MODULE 2

• Personal safety in the workplace depends on your own awareness of

potential threats and risks as well as your employer's safety policies
and procedures.
 PERSONAL PROTECTIVE
EQUIPMENTS
• PPE is equipment that will protect the user against the risk of accidents or of adverse
effects on health.
• It can include items such as;
• Safety helmets
• Gloves
• Eye protection goggles
• High-visibility clothing
• Safety footwear
• Safety harnesses
• Respiratory protective equipment (RPE).
 • Even where engineering controls and safe
systems of work have been applied, some
Why is PPE hazards might remain.
important? • These include injuries to:
• The lungs, e.g. From breathing in
contaminated air;
• The head and feet, e.g. From falling
materials;
• The eyes, e.g. From flying particles or
splashes of corrosive liquids;
• The skin, e.g. From contact with
corrosive materials;
• The body, e.g. From extremes of heat
or cold.
• PPE is needed in these cases to reduce the
risk.
ARJUN P K
• Any item of PPE imposes a barrier between the wearer/user and the
working environment.
• This can create additional strains on the wearer, impair their ability to
carry out their work and create significant levels of discomfort.
• Any of these can discourage wearers from using PPE correctly,
therefore placing them at risk of injury, ill-health or, under extreme
circumstances, death.
• Good ergonomic design can help to minimise these barriers and can
therefore help to ensure safe and healthy working conditions through
the correct use of PPE.
 When selecting and
using PPE
1. Choose products which are suitable to the residual risk and
are the required standard, suppliers can advise you.
2. Choose equipment that suits the user – consider the size, fit
and weight of the PPE. If the users help choose it, they will be
more likely to use it.
3. If more than one item of PPE is worn at the same time, make
sure they can be used together, e.g. wearing safety glasses
may disturb the seal of a respirator, causing air leaks.
4. Instruct and train people how to use it, e.g. train people to
remove gloves without contaminating their skin.
5. PPE must be properly looked after and stored when not in
use, e.g. in a dry, clean cupboard. If it is reusable it must be
cleaned and kept in good condition.
• There are two types of PPE these include simple and complex
• Types:
• 1. Respiratory
• 2. Nonrespiratory
II.Types of PPE- Respiratory
Respiratory protection:

Source of photos: OSHA

Respiratory Protective Equipment (RPE) is a particular type of

Personal Protective Equipment
(PPE), used to protect the individual wearer against the
inhalation of hazardous substances in the
workplace air.
• Types of respirators
• Air-Purifying (APR) –
remove contaminants from
air
• Particulate respirators
• Chemical cartridge/
gas mask respirator
• Powered Air-Purifying
Respirator (PAPR)

Source of photos: OSHA

• Atmosphere-Supplying – provide clean,
breathable air
• Self-Contained Breathing Apparatus (SCBA)
• Supplied-Air Respirator (SAR)

Source of photos: OSHA

ARJUN P K
ARJUN P K
• Medical evaluation
• Before fit tests are conducted and employee is authorized the use of a
respirator, a medical evaluation must be provide to determine the ability of the
employee to use a respirator.

• Identify a physician or other license health care professional (PLHCP) to perform

medical evaluations using a medical questionnaire or an initial medical
evaluation with which the same information is obtained.
• Inspecting and cleaning respirators
• Inspect all respirators for wear and tear before and
after each use
• Wash in a detergent solution; then, disinfect by
immersing in a sanitizing solution

Source of photos: Carmen Vazquez

• Storing respirators
• Protect against dust, sunlight, heat, extreme cold,
excessive moisture, and damaging chemicals
• Store in position to retain natural configuration

Source of photos: Carmen Vazquez

II. Types of PPE-Non Respiratory
II. Types of PPE-Non Respiratory
A. Head protection:
• Frequent causes of head injuries
• Falling objects from above striking on the head;
• Bump head against fixed objects, such as exposed
pipes or beams; or
• Accidental head contact with electrical hazards.

Source: OSHA
• Classes of hard hats:
• CLASS G (General)
• Protect against impact, penetration
• Low-voltage electrical protection (proof-tested to 2,200
volts)

Source of graphics: OSHA

• CLASS E (Electrical)
• Designed for electrical/utility work
• Protect against falling objects, impact
• Electrical protection against high-voltage
(proof-tested to 20,000 volts)

Source: OSHA
• CLASS C (Conductive)
• Designed for comfort; offers limited protection
• Protects heads that may bump against fixed objects
• Does not protect against falling objects or electrical
hazards

Source: OSHA
Types of PPE
B. Eye and face protection:

Source of images: OSHA

• Common causes of eye injuries
• Chemical splashes
• Blood or OPIM splashes or sprays
• Intense light
• Dust and other flying particles
• Molten metal splashes

Source: OSHA
• Selecting eye and face protection – elements
to consider:
• Ability to protect against workplace hazards
• Should fit properly
• Should provide unrestricted vision and movement
• Durable and cleanable
• Allow unrestricted functioning of other PPE
• Safety glasses
• Used to protect against moderate impacts from
particles

Source of graphics: OSHA

• Prescription glasses
• Employees who use
prescription glasses while
performing operations with
potential eye hazards must use
Source: OSHA
eye protection that:
• Incorporates the prescription in its design, or
• Can be used over your prescription glasses without
interfering with the proper positioning of the prescription
glasses or goggles
• Goggles
• Protect eyes, and the
facial area immediately surrounding
the eyes from
impact, dust, splashes. Source: OSHA

• Some can be used over corrective

lenses, if they fit them.
 • Goggle types

Direct-ventilated Indirect-ventilated Non-ventilated

• Resist direct passage • Prevents fogging • Does not allow the
of large particles into by allowing air passage of air into the
the goggle circulation goggle
• Prevents fogging by • Protects against • Prevents splash entry
allowing air circulation liquid or chemical
• May fog and require
splash entry
frequent lens cleaning
Source: OSHA.gov
• Laser safety goggles
• Provide protection from hazards:
• physical contact such as flying particles
• ultraviolet light, laser, and welding

