1147 - DIPLOMA IN DIGITAL

MANUFACTURING TECHNOLOGIES

Book Material
Of
INDUSTRIAL SAFETY AND
ENVIRONMENTAL MANAGEMENT

SUBJECT CODE: 1147233210

(FOR III SEMESTER DIPLOMA DIGITAL MANUFACTURING

TECHNOLOGIES)

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 PROGRAMME OUTCOMES

PO1: Basic and Discipline specific knowledge: Apply knowledge of basic mathematics, science and
engineering fundamentals and engineering specialization to solve the engineering problems.

PO2: Problem analysis: Identify and analyse well-defined engineering problems using codified standard
methods.

PO3: Design/ development of solutions: Design solutions for well-defined technical problems and assist
with the design of systems components or processes to meet specified needs.

PO4: Engineering Tools, Experimentation and Testing: Apply modern engineering tools and appropriate
technique to conduct standard tests and measurements.

PO5: Engineering practices for society, sustainability and environment: Apply appropriate technology
in context of society, sustainability, environment and ethical practices.

PO6: Project Management: Use engineering management principles individually, as a team member or a
leader to manage projects and effectively communicate about well-defined engineering activities.

PO7: Life-long learning: Ability to analyse individual needs and engage in updating in the context of
technological changes.

COURSE OBJECTIVE:
 To understand the importance of natural resources, pollution control and waste management.
 To provide the students about the current social issues and environmental legislations.

CURRICULAM TABLE:

UNIT TOPIC HOURS PER UNIT

I CONCEPTS AND TECHNIQUES 9

II SAFETY EDUCATION ANDTRAINING 9

III SAFETYAUDITAND ACCIDENT INVESTIGATION 9

IV ENVIRONMENTAL SAFETY 9

V POLLUTION CONTROL AND FACTORIES ACT 9

TOTAL HOURS 45 hours

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 INDUSTRIAL SAFETY AND ENVIRONMENTAL MANAGEMENT

DETAILED SYLLABUS

UNIT- I: CONCEPTS AND TECHNIQUES (9 HOURS)

History of Safety movement –Evolution of modern safety concept- general concepts of management –
planning for safety for optimization of productivity - productivity, quality and safety-line.job safety analysis,
safety survey, safety inspection, safety sampling, evaluation of performance of supervisors on safety.

UNIT – II SAFETY EDUCATION AND TRAINING (9 HOURS)

Importance of training-identification of training needs-training methods – programs, seminars, conferences,
competitions – method of promoting safe practice - motivation – communication – creating awareness,
awards, celebrations, safety posters, safety displays, safety pledge, safety incentive
scheme, safety campaign–Domestic Safety and Training.

UNIT-III: SAFETY AUDITAND ACCIDENT INVESTIGATION (9 HOURS)

Components of safety audit, types of audit, audit methodology, audit checklist and report – review of
inspection, remarks by government agencies, consultants, experts perusal of accident and safety records,
formats, Concept of an accident, reporting to statutory authorities–principles of accident prevention–accident
investigation and analysis.

UNIT-IV: ENVIRONMENTALSAFETY (9 HOURS)

Air pollutants – Pollution sources – Effects of air pollutants on human beings, Animals, Plants and
Materials- water pollutants-health hazards-sampling and analysis of water-water treatment - Hazardous
waste management, waste identification, characterization and classification technological options for
collection, treatment and disposal of hazardous waste.

UNIT-V: POLLUTION CONTROL AND FACTORIES ACT (9 HOURS)

Pollution control in process industries like cement, paper, petroleum - petroleum products textile-tanneries-
thermal power plants – dying and pigment industries. Tamilnadu Factories Rules1950 under Safety and
health chapters of Factories Act1948.–Tamilnadu Safety Officer Rules 2005.

