MX3089 INDUSTRIAL SAFETY

Presented by
Dr.N.SANKAR
AP/MECH
JKKMCT
 UNIT II STANDARDS AND REGULATIONS

Indian Factories Act-1948 - Health- Safety-

Hazardous materials and Welfare- ISO
45001:2018 occupational health and safety
(OH&S) - Occupational Safety and Health Audit
IS14489:1998- Hazard Identification and Risk
Analysis- code of practice IS 15656:2006
• Indian Factories Act-1948
• Health- Safety- Hazardous materials and
Welfare
• ISO 45001:2018 occupational health and
safety (OH&S)
• Occupational Safety and Health Audit
IS14489:1998
• Hazard Identification and Risk Analysis- code
of practice IS 15656:2006
OCCUPATIONAL HEALTH AND
SAFETY (OH&S)
and
OCCUPATIONAL SAFETY AND
HEALTH AUDIT (OS&SA)
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 Elements of Occupational Safety and
Health System-IS14489
• Occupational Health and Safety Policy
• OS&H organizational set up
• Education and Training
• Employees participation in OS&H Management
• Motivational and Promotional measures for
OS&H
• Safety Manual and Rules
• Compliance with Statutory Requirements
• New Equipment review and inspection
 Elements of Occupational Safety and
Health System-IS14489
• Electrical and Personal safeguarding
• Ventilation, illumination and noise
• Work environment monitoring system
• Prevention of occupational diseases including
periodic medical examination
• Safe operating procedures
• Work Permit systems
• Fire Prevention, Protection and fighting systems
• Emergency Preparedness plans(onsite/offsite)
• Process Plant modification procedure
 Elements of Occupational Safety and
Health System-IS14489
• Transportation of hazardous substances
• Hazardous waste treatment and disposal
• Safety in storage and warehousing
• Contractor safety systems
• Safety for customers(including MSDS)
 What is Safety Audit?
“Verifying the existence and
implementation of elements of
occupational safety and health system and
for verifying the system’s ability to achieve
defined safety objectives”
 Why do organizations have to bother
about Safety?
• Corporate Strategy
• Finance
• Human Resources
• Marketing, Product Design and Product
Liability
• Manufacturing and operating policy
• Information Management and systems
• Public Concerns
 Corporate Strategy
• Business Mission, Philosophy and codes of
ethics
• Company image in the community
• Environment impact
• Management Professionalism
 Finance
• Loss Control and cost reduction strategies
• Product liability, Legal liability, Property
damage
• Risk retention or transfer
• Investment decisions concerning business
acquisitions
 Human Resources
• Work and job structuring
• Morale and retaining people
• Positive health structure
 Marketing, product design and product
liability
• Specification of product and service
• Legal requirement
• International requirement
• Consumer protection act
 Manufacturing and operating policy
• Design/selection/construction/maintenance
of premises, plant, equipment and substances
• Quality management
• Environment management and waste disposal
 DIFFERENT TYPES OF AUDIT
• Electrical Audit
• Fire Safety Audit
• Pressure vessels Audit
• Lifting Tackles Audit
• Statutory Regulations Compliance Audit
• Emergency Communication Audit
• Pipe lines Audit
 SCOPE OF AUDIT
• Fire and explosion; prevention, protection and
emergency management.
• Work injury prevention.
• Health hazards control.
• Consequences of emergencies.
• On site emergency control
 Records to be examined during Audit
• OS & H Policy
• Safety organization chart
• Training Records on safety, fire and first aid
• Accident investigation reports
• Accidents and dangerous occurrences-
Statistics and analysis
 Records to be examined during Audit
• Records of tests and examination of equipment
and structures
• Safe operating procedures for various operations
• Record of work permits
• Record of montioring of flammable and explosives
• Maintenance and testing records of fire detection
and fire fighting equipment
• Medical records of employees