Source: OSHA
• Face shields
• Protect face from nuisance
dusts and potential splashes
or sprays of hazardous liquids
• Shields do not protect from
impact hazards unless so rated
• Shields are for face protection, not eye Source: OSHA

protection. To protect the eyes, wear safety

glasses with side shields, or goggles under the
face shield.
• Welding shields
• Protect eyes from burns caused
by:
• Infared light
• Intense radiant light

• Protect eyes and face from flying

sparks, metal spatter, and slag
chips

Source of photos: OSHA

Types of PPE
C. Hearing protection:

Source of photos: OSHA

• Exposure to noise levels over
85 dB can cause hearing loss
• Hearing protection required
at 90 dB
• Implement effective Hearing
Conservation Program

Source: OSHA
• The employer must provide
Permissible Noise Exposure
ear protection when the 29 CFR 1910.95(b)(1)
noise level in the work area Duration per Sound Level
is greater than indicated in Day (hours) (dBA)
this table. 8 90
6 92
4 95
3 97
2 100
1 105
1/2 110
1/4 115
Source: NIOSH
Impact noise should not exceed 140 dB
 • Disposable foam plugs
• Molded ear plugs
• Noise-cancelling ear plugs
• Ear muffs Source of photos: OSHA

• Consider Noise Reduction

Rating (NRR) of devices

NIOSH/John Rekus/elcosh.org
 Types of PPE
D. Hand protection:
Hand and finger injuries account for 18% of all disabling injuries
and about 25% of all industrial
work place accidents

• Potential hazards for hands

• Skin absorption of hazardous substances
• Lacerations or severe cuts
• Punctures
• Chemical burns
• Thermal burns
• Extreme temperatures
• Biological agents
Source of photos: OSHA
• Types of gloves

Anti-vibration
Chemical-resistant Leather Palm

Heat-resistant Cut-resistant
Permeation-resistant
Source of photos: OSHA
E. Foot and leg protection:
• Causes of foot injuries:
• Falling or rolling of heavy objects
• Crushing or penetrating materials
• Sharp objects that can penetrate
the sole
• Exposure to molten metal
• Working on, or around, hot, wet, or
slippery surfaces
Source: OSHA

• Working when electrical

hazards are present.
• Conditions requiring
foot protection
• Impacts
• Compressions
• Cuts/punctures
• Chemicals
• Temperatures
Source: OSHA
Source of photos: OSHA
• Protection from hazards
• Shoes with metal toe-cap protects
against knocks, falling objects
• Rubber shoes protect against
chemical materials, as directed
by the SDS

Source of photos: OSHA

Types of PPE
F. Body protection –
protective clothing:

Source of photos: OSHA

• Selection of body protection –
variety of materials effective against
particular hazard
• Paper-like fiber – dust and splashes
• Treated wool and cotton – fire-
resistant; dust, abrasions,
rough/irritating surfaces
• Duck – cuts, bruises
• Leather – dry heat, flames
• Rubber, rubberized fabrics,
neoprene, and plastics – certain
chemicals and physical hazards
Source of photos: OSHA
 • Protective clothing is required for HAZWOPER
activities
• Environmental Protection Agency (EPA) levels of
PPE
• Level A
• Provides highest level of protection
• Required when greatest potential for exposure exists and
Hazardous Waste greatest level of skin, respiratory, and eye protection is
Operations and Emergency required
Response is a set of • Examples
guidelines produced and • Positive pressure, full facepiece SCBA, or positive pressure supplied air
respirator with escape SCBA
maintained by the • Totally encapsulated chemical- and vapor-protective suit
Occupational Safety and • Inner and outer chemical-resistant gloves
Health Administration which • Disposable protective suit, gloves, and boots
regulates hazardous waste
operations and emergency
services in the United States
and its territories
• Level B
• Required for highest level of respiratory protection
and lesser level of skin protection
• Examples
• Positive pressure, full facepiece SCBA, or positive pressure supplied air
respirator with escape SCBA
• Inner and outer chemical-resistant gloves
• Face shield
• Hooded chemical-resistant clothing
• Coveralls
• Outer chemical-resistant boots
• Level C
• Required when concentration and
type of airborne substances are
known and criteria for using APR is
met
• Examples
• Full-face air-purifying respirators
• Inner and outer chemical-resistant gloves
• Hard hat
• Escape mask
• Disposable chemical-resistant outer boots
• Level D
• Required when minimum protection is needed
• Sufficient when no contaminants are present or work operations preclude splashes,
immersion, or potential for unexpected inhalation or contact
• Examples
• Gloves
• Coveralls
• Safety glasses
• Face shield
• Chemical-resistant, steel-toe boots or shoes
 • The Bureau of Indian Standard (BIS) has brought out many standards describing
the quality of Personal
INDIAN
• Protective Equipment used for the protection of head, eyes, face, arms, hands, legs,
STANDARDS feet and body.
• However, the testing facilities to examine the quality of Personal Protective
FOR PPE Equipment as per the specification laid down by the BIS are available only in some
manufacturing units and government laboratories with specific purpose.
• Specifications for Industrial Safety Helmets (IS: 292 1984) and Specifications
for Leather and Coton Gloves [IS: 690 IPart 1)-1973] are discussed here
 Specifications for Industrial Safety Helmets (IS: 292 1984):
1. Material: 5. Mass: 400 g (maximum)
Shell: non-metallic. 6. Test and Performance Requirements:
2. Size ● Shock absorption resistance against a wooden
Circumference inside headband: Small: 500 540 mm. block of 3 kg dropped from a height of 1.5 m.,
Medium : 540-590 mm. Large: 590-640 mm. ● Penetration resistance against a plumb of 500
g with conical steel point falling from a height
3. Essential Parts: of 3 m.,
● Shell, peak, ventilation holes. ● Electrical resistance against 2000 V, 50 Hz for one
● Harness consisting of headband. minute.
● Anti-concussion tapes. ● >5% water absorption when immersed in
● Chin strap. water for 24 hours at a temperature of 25°C.
4. Marking:
● Heat resistance in an oven at 93° t 50°C for 15
The following should be marked on the helmet: min.,
Trademark of manufacturer, size, ISI marking, ● Non visible damage when a flame from a barthel
and year of manufacture. Durner (IS: 4355- 1977) is applied on the shell
for 10 seconds,
● Sterilisation and corrosion resistance tests.
• Specifications for Leather and Cotton Gloves
[IS: 690 IPart 1)-1973]
• It covers eleven types of industrial gloves made of leather and cotton.
• Material for leather gloves: Chrome, tanned cow or young buffalo
grain or split leather to conform to the following requirements:
• Material for cotton drill gloves:
• Cotton drill shall be unbleached 315g/m2 with a tolerance of 19
g/ sq.m.
• Knitted fabrics for cuffs :2/20 all cotton.
• Thread Cotton sewing thread as per IS: 1720-1969.
• Size, design and stitching: As per IS: 6994 (Part 1)-1973.