REFERENCE BOOKS:
1. Blake R.B., “IndustrialSafety” Prentice Hall, Inc., NewJersey,.3rd Edition 2000.
2. Dan Petersen, “Techniques of Safety Management”, McGraw-Hill Company, Tokyo, 1981.
3. G.T Miller, Environmental Science : Working with the Earth,11Edition,Wadsworth Publishing Co.,
Belmont, CA, 2006.
4. Rao, CS,“Environmental pollution engineering:,Wiley Eastern Limited, NewDelhi,1 January 2018.
5. S.P.Mahajan,“Pollution control in process industries”,Tata McGraw Hill Publishing Company, New
Delhi, 2006.

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 Industrial Safety and Environmental Management involves creating
and maintaining a safe industrial environment, identifying hazards,
preventing accidents, and ensuring sustainable practices

UNIT- I
CONCEPTS AND TECHNIQUES
TOPICS History of Safety movement –Evolution of modern safety concept- general concepts of
management – planning for safety for optimization of productivity - productivity, quality
and safety-line. Job safety analysis, safety survey, safety inspection, safety sampling, and
evaluation of performance of supervisors on safety.
DURATION (9 HOURS)

History of the Safety Movement

The safety movement has a long and varied history, with several key events and milestones that have shaped
the modern safety landscape. Here are some of the most significant events in the history of the safety
movement:

- Early Beginnings: The safety movement began in the late 18th century, with the publication of
Bernardino Ramazzini's book on occupational diseases in 1700.

- Factory Act of 1802: The Factory Act of 1802 was one of the first laws to regulate working conditions
in factories and mills, and was a major milestone in the safety movement.

- Industrial Revolution: The Industrial Revolution brought about significant changes in working
conditions, with many workers facing hazardous conditions and long hours.

- Labor Movement: The labor movement of the late 19th and early 20th centuries led to significant
improvements in working conditions and labor laws.

- OSHA: The Occupational Safety and Health Act (OSHA) was passed in 1970, and established the
Occupational Safety and Health Administration (OSHA) to regulate workplace safety.

- HSE: The Health and Safety Executive (HSE) was established in the UK in 1974, following a major
chemical plant disaster.

- Modern Safety Movement: Today, the safety movement continues to evolve, with a focus on
preventing workplace injuries and illnesses, and promoting safe working conditions.

Key Events and Milestones

- 1911: The Triangle Shirtwaist Company fire killed 146 employees, leading to major changes in labor
laws and workplace safety regulations.

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 - 1960: The Hogg's Hollow disaster in Canada led to the modernization of safety regulations and the
enactment of the Industrial Safety Act.

- 1970: OSHA was passed, establishing the Occupational Safety and Health Administration to regulate
workplace safety.

- 1974: The Health and Safety at Work Act was passed in the UK, following a major chemical plant
disaster.

- 2000: The Institute of Medicine published a report on the history of occupational safety and health,
highlighting the major milestones and events in the safety movement.

Evolution of Modern Safety Concept

The evolution of modern safety concepts has transformed significantly over time, with various
milestones and developments contributing to its growth. Here are some key aspects of the evolution of
modern safety concepts:

- Early Beginnings: The concept of safety evolved from a population-based approach, with early
civilizations focusing on common interests and kinship.

- Code of Hammurabi: The Code of Hammurabi (2100 BC) is one of the earliest known safety
regulations, focusing on punishing countermeasures rather than direct prevention.

- Industrial Revolution: The Industrial Revolution brought about significant changes in working
conditions, leading to the development of labor laws and regulations.

- Worker's Compensation: The concept of worker's compensation emerged, focusing on

indemnification and enforcement approaches.

- OSHA: The Occupational Safety and Health Administration (OSHA) was established in 1970,
marking a significant milestone in modern safety concepts.

- Risk Management: Modern safety concepts focus on risk management, with an emphasis on
identifying and mitigating potential hazards.

- Technology: Technology plays a crucial role in modern safety concepts, with advancements in
digital technology enabling the transformation towards functional safety approaches.

- Safety Science: The field of safety science has emerged, focusing on understanding accident
processes and developing theories to prevent them.