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Records to be examined during Audit
• Minutes of Safety committee meetings
• Records of any modifications carried out in
plant and process
• Maintenance procedure records
• Calibration and testing records
• Shutdown maintenance procedures
• Safety Budget
• Statutory Records, Previous audit reports,
Transportation of Hazardous substances
Records to be examined during Audit
• Records of industrial hygiene surveys(noise,
ventilation, illumination levels, airborne
and toxic substances, explosive gases)
• Onsite emergency plans
• Records of waste disposal
• Records of effluent discharge to the
environment
• Housekeeping inspection records
HAZARD IDENTIFICATION
AND RISK ASSESSMENT

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 Introduction
Safety management leads to
• Increased productivity
• Avoiding injuries
• Avoiding costly, time consuming, stressful and
inconvenient incidents
 Hazards
• Hazard: condition or set of circumstances that
present a potential for harm

• Two categories
 Hazards
• Health hazards: occupational illnesses

• Safety hazards: physical harm, injuries

 Hazard Identification
• Process of identifying all hazards in the workplace
 Example : Dairy Product Manufacturing

• Manure storage facilities and collections

structures

• Dairy bull and cow behavior/worker positioning

• Electrical systems
 Dairy DPM
• Skid-steer loader operation

• Tractor operation

• Guarding of Power Take-Offs (PTOs)

 Dairy DPM
• Guarding of other power transmission and
functional components

• Hazardous energy control while performing

servicing and maintenance on equipment

• Hazard communication
 Dairy DPM
• Confined spaces

• Horizontal bunker silos

• Noise
 Hazard Identification

• Main cause of occupational health and safety

problems

• Eliminating hazards or controlling risks is the

best way to reduce workplace injury and illness
 How to Start?
• Check your farm for:
– Regular hazard assessment surveys of
operations, equipment, substances and tasks

– A system of recording injuries, near misses and

identified hazards

– Safe procedures for dairy farm tasks

 How to start ?
– Safety training and supervision for new and
young employees

– Protective clothing and equipment

– Safety training and practice for each new piece of

equipment
 How to start ?
– Safety discussions between employers,
contractors and employees

– Safety information readily available for

hazardous substances

– Copies of the regulations

 Develop a plan
• Written plan

• Store with other safety information

 Develop a plan
• Discuss the program with others during
development
– Assure all safety concerns are met
– Incorporate a system for hazard identification,
risk assessment and risk control
 Develop a Plan
• Ensure employees are familiar with:
– the plan
– safe work procedures
– current legal safety and health requirements
 Develop a plan

• Other components
– Providing farm workers with safety information
– Orientation for new employees
– Safety training for new procedures
– Special safeguards for young employees
– Record of injuries, near misses and potential
hazards
 Identify the Hazard
• 24 hour approach

• Environments

• Substances

• Workplace layout
 Identify the
hazard
• Work organization

• Equipment

• Farm animals
 Identify the
hazard
• Heights

• Electricity
 Hazard Identification
• Observation

• Material Safety Data Sheets (MSDSs)

• Hazard and risk surveys

• Children and visitor considerations

 Hazard
Identification
• Record analysis

• Discussion groups

• Safety audits
 Hazard Identification
• Information updates

• Consumer information

• Regulations and best practices

 Assessment of Risk
• Assess likelihood and possible severity of
injury

• Determine how to best minimize risk

• Address high risk hazards first

 Assessment of Risk
• The same hazard could lead to several
outcomes

• Consider likelihood of each possibility

• Prioritize

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 Make the Changes
Potential control measures include:

• Remove the hazard

• Substitute

• Isolate

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 Make the changes
• Add engineering controls

• Safe work practices

• Provide PPE

• Implement and monitor controls

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 Make the changes
• Controls should be agreed upon

• Make changes as soon as possible

• May require more than one risk control measure

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 Checking the Changes
• May need to be tested
– Ensure that risk is minimized
– No new hazard created

• Consultation

• New procedures

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 Job Hazard Analysis (JHA)
• Focus on job tasks
• Prevention
• Relationship between
– worker
– task
– tools
– environment

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