• Markings:

• The gloves shall be legibly stamped on the inside of the cuffs with the
following information:
• Type and nominal size of the gloves, where applicable, the words 'light
mass', 'medium mass' or 'heavy mass', manufacturer's name or
recognised trademark, and year of manufacture.
• Specifications for Leather Safety Boots and
Shoes |IS 1989 (Part-1 & 2)-1986]:

• Should be ankle high.

• Should have six eyelets (four eyelets or less
in each of safety shoes.)
• Toe should be reinforced with steel toe cap.
• Tongue should be padded.
• Bottom be made of vegetable-tanned sole
leather moulded rubber sole and heel.
• Eyelets be made of aluminum or brass
coated steel of size 10 mm.
• Mass: 1750 g/pair of size of 8 (maximum)
with hobnail, toe tips and heel tips, 1650
z/pair of size 8 (rnaximum) without hob
nails, toe tips and heel tips. The mass shall
increase or decrease by 75g per pair for each
bigger or smaller size respectively.
• Steel toe cap should be as per IS 5852- 1996
and should withstand blows of 14.2 kgf.m.
PPE
STANDARDS(GLOB
AL)
 PPE Standards:
1. 29 CFR 1910.133 Eye and Face
Protection:
• “The employer shall ensure that each
employee uses appropriate eye or face
protection when exposed to eye or face
hazards from flying particles, molten
metal, liquid chemicals, acids or caustic
liquids, chemical gases or vapors, or
potentially injurious light radiation.”
 PPE Standards
2. 29 CFR 1910.134 Respiratory
protection:
• “The employer shall provide a
respirator to each employee
when such equipment is
necessary to protect the
health of such employee.
• The employer shall provide
the respirators which are
applicable and suitable for the
purpose intended.
• The employer shall be
responsible for the
establishment and
maintenance of a respiratory
protection program
 PPE Standards
3. 29 CFR 1910.135 Head protection
• “The employer shall ensure that each
affected employee wears a protective
helmet when working in areas where
there is a potential for injury to the
head from falling objects.
• The employer shall ensure that a
protective helmet designed to reduce
electrical shock hazard is worn by each
such affected employee when near
exposed electrical conductors which
could contact the head.
 PPE Standards
4. 29 CFR 1910.136 Occupational foot
protection:
• “The employer shall ensure
that each affected employee
uses protective footwear when
working in areas where there is
a danger of foot injuries due to
falling or rolling objects, or
objects piercing the sole, and
where such employee's feet
are exposed to electrical
hazards.”
PPE Standards
5. 29 CFR 1910.137 Electrical
protective equipment:
• details the design
requirements for specific
types of electrical
protective equipment—
rubber insulating blankets,
rubber insulating matting,
rubber insulating covers,
rubber insulating line hose,
rubber insulating gloves,
and rubber insulating
sleeves used for the
primary insulation of
employees from energized
PPE Standards
6. 29 CFR 1910.140 Hand protection:
• “Employers shall select and
require employees to use
appropriate hand protection
when employees' hands are
exposed to hazards such as
those from skin absorption of
harmful substances; severe cuts
or lacerations; severe abrasions;
punctures; chemical burns;
thermal burns; and harmful
temperature extremes.”
 PPE Standards
7. 29 CFR 1910.132 General requirements:
• says that all PPE has to meet these minimum
requirements:
1. Provide adequate protection against the
particular hazards for which they are designed
2. Be of safe design and construction for the work
to be performed
3. Be reasonably comfortable when worn under
the designated conditions
4. Fit snugly and not unduly interfere with the
movements of the wearer
5. Be durable
6. Be capable of being disinfected
7. Be easily cleanable
8. Be distinctly marked to facilitate identification
only of the manufacturer
 Monitoring Safety
Performance:
• The primary goal of a safety system is to reduce
operational risks and improve the overall process safety of
a plant over its entire lifecycle.
• In the event of a deviation or failure of the safety system,
Safety Instrumented Systems (SIS) are there to ensure
that a plant is taken into a safe state, limiting the negative
consequences to people, equipment and the environment.
• It is important that organizations in the process industry are
able to react quickly under variable conditions and have
the capabilities to continuously monitor and evaluate safety
system performance.
• Lets discuss about a few factors which are useful for the
statistical analysis of safety.
• Safety Indices which are indicators are used as tool for safety
performance measurement for assessment of relative
performance of safety management system.
• Quantitative measurement of safety performance gives a proper
valve & clear information about the most & least unsafe work in terms
of lost time injuries & man days lost between the consecutive years.
• It also helps to find out the deficiency or draw back in safety
management system & to suggest the safety measures area where
safety improvement is necessary to raise its safety performance.
● Man days lost: Charges in days of earning capacity lost due to
permanent disability (total or death) or due to partial
disablement as specified in IS 3786. Man day lost charged for
death (6000 days).
● Man hours worked: The total number of employees hours
worked by all employees working in the industrial premise. It
includes managerial, supervisory, and professional, technical,
clerical and other workers including contractor's labor
SAFETY PERFORMANCE INDICATORS
Frequency rate (F.R) :- Number of lost time injuries per million man hours worked.

Severity Rate (S.R): Number of man-days lost per million manhours worked.

