man Days
Lost Due to Reportable Accident Total Man- Hours Worked Average No. of Employee
Present in one Day Total No. of Accident (Per Year)

Fatal
(F) Non-Fatal (NF) Reportable
(R) Non-Reportable
(NR)
 breaking the identifying
selecting the job job down into a potential
to be analyzed sequence of hazards
steps

► determining
preventive
measures to
overcome
these
hazards
 JSA

►
What are the four basic steps?
► Four basic stages in conducting a JSA are:
• selecting the job to be analyzed
• breaking the job down into a sequence of steps
• identifying potential hazards
• determining preventive measures to overcome these hazards
https://www.ccohs.ca/oshanswers/hspr
ograms/job-haz.html
Sequence of Events Potential Accidents or Hazards Preventive Measures

Park vehicle a) Vehicle too close to passing traffic a) Drive to area well clear of traffic. Turn on
b) Vehicle on uneven, soft ground emergency flashers
c) Vehicle may roll b) Choose a firm, level parking area
c) Apply the parking brake; leave transmission
in PARK; place blocks in front and back of the
wheel diagonally opposite to the flat

Remove spare and tool kit a) Strain from lifting spare a) Turn spare into upright position in the wheel
well. Using your legs and standing as close as
possible, lift spare out of truck and roll to flat tire.

Pry off hub cap and loosen lug bolts (nuts) a) Hub cap may pop off and hit you a) Pry off hub cap using steady pressure
b) Lug wrench may slip b) Use proper lug wrench; apply steady
pressure slowly
► Safety sampling is a technique performed in a workplace or
hazardous area that is used to measure potential for accidents. This
is done using a list of standards or regulations from a federal agency
including The Occupational Safety and Health Administration (OSHA),
or The American National Standards Institute (ANSI), and any
unacceptable deviations from those standards or regulations.
PPE

► VIDEIO
► https://youtu.be/loQ9Dbsy2ag
► Head protection -class A –VOLTAGE upto 2200v
► Eye
► Respiratory –respirators, breathing apparatus….- SCABA
► Ear
► Body
► Hand
► Fall protection
► Foot protection
Personnel Protective Equipment

Personnel protective equipment (PPE) may be

broadly divided as follows:
► Hearing protection.
► Respiratory protection.
► Eye and face protection.
► Protective clothing.

PPE does nothing to stop the hazard at source,

but simply provides protection to reduce the
severity of the potential accident.
Personnel Protective Equipment

It is only an effective control if worn and so

any organisation which provides for the issue
of PPE should:

► Carry adequate stock.

► Enable accessibility at appropriate times.
► Respond to changing demands.
► Have a system for exchanging equipment.
► Be managed to ensure its effective
running.
 PROTECTIVE EQUIPMENT REQUIREMENTS
Eye
Head
WHERE Where machines or Foot/Toe
NEEDED Where there is danger
operations present a In areas where
from impact and
danger from flung there is a potential
penetration from falling or
objects,, hazardous for foot or toe
flying objects or from
liquids, or injurious injuries.
limited electric shock.
radiation.
TYPES OF Goggles, full face Safety hats full brim, Impact and compression
PROTECTION shields, safety glasses, brimless, limited resistance, metatarsal
side-shields, welders’ voltage protection, no protection, puncture
lenses (should meet voltage protection, resistance, electrical hazard
standards). (should meet resistance, conductive
standards).
FITTING
REQUIREMENT Comfortable fit (not Comfortable, proper
interfere with fit. Proper fit.
SUGGESTED movement). Date issued, type Date issued, amount
RECORDS reimbursed,
Date issued, reissued, issued, instructions
given (need to instructions given
type issued, (need to wear,
instructions given wear, maintenance, maintenance,
disciplinary action). disciplinary action).
EXAMINATIONS Visual acuity, depth
NEEDED perception.
 PROTECTIVE EQUIPMENT REQUIREMENTS (2)

WHERE Hand Hearing Respiratory

NEEDED Danger of cuts, or from Noise exposure that equals In areas that present a
handling corrosives, solvents, or exceeds 85 dBA in an limited breathable
or other chemicals. 8-hour time-weighted environment
period.

TYPES OF Cotton/leather gloves; Full muffs, disposable Air-purifying respirators,

PROTECTION gauntlets; heat-resistant plugs, Swedish wool, chemical cartridge
gloves; barrier creams; chain non-disposable plugs. respirators, air-supplied
mail gloves; haly-gloves; (Should meet standards). respirators, combination
rubber gloves. (Should meet respirators, self contained
standards). breathing devices. (Should
meet standards).

FITTING Proper fit. Proper fit, correct type for Significant fitting
REQUIREMENTS noise exposure. requirements.

SUGGESTED Date issued, reissued, type Audiometric exam, date Date issued, reissued, type
RECORDS issued, instructions given, issued, instructions given issued, instructions given
(need to wear, maintenance, (need to wear, effects of (respiratory hazards
conservation, disciplinary noise, cleaning, present; functions; fit
action.) conservation, fitting, testing; proper utilisation,
disciplinary action.) cleaning and maintenance;
conservation, disciplinary
action).
EXAMINATIONS Audiometric Pulmonary function.
NEEDED (baseline and annual).