- Contemporary Approaches: Contemporary approaches to safety emphasize the importance of

culture, training, and employee involvement in creating safer workplaces

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General Concepts of Management

Management involves planning, organizing, leading, and controlling resources to achieve specific goals and
objectives. Here are some general concepts of management:

1. Planning: Defining goals, objectives, and strategies for achieving them.

2. Organizing: Allocating resources, assigning tasks, and structuring the organization.

3. Leading: Directing, motivating, and influencing others to achieve goals.

4. Controlling: Monitoring, measuring, and correcting performance to ensure goals are met.

5. Decision Making: Identifying problems, generating options, and choosing solutions.

6. Communication: Exchanging information, ideas, and feedback within the organization.

7. Motivation: Encouraging and inspiring others to achieve their best.

8. Leadership: Influencing and guiding others to achieve shared goals.

9. Teamwork: Collaborating and working together to achieve common objectives.

10. Accountability: Taking responsibility for actions, decisions, and outcomes.

11. Adaptability: Responding to changes, challenges, and opportunities.

12. Innovation: Generating new ideas, methods, and solutions.

13. Problem-Solving: Identifying, analyzing, and resolving problems.

14. Time Management: Prioritizing, scheduling, and managing time effectively.

15. Delegation: Assigning tasks, responsibilities, and authority to others.

These general concepts of management provide a foundation for effective management practices in various
contexts and organizations.

Planning for Safety to Optimize Productivity

To optimize productivity, safety planning is crucial. Here are some steps to consider:

1. Hazard Identification: Identify potential hazards and risks associated with tasks and processes.

2. Risk Assessment: Assess the likelihood and impact of identified hazards.

3. Safety Goals and Objectives: Establish clear safety goals and objectives aligned with productivity
targets.

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 4. Safety Policies and Procedures: Develop and implement safety policies and procedures to mitigate
risks.

5. Training and Awareness: Provide regular training and awareness programs for employees on
safety procedures and best practices.

6. Personal Protective Equipment (PPE): Ensure adequate PPE is available and used correctly.

7. Safety Inspections and Audits: Conduct regular safety inspections and audits to identify and
address potential safety issues.

8. Incident Reporting and Investigation: Establish a system for reporting and investigating incidents
to identify root causes and implement corrective actions.

9. Continuous Improvement: Regularly review and update safety plans to ensure they remain
effective and aligned with changing processes and technologies.

10. Employee Participation: Encourage employee participation in safety planning and decision-
making processes.

By integrating safety planning into productivity optimization efforts, organizations can:

- Reduce accidents and injuries

- Minimize downtime and lost productivity
- Improve employee morale and engagement
- Enhance reputation and compliance
- Achieve cost savings through reduced workers' compensation claims and liability

Remember, safety and productivity are interdependent; a safe work environment is essential for optimal
productivity.

Productivity, Quality, and Safety: Interconnected Concepts

Productivity, quality, and safety are interconnected concepts that impact each other and are essential for
organizational success. Here's how they relate:

Productivity:
- Refers to the efficiency and effectiveness of processes and workflows
- Aims to maximize output while minimizing resources and time
- Impacts quality and safety by:
- Influencing the pace of work, which can affect attention to detail and safety protocols
- Determining resource allocation, which can impact quality control measures

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Quality:
- Refers to the standard of products, services, or processes
- Aims to meet or exceed customer expectations and requirements
- Impacts productivity and safety by:
- Requiring attention to detail, which can slow down productivity
- Influencing the design and implementation of safety protocols to prevent defects or errors
Safety:
- Refers to the protection of people, equipment, and the environment from harm
- Aims to prevent injuries, illnesses, and damage
- Impacts productivity and quality by:
- Requiring adherence to safety protocols, which can slow down productivity
- Influencing the design and implementation of processes to prevent accidents and ensure quality

The Safety-Line:
- Represents the minimum safety standards and protocols required to protect people and the
environment
- Serves as a boundary beyond which productivity and quality efforts should not compromise safety
- Ensures that productivity and quality gains do not come at the expense of safety

Balancing Productivity, Quality, and Safety:

- Organizations must strike a balance between these interconnected concepts
- Improving one aspect can positively impact the others, but compromising one can negatively
impact the others
- Continuous monitoring and improvement are necessary to maintain this balance and ensure overall
organizational success

1. Job Safety Analysis (JSA): A systematic process to identify and evaluate potential hazards associated
with a specific job or task, and implement controls to mitigate or eliminate risks.