Incidence Rate (IR) :- Number of lost time injuries per thousand persons employed.
• Disabling Injury ( Lost Time Injury ) - An injury causing disablement
extending beyond the day of shift on which the accident occurred.

• Reportable Disabling Injury ( Reportable Lost Time Injury ) - An injury

causing death or disablement to an extent as prescribed by the
relevant statute.
What does 1000000 mean ?
• No of workers in a year = 500
• Daily Hour Worked = 8 hrs
• No. of days worked in a week = 5 days
• Total hours worked in a week = 8 * 5 = 40 hrs
• Total week in a year = 50 week
• So, In a year = 50 week * 40 hrs/week * 500 workers = 10 00 000

• The frequency rate is the number of disabling injuries

per one million man-hours worked
 Man-Hours Worked
• The total number of employee-hours worked by all employees in the
industrial premises,
• It includes managerial, supervisory, professional, technical, clerical
and other workers including contractors labour
• It shall be calculated from the pay roll or time clock recorded
including overtime.
• When this is not feasible, the same shall be estimated by multiplying
the total man-days worked for the period covered by the number of
hours worked per day
• Total number of man-days is the sum of the number of men at work on
each day of the period
• Example 1.Using the following data calculate the
frequency rate of accident in an industrial plant.
1.Number of workers=500
2.Number of disabling injuries per year= 5.
3.Average number of hours worked by worker per
year=2000.

• Sol. Frequency rate=numbers of disabling

injuries/number of man-hours worked x 1000,000
• = 5x 1000000/(500×2000) =5.
The severity rate is the total number of days lost or charged due to accidents per one million
man-hours worked
• Here days lost= actual days lost due to accidents +
standard number of days considered to be lost
depending on nature of disabling injury.

• Standard number of days lost is correlated to the

nature of injury, as for example, standard number of
days lost is 35days, the nature of injury being cutting of
the tip of a finger, whereas standard number of days
lost in 6000 days for a total disability case.
Example . Using the following date calculate the severity rate of accident in an
industrial plant where only one accident occurred during the year, the type of
injury being cutting of the tip of a finger.
Number of workers=2000.
Number of days lost in a year due to accidents=100
Average number of hours worked by worker per year=2000.

Sol. Severity rate=days lost in year due to

accidents/number of man-hours worked x 1000,000
Number of man-hours worked in this case=2000 X 2000.
Days lost in year due to accidents=100+35=135.
Q: Using the following data calculate the severity rate of accident in an
industrial plant where only one accident occurred during the year involving total
disability of a worker.
Number of workers=2000.
Number of days lost in a year due to accident=100.
Average number of hours worked by worker per year=2000.

• Sol. Severity rate= days lost in year due to

accidents/number of man hours worked x 1000000.
• Number of hours worked in this case=2000×2000.
• Total disability; days lost=100+6000=6100 days.
• Severity rate =6100/2000x2000x1000000=
6100/4=1525
• General Incidence rate is the ratio of the number of injuries to the
number of persons during the period under review. It is expressed as
the number of persons per 1000 persons employed
• includes keeping work areas neat and orderly, maintaining halls and
floors free of slip and trip hazards, and removing of waste materials
(e.g., paper, cardboard) and other fire hazards from work areas.
• Good housekeeping and cleanliness normally results into
1. a workplace which is cleaner, safer, well organized and more pleasant for
work,
2. improved utilization of floor space,
3. smoother and systematic workflow with substantial reduction in non-value
added activities,
4. better inventory control of tools and materials,
5. reduced handling to ease the flow of materials,
6. reduction in wastages of materials,
7. more efficient equipment clean-up and maintenance leading to lower
break-downs,
8. minimization of errors leading to better products,
9. safe environment for work and lower exposures of employees to
hazardous substances (such as dusts, and vapours etc.),
10. more hygienic workplace conditions which lead to improved health of the
employees,
11. improved overall look and feel of the work environment, and
12. improved morale of the employees.
• Poor housekeeping and cleanliness, on the contrary, creates
workplace hazards which lead to various accident such as
1. slips, trips and falls,
2. caught in-between objects,
3. struck by falling objects,
4. struck by moving objects,
5. cut/stabbed by objects, and
6. struck against objects.
7. Furthermore, poor housekeeping and cleanliness also create
fire hazards which inevitably lead to increased fire risk.
 Elements Of An Effective
Housekeeping Program
1. Maintenance
• Maintenance involves keeping buildings, equipment
and machinery in safe efficient working order and in
good repair.
• It include maintaining sanitary facilities and regularly
painting and cleaning walls.
• Broken windows, damaged doors, detective plumbing
and broken floor surfaces can make a workplace look
neglected; these conditions can cause incidents and
affect work practices.
• So it is important to replace or fix broken or damaged
items as quickly as possible. A good maintenance
program provides for the inspection, maintenance,
upkeep and repair of tools, equipment, machines and
processes.
 2. Dust and Dirt Removal
• Enclosures and exhaust ventilation systems may fail to
collect dust, dirt and chips adequately.
• .
• Special-purpose vacuums are useful for removing hazardous
products. For example, vacuum cleaners fitted with HEPA
(high efficiency particulate air) filters may be used to capture
fine particles of asbestos or fibreglass.
• Dampening (wetting) floors or using sweeping
compounds before sweeping reduces the amount of
airborne dust
• The dust and grime that collect in places like shelves,
piping, conduits, light fixtures, reflectors, windows,
cupboards and lockers may require manual cleaning.
• Compressed air should not be used for removing dust, dirt or
chips from equipment or work surfaces.
 3. Employee Facilities
• Employee facilities need to be adequate, clean and well maintained.
• Lockers may be necessary for storing employees personal belongings.
• Washroom facilities require cleaning once or more each shift. They also
need to have a good supply of soap, towels plus disinfectants, if needed.
• If workers are using hazardous products, employee facilities should provide
special precautions as needed such as showers, washing facilities and change
rooms. Some facilities may require two locker rooms with showers between..
• Smoking, eating or drinking in the work area should be prohibited where
hazardous products are handled.
• The eating should be separate from the work area and should be cleaned
properly each shift.
 4. SURFACES
• Floors:

• Poor floor conditions are a leading cause of incidents so

cleaning up spilled oil and other liquids at once is
important.
• Allowing chips, shavings and dust to accumulate can
also cause incidents.
• Trapping chips, shavings and dust before
they reach floor or cleaning them up
regularly can prevent their accumulation.
• Areas that cannot be cleaned continuously, such as
entrance ways, should have anti-slip flooring.
• Keeping floor in good order also means replacing any
worn, ripped, or damaged flooring that poses a tripping
hazard.
• Walls:

• Light-coloured walls reflect light while dirty or dark

coloured walls absorb light.
• Contrasting colours warn of physical hazards and mark
obstructions such as pillars.
• Paint can highlight railings, guards and other safety
equipment, but should never be used as a substitute for
guarding.
• The program should outline the regulations and
standards for colours.
5.Maintain Light Fixtures
• .
• Dirty light fixtures reduce essential light
levels. 6.Aisles and Stairways
• Clean light fixtures can improve lighting
efficiency significantly • Aisles should be wide enough to accommodate
people and vehicles comfortably and safely.
• Aisle space allows for the movement of people,
products and materials.
• Warning signs and mirrors can improve sight-lines
in blind corners.
• Arranging aisles properly encourages people to use
them so that they do not take shortcuts through
hazardous areas.
• Keeping aisles and stairways clear is important.
• They should not be used for temporary "overflow"
or "bottleneck" storage.
• Stairways and aisles also require adequate lighting.
7Tools and Equipment

• Tool housekeeping is very important, whether in the tool room, on

the rack, in the yard, or on the bench.
• Tools require suitable fixtures with marked locations to provide
an orderly arrangement.
• Returning tools promptly after use reduces the chance of it being
misplaced or lost.
• Workers should regularly inspect, clean and repair all tools and
take any damaged or worn tools out of service.
• 8.Spill Control

• The best way cleaning and maintaining machines and the best
way to control spills is to stop them before they happen.
• Regularly cleaning and maintaining machines and equipment is
one way.
• Another is to use drip pans and guards where possible spills
might occur.
• When spills do occur, it is important to clean them up
immediately.
• Absorbent materials are useful for wiping up greasy, oily or other
liquid spills.
• Used absorbents must be disposed of properly other and safely.
9Waste Disposal
• The regular collection, grading and sorting of scrap contribute to good housekeeping practices. It also
makes it possible to separate materials that can be recycled from those going to waste disposal facilities.
• Allowing material to build up on the floor wastes time and energy since additional time is required for
cleaning it up.
• Placing scrap containers near where the waste is produced encourages orderly waste disposal and
makes collection easier.
• All waste receptacles should be clearly labelled (e.g, recyclable glass, plastic, scrap metal, etc.).
i) Storage
● Good organization of stored materials is
essential for overcoming material storage
problems whether on a temporary or
permanent basis.
● There will also be fewer strain injuries if the
amount of handling is reduced, especially if less
manual material handling is required.
● The location of the stockpiles should not
interfere with work but they should still be
readily available when required.
● Stored materials should not obstruct aisles,
stairs, exits, fire equipment, emergency
eyewash fountains, emergency showers, or
first aid stations. All storage should be
clearly marked.
● Flammable, combustible, toxic and other
hazardous material should be stored in
approved containers in designated areas that
are appropriate for the different hazards that
they pose.
 5S IN
INDUSTRIAL
HOUSEKEEPI
NG
• 5S occupies a prominent place as one of
the basic tools to enhance the quality of
the workplace.
• In fact, it forms the foundation for all
improvement efforts.
• It is an acronym for five Japanese words
and denotes a step-by-step approach for
developing a clean and well-organized
workplace.

• A well-designed and implemented program of 5S would instill discipline and change the attitude of
employees toward work.
• It is considered one of the foundation level techniques for continuous improvement.
• The 5S was invented in Japan and it stands for the five Japanese words that start with the letter 'S': Seiri,
Seiton, Seiso, Seiketsu,and Shitsuke.

5S CONCEPT OF HOUSEKEEPING
• What Is the Goal of 5S?

5S is a Lean method intended to implement order in the workplace.

The goal of 5S is to improve efficiency by eliminating various wastes,

including the waste of motion and time spent looking for tools,
materials or information.

Other benefits include improved safety and morale due to a more

effective work environment.
 a) Seiri (Sort)
● The first step of the 5 S processes, seiri, refers to the act of throwing away all the unwanted, unnecessary and

unrelated materials in the workplace.

● The idea is to ensure that everything left in the workplace related to the work.

● Even the number of necessary items in the workplace must be kept to its absolute minimum.

● Because of seiri, the simplification of tasks, an effective use of space, and the careful purchase of the items
follow.

● The most effective method to implement Seiri is to place/ attach a red tag to all unneeded items and move them to

a location outside the work area for storage until disposed off.

● Sorting is an excellent way to free up valuable space and eliminate such things as obsolete stock, used and

broken tools,etc. irreparable jigs and fixtures, non-renewable jobs, surplus stocks
• Create a log maintained by the Red Tag Area Manager. • Red Tagging:
• How to Use the Red Tag Method: • A method to identify items that will
• Place items with red tags from sorted areas into the Red eventually be removed from an area.
Tag holding area. Contains Data describing:
• Keep items highly visible. • Red Tag No.
• Clearly label items. • Name/Description of item
• Assign a Red Tag Manager.
• Reason for Tagging
• Document rules for:
– Placing items in Red Tag area • Date Tagged
– Removal of items • Current Location
– Disposition of items
b) Seiton ( Set in order) [Straighten]
● Seiton means systematic, orderly, efficient, and effective arrangement of items in use.
● For effective storage, answers to the following questions are required.
○ What items are to be stored?
○ Where should the items be stored?
○ What quantity of the items is generally required to be stored?
○ Are there any special storage requirements?
○ How often the items are to be stored or retrieved?

Therefore , Seiton means, "to arrange correctly, following correct method of doing activities and making
thorough preparation so that the activities can be performed even if they occur abruptly."

Since arranging correctly is a natural follow up activity after segregation, seiri and seiton are often used and
practiced together.
A place for everything and everything in its
place.
 Easy retrieval of materials.
Benefits
of Seiton: Time taken to search is minimized.

Unnecessary purchase is avoided.

Categorize files, mails, papers, etc. based on

specific criterion
Compartmentalize
cabinets/drawers/shelves/ desks.
Determine the quantity of each item and
plan storage according to pre-fixed quantity.
Plan storage to ensure easy retrievability
(within pre-set target time).
Color code items for easy identification.

Keep files/binders vertically and not laid out. Plan storage of compact disks to prevent
them from getting scratched.
Install visual control for the replenishment of
stocks and checking missing items.
Observe a Paper destruction day once every
quarter of the year.
 c) Seiso (Shine)
• Seiso is cleaning the workplace completely so that there is no dust on the floor, machines,
and equipment.
• The objective of seiso is to return items, jigs/fixtures, molds, equipment, and other utilities
and workplaces used during work to their original clean and polished condition by removing
scrap and leftovers and wiping all surfaces to make dust/ dirt free.
• The presence of dust can cause abrasions, scratches, blockages, leakages, bad connection
(electrical defects), quality defects (e.g. painting on dusty surfaces), variability (e.g. wrong
measurements and lack of process control)..
• People generally take pride in working in clean and clutter-free area and
sparkling/shining helps to create ownership of the equipment and facility.
• Cleaning is not a one-time activity. Some sort of standards of cleaning needs to be
developed and regular follow up is necessary to sustain this improvement.
• This can be done with the help of making checklists the example is shown in below.
The activities necessary to implement Seiso in the organization:

1. Keep the machines and workplace clean through sweeping floor and surroundings, dusting to make dirt free,
cobweb free wiping to make oil/grease, free polishing and painting
2. Clean machines/work table before the start of the daily routine. Eliminate leakage/spillage.
3. Brainstorm for creative ideas to make cleaning and inspection easier.
4. Clean even places most people don't notice. Remove scrap to avoid scratching.
5. Clean elements to remove dirt that cause sub-standard performance.
6. Clean electrical contacts to avoid bad connections ( eg: electrical contacts, pushbuttons, switches, etc.)
7. Dust off dirt inside the computer .
8. Remove oil and dust before painting to ensure a better finish.
9. Prepare a schedule for cleaning and assign clear-cut responsibilities.
10. Conduct inspection to unearth problems, identify root causes, and establish corrective action.
11. Carry out daily follow-up cleaning to sustain this improvement.
12. Clean up machine, jigs/fixtures, tools/gauges, etc. after use.
13. Place trash bins at strategic places and empty them at the end of the shift/day.
14. Clean up supply lines and coolant tanks; spray paint booth, water storage tank, material handling trolleys.
15. Dust off parts, components, items lying on shelves in store.
d) Seiketsu (Standardize)

• The first three steps of 5S cover the

basics of clearing, organizing, and
cleaning a work space; on their own,
those steps will provide short-term
benefits.
• The fourth step simply means
Standardize, or "seiketsu," which
standardization. By writing down what is
being done, where, and by whom, we
can incorporate the new practices into
normal work procedure. This paves the
way for long-term change.
Tools for Standardizing ● 5S checklists : Listing the individual steps
of a process makes it easy for workers to
follow the process completely. It also
provides a simple auditing tool to check
progress later on.
● Job cycle charts - identify each task to be
performed in a work area, and decide on a
schedule or frequency for each of those tasks.
Then, assign responsibility to a particular worker
(or job duty). The resulting chart can be posted
visibly to resolve questions and promote
accountability
● Procedure labels and signs: Provide operating
instructions, cleaning steps, and maintenance
procedures right where that information will be
needed.
 • Shitsuke means self-discipline. It denotes
commitment to maintain orderliness and to
practice the first 4S as a way of life.
e) Shitsuke (Sustain) • The emphasis of shitsuke is the elimination of
the bad habits and constant practice of the
good ones.
• Once a true shitsuke is achieved, the
personnel voluntarily observe cleanliness
and orderliness at all times, without
having to be reminded by the
management.
• One must train oneself to keep the 4S
principles and realize that by following
the 5S, ultimately the work will become
easier.
• Shitsuke is the most difficult 'S' to implement
and achieve
• Since human nature is to resist change, many
organiza returns to the status quo (i.e. end up
with a dirty cluttered shop) a few weeks
following the implementation of 5S.
Methodology of Shitsuke (Sustain)

1. Monitor the refined methods consistently.

2. Maintain the defined methods for continuous
improvement.
3. Establish norms and follow them.
4. Keep repeating the 1 to 4 'S'
Benefits of Shitsuke
(Sustain)
1.Discipline in the system.

2.Waste reduction.

3.High morale.

4.Neat and cleanliness.

5.Easier to work.

6.Lesser stress at work.

Advantages of 5S System

Reduction in errors/defects due to standardized procedures.

Consistent and improved quality.
Higher productivity.
Lesser accidents.
Higher morale of employees.
Gets to work in a clean, organized, and clutter-free workplace.
Lesser time to retrieve things when required.
More useable space.
Reduction in machine downtime.
Disadvantages of using the 5S method

The major problems with 5S appear when it is not properly understood, used, or implemented.

1. Misunderstanding of what 5S accomplishes

2. Resistance to change

3. Not addressing problems in the workplace

4. Lack of management support

• Permits to work are special authorization
documentation that ensures adequate risk
has been accessed for the process and a
level of control has been put in place to
reduce the severity, likelihood, and
potential of an incident occurring
• A permit to work (PTW) system is a process
to keep employees safe during hazardous
and nonstandard operations.
• The PTW system is designed to mitigate
environmental, health, sustainability, and
safety risks in certain operations.
They consist of specific instructions regarding the nature of the
job, time and place, and
communicate information regarding safety procedures.
WORK PERMIT • Work Permit System or Permit-To-Work (PTW) system is a
formal written system used to control and execute
SYSTEM
• certain types of jobs safely, which are identified as
potentially hazardous.