2. Safety Survey: A comprehensive review of a workplace or facility to identify potential safety hazards,
assess compliance with safety regulations, and provide recommendations for improvement.

3. Safety Inspection: A regular, thorough examination of a workplace or facility to identify and correct
safety hazards, ensure compliance with safety regulations, and maintain a safe working environment.

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4. Safety Sampling: A method of monitoring and assessing workplace hazards by collecting and analyzing
samples of substances, materials, or environmental factors to determine potential risks.

5. Evaluation of Performance of Supervisors on Safety: A process to assess and measure the safety
performance of supervisors, including their ability to:
- Identify and mitigate hazards
- Implement safety procedures and protocols
- Train and supervise employees on safety practices
- Investigate incidents and implement corrective actions
- Maintain a safe working environment

These tools and processes are essential components of a comprehensive safety management system, helping
organizations to:

- Identify and control hazards

- Prevent injuries and illnesses
- Ensure compliance with safety regulations
- Promote a safety culture
- Continuously improve safety performance

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 UNIT- II
SAFETY EDUCATION AND TRAINING
TOPICS Importance of training- identification of training needs - training methods – programs,
seminars, conferences, competitions – method of promoting safe practice - motivation –
communication – creating awareness, awards, celebrations, safety posters, safety displays,
safety pledge, safety incentive scheme, safety campaign – Domestic Safety and Training.

DURATION (9 HOURS)

Safety Education and Training:

Safety education and training are essential components of a comprehensive safety management system. They
aim to equip employees with the knowledge, skills, and attitudes necessary to perform their jobs safely and
efficiently.

Safety Education and Training:

1. Induction Training: New employee orientation, company policies, and safety procedures.
2. Refresher Training: Periodic updates for existing employees to reinforce safety knowledge.
3. Specialized Training: Equipment-specific, process-specific, or role-specific training.
4. Safety Awareness Programs: General safety awareness, hazard recognition, and risk assessment.
5. Emergency Response Training: Fire evacuation, first aid, and emergency procedures.
6. Job-Specific Training: Task-specific training for high-risk jobs or new equipment.
7. Supervisory Training: Leadership, safety responsibility, and incident investigation.
8. Safety Officer Training: Comprehensive training for safety officers and committee members.
9. Contractor Safety Training: Site-specific safety training for contractors and visitors.
10. Regulatory Compliance Training: Training on relevant safety regulations and standards.

Training Methods:
1. Classroom instruction
2. On-the-job training
3. Simulations and mock drills
4. Online training and e-learning
5. Workshops and group activities
6. Demonstrations and hands-on practice
7. Case studies and scenario-based training
8. Video-based training
9. Virtual reality training
10. Gamification and interactive training

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Training Evaluation:
1. Written tests and quizzes
2. Practical demonstrations and skills assessment
3. Observations and feedback
4. Training program evaluation and audit
5. Employee feedback and suggestions
6. Incident and accident analysis
7. Compliance audits and inspections
8. Continuous improvement and updating of training programs

Importance of Training:
1. Improved Safety: Reduces accidents and incidents by teaching employees how to work safely.
2. Increased Productivity: Enhances employee performance and efficiency by providing them with
the necessary skills and knowledge.
3. Compliance: Ensures adherence to regulatory requirements and industry standards.
4. Employee Confidence: Boosts employee confidence and morale by providing them with the skills
and knowledge to perform their jobs effectively.
5. Reduced Errors: Minimizes errors and mistakes by teaching employees how to perform tasks
correctly.
6. Better Decision Making: Empowers employees to make informed decisions by providing them
with the necessary knowledge and skills.
7. Improved Communication: Fosters effective communication among employees, supervisors, and
management.
8. Adaptability: Prepares employees to adapt to new technologies, processes, and procedures.
9. Competitive Advantage: Enhances the organization's reputation and competitiveness by
demonstrating a commitment to employee development and safety.
10. Cost Savings: Reduces costs associated with accidents, errors, and rework by investing in
employee training and development.

By providing regular training, organizations can ensure that their employees have the necessary skills,
knowledge, and attitudes to perform their jobs safely and effectively.

Identification of Training Needs:

1. Job Analysis: Analyze job tasks and responsibilities to identify skills and knowledge required.
2. Performance Appraisal: Evaluate employee performance to identify skill gaps.
3. Safety Audits: Conduct safety audits to identify areas for improvement.
4. Employee Feedback: Solicit feedback from employees to identify training needs.

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 5. Industry Standards: Review industry standards and regulations to ensure compliance.

Training Methods:
1. Classroom Training: Instructor-led training in a classroom setting.
2. On-the-Job Training: Training while performing actual job tasks.
3. Simulation-Based Training: Training using simulated scenarios.
4. Mentoring: One-on-one training with an experienced mentor.
5. E-Learning: Online training using digital resources.
6. Coaching: Guided training to improve specific skills.
7. Workshops: Interactive training sessions on specific topics.

Training Programs:
1. Induction Training: Training for new employees.
2. Job-Specific Training: Training for specific job tasks.
3. Safety Training: Training on safety procedures and protocols.
4. Soft Skills Training: Training on communication, teamwork, and leadership.
5. Compliance Training: Training on industry regulations and standards.
6. Refresher Training: Training to reinforce existing knowledge and skills.
7. Certification Programs: Training leading to industry-recognized certifications.

By identifying training needs and selecting appropriate training methods and programs, organizations can:
1. Improve employee knowledge and skills.
2. Enhance safety performance.
3. Increase productivity.
4. Ensure compliance with regulations.
5. Develop a competent and confident workforce.

Seminars, Conferences, and Competitions:

These events offer opportunities for learning, networking, and skill-building in the field of safety and health.
Seminars:
- In-depth discussions on specific safety topics
- Expert-led presentations and workshops
- Small group settings for interactive learning

Conferences:
- Large-scale events with multiple sessions and speakers
- Keynote addresses from industry leaders

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 - Networking opportunities with peers and experts

Competitions:
- Safety quizzes and trivia contests
- Poster or presentation competitions
- Innovation challenges for safety solutions

Benefits:
- Stay updated on latest safety trends and research
- Network with professionals and experts
- Showcase skills and knowledge
- Learn from best practices and case studies
- Enhance career development and professional growth

Examples:
- National Safety Council (NSC) Congress & Expo
- American Society of Safety Professionals (ASSP) Conference
- International Safety Conference (ISC)
- Safety Innovation Awards
- Safety Quiz Bowl competitions

By participating in seminars, conferences, and competitions, individuals can:

- Enhance their safety knowledge and skills
- Stay current with industry developments
- Connect with peers and thought leaders
- Demonstrate expertise and commitment to safety
- Contribute to the advancement of the safety profession

Methods of Promoting Safe Practice:

1. Motivation:
- Recognize and reward safe behavior
- Encourage employee participation in safety initiatives
- Provide incentives for reporting hazards and near misses
- Foster a sense of ownership and responsibility for safety
2. Communication:
- Clear and concise safety policies and procedures
- Regular safety training and updates

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 - Open communication channels for reporting concerns
- Visible leadership commitment to safety
- Safety signage and visual reminders
3. Leading by Example:
- Demonstrate safe behavior by leaders and managers
- Encourage a safety-first culture
4. Employee Empowerment:
- Involve employees in safety decision-making
- Provide resources and support for safety initiatives
5. Continuous Improvement:
- Regularly review and update safety procedures
- Encourage feedback and suggestions for improvement
6. Safety Champions:
- Appoint safety champions to promote safety in their areas
- Provide training and support for safety champions
7. Safety Recognition Programs:
- Recognize and reward employees for safety achievements
- Celebrate safety milestones and successes
Effective communication is critical to promoting safe practice. It should be:
1. Clear: Easy to understand
2. Concise: To the point
3. Consistent: Regular and repeated
4. Visible: Safety information should be prominently displayed
5. Accessible: Safety information should be easily accessible to all