• It is also a means of communication between different

departments, plant supervisors, operators, agencies etc.
• Before starting any job in an area, it must be ensuring
that it is safe to work in the environment as well as with
the machinery, equipment involved. In order to ensure
that no work has to start before ascertaining the safe
conditions, work permit system is being followed.
• The work permit specifies the conditions and procedures
for safe execution of the work and allows the work to be
carried out under controlled risk conditions.
 Objectives of Work Permit System
• Give written permission to carry out a task

• Ensure every aspect of the work is planned

• Make sure every aspect of the work is checked

• Put risk assessments and method statements into action

• Communicate health and safety information

• Provide a procedure to ensure essential controls remain

in place

• Provide a procedure to return the area to a safe state on

completion of the work
• Work Permit System is an important element of safety management system
and implementation of this in true spirit shall help in ensuring a safe working
environment, thereby reducing possibility of injury to personnel, protect
property, avoid fire, explosion & adverse affect on environment
Work not requiring the
permit
• Routine work in established workshop and
adjacent yard with boundaries.
• Routine material handling work in
warehouses and lay down area.
• Routine office work.
• Visual inspection or checking without using
any tools in operation area of verbal
permission from assist custodians.
• Work carried out by operation employees as
their daily start up and shutdown of plant.
• Work carried out in designated area which
has declared as work permit free by Client.
• Any work approved by Client on special
request by contractor.
 Cold work permit (Green color) is required
for any job which does not involve or use of
any source of ignitions, spark, and fire.

Hot work permit (Red color) is required for

work any job which involves or use of source of
ignition, spark, and fire.
permit
symbols Confined space entry authorization (Yellow
color) is required to enter into the confined
space.

Excavation Authorization is associated with

permit for excavation job, which having
validity of 1 month and can be renewed for
3 months at least 3 days before expiry.
• HOTWORK PERMITS
• A hot work permit is a permit that
is needed in some countries, and on
some job sites, in order to perform
work that involves a source of
ignition when flammable materials
are in the vicinity or that can be
considered a fire hazard.

• Welding, soldering, cutting and

brazing are all considered hot work,
as is grinding and drilling in the
presence of flammable materials
 ● Before performing hot work, the
worker should consider following
○ The fitness and readiness-to-use of all the involved equipment must be tested
○ Task-specific personal protective equipment/ gear should be available at the site
and workers must be well- qualified on how to use, clean, and store them properly
○ Examine the workplace completely and eliminate any visual hazards
○ All combustible and flammable materials should be kept away from the workplace
○ All appropriate fire extinguishers and first-aid boxes should be available and easily
accessible
○ Examine the area after completing the hot work to make sure that wall surfaces and
wires have not heated up
○ Comply with applicable regulatory requirements and legislation in the
sector/location.
○ Risks triggered by hot work
Precautions taken to overcome the risk
 COLD WORK PERMITS

• Cold work permits are green colored

permit issued for hazardous
maintenance work that does not
involve the ignition hazards found in
hot work.
• Cold work situations are determined by
conducting a risk assessment for the task
and the working environment. If no
flammable or explosive risks are
identified, a cold work permit is
sufficient for carrying out
Some examples include:
● Chemical cleaning or the use of solvents,
● Handling of hazardous substances (e.g.,
toxic/corrosive chemicals, asbestos, etc.)
● The Use of resins typically used during blade
repairs, any painting activity,
● Heavy lifts (refer to Crane/Lifting procedure
for definition),
● Erecting or dismantling scaffolds,
● Any non-routine and potentially hazardous
activity,
● Any activity requiring specific control
measures to confirm safety.
sewers, pipes, access shafts, truck or rail tank cars, aircraft wings, boilers,
manholes, pump stations,
Ditches, wells, and trenches may also be a confined space when access is
limited
 CLASSES OF CONFINED SPACE
Class A – IDLH atmosphere. May contain oxygen
deficiency, explosive or flammable atmospheres, and
/or concentrations of toxic substances.

Immediately Dangerous To Life or Health (IDLH)

Class B – space has potential for causing injury if
proper safety steps are not followed.
Class C – space has potential hazards, but would not
require any special modification of the work
procedures.
TYPES OF CONFINED SPACE…
• Non-Permitted
• … does NOT contain physical, chemical or
atmospheric hazards capable of causing death or
serious physical harm
• Permitted
• … DOES contain physical, chemical or atmospheric
hazards capable of causing death or serious physical
harm
GENERAL CS ENTRY PROCEDURE
1. Conduct an assessment 6. Pre-entry briefing
2. Post signage; Barricade 7. Perform entry & work
3. Write the Permit 8. Perform continuous
4. Perform pre-entry tests atmospheric tests
5. Follow all other safety 9. Exit the confined space
procedures 10. Debrief
• PPE employees/contractors
• LO/TO 11. Verify completion
• Ventilation
1. CONFINED SPACE ASSESSMENT

ASSESSMENTS MUST INCLUDE:

1. Pre-entry testing and monitoring
of/for:
• Atmospheric conditions
• Potential hazards in and around the
area
• Continuous monitoring should be considered in situations where a
worker is in a space where atmospheric conditions have the potential
to change (e.g., broken or leaking pipes or vessels, work activities
create a hazardous environment, isolation of a substance is not
possible).
• A trained worker using detection equipment which has remote
probes and sampling lines should do the air quality testing.
• Always ensure the testing equipment is properly calibrated and
maintained.
• Ventilation equipment is operating properly.
 POTENTIAL HAZARDS
• Deficient or enriched oxygen
• Safe level: 19.5% - 23.5%
• Combustible, flammable, and explosive atmospheres
• Toxic gases and vapors
• Corrosive chemicals or biological agents
• Physical hazards–
• Falling,tripping,moving parts,engulfment,heat
extremes,etc…
• Electrical hazards—
• Shock hazard, static electricity, sparks, etc…
• Rodents,snakes, and insects
 ON-SITE RESCUE
• Employer determined if on/off-site rescue will be
used
• On-site, usually comprised of in-house
personnel—
• Motivated team
• Extensive training
• Practical exercises (min. once/12 months)
• Regular reinforcement of training
 OFF-SITE RESCUE
• Assessment necessary
• Determine the practicality of off-site rescue
• If used:
• Close proximity
• Extensive pre-coordination
• Must understand the hazards to be faced
• Must have access to all spaces for pre-planning
ASSESSMENTS MUST ALSO INCLUDE:

2. Written procedures to remove

or control hazards including
ventilation, LOTO, PPE and
communication
3. Written emergency response
 2. POST SIGNAGE AND BARRICADE
• MUST be in the immediate area
• MUST identify the Confined Space
• Restricts unauthorized personnel
• E.G.: “DANGER—PERMIT REQUIRED CONFINED SPACE, DO
NOT ENTER”
Barricades
• MUST prevent unwanted access to the work area
• MUST ensure clear workspace for attendant and emergency rescue (if
needed)
 3. WRITE THE PERMIT

• Are written authorization and approval

specifying the location and type of work
• Certify that all existing hazards have been
assessed
• Ensure the safety of each worker
• Specify the date & length of time it
applies
4. PERFORM PRE-ENTRY TESTS

• Duration—Recommend continuous
• Sample priority—Oxygen; Flammable/combustible chemicals; Toxic
chemicals
TESTING METHODS
• Sample in layers
• Every four feet in direction of travel
• Different chemicals stratify
• Do not get equipment wet!
CHEMICAL STRATIFICATION

*Chemicals will stratify

according to their
vapor density

*Strata changes with

environmental
conditions
(ex. Temperature and
pressure)
5. TAKE OTHER SAFETY PRECAUTIONS
• PPE
• Lockout/Tag out
• Verify emergency response
• Remove sources of hazardous materials outside of confined space
• Ventilation
• Exhaust
• Negative pressure
• Local - for specific sources
• General - for non-specific sources
• Purging
• Positive pressure
• Using inert gases in flammable/combustible environment
• Causes need for additional PPE
 6. PRE-ENTRY BRIEFING

• Conduct meeting
• Include all affected persons
• Document topics discussed at the briefing.
7. PERFORM ENTRY AND WORK

• Entry documentation
• Each entrant should sign an entry log
• Posted in immediate area
• Follow work procedures and safety rules for job task!!!
 8. PERFORM CONTINUOUS MONITORING

• sampling methods
9. EXIT THE CONFINED SPACE

• When work is complete, when replacement

arrives, or if an alarm sounds
• In the event of an emergency, utilize emergency
rescue
• Remember to update the entry log!!
 10. CONDUCT DEBRIEFING

• Discuss the success of the work

• Identify concerns that occurred
• Verify completion of all documentation
• Document meeting, if possible
11. VERIFYING COMPLETION

• The entry supervisor should remain for at least 30 minutes after the
entry to ensure the security of the site and that no hazards remain
(ex. Fires)
How are hazards controlled in confined spaces?
• engineering controls, administrative controls and personal
protective equipment.
• Engineering controls are designed to remove the hazard while
administrative controls and personal protective equipment try to
minimize the contact with the hazard.
• The engineering control commonly used in confined spaces is
mechanical ventilation. The entry permit system is an example of an
administrative control used in confined spaces.
• Personal protective equipment (such as respirators, gloves, hearing
protection, etc.) is commonly used in confined spaces as well.
• However, wearing of PPE sometimes may increase heat and loss of
mobility.
How is air quality maintained?

• Natural ventilation (natural air currents) is usually not reliable and not
sufficient to maintain the air quality. Mechanical ventilation (e.g.,
blowers, fans) is usually necessary to maintain air quality.
• If mechanical ventilation is provided, there should be a warning
system in place to immediately notify the worker in the event of a
hazard or a failure in the ventilation equipment.
How are fire and explosion prevented?

• Hot work should not normally be performed in a confined space unless:

• All flammable gases, liquids and vapors are removed before the start of any hot work.
• Mechanical ventilation is usually used to
1. Keep the concentration of any explosive or flammable hazardous substance less than 10% of its
Lower Explosive Limit.
2. Make sure that the oxygen content in the confined space is not enriched. Oxygen
content should be less than 23% but maintained at levels greater than 19.5%. (These
numbers can vary slightly from jurisdiction to jurisdiction.)
• Surfaces coated with combustible material should be cleaned or shielded to prevent ignition.
• Do not bring fuel or fuel containers into the confined space (e.g., gasoline, propane), if possible.
• Ensure welding equipment is in good condition.
• Where appropriate, use spark-resistant tools, and make sure all equipment is bonded or
grounded properly
Typical Industrial Models and Methodology
• There are several industrial models and methodologies commonly used to
improve safety in the workplace:
The Hierarchy of Control: This is a systematic approach that prioritizes the
most effective ways to eliminate or reduce hazards.
It includes five levels of control, starting with elimination of the hazard at the
top, followed by substitution, engineering controls, administrative controls,
and personal protective equipment.
The Five Steps of Risk Assessment: This method involves identifying hazards,
evaluating the risks associated with those hazards, assessing the feasibility of
control measures, implementing controls, and monitoring and reviewing the
effectiveness of the controls.
Failure Modes and Effects Analysis (FMEA): This is a systematic approach to
identifying potential failures in a process, determining the effects of those
failures, and assessing the likelihood of the failures occurring.
• Job Safety Analysis (JSA): This method involves breaking down a job into
its individual tasks and evaluating the hazards associated with each task.
• Incident Investigation: This process involves conducting an investigation to
determine the causes of an incident and identifying ways to prevent similar
incidents from happening in the future.
• Safety Management Systems (SMS): This approach involves developing a
comprehensive system to manage safety, including setting safety goals and
objectives, establishing policies and procedures, implementing programs to
meet those goals and objectives, and monitoring and evaluating the
effectiveness of the programs.
• Human Factors Engineering (HFE): This approach is based on
understanding how human behavior and cognition interact with the
design of equipment, systems, and work environments, to improve
safety and reduce errors.
• Root Cause Analysis (RCA): This method is used to identify the
underlying causes of an incident or problem, rather than just the
immediate or surface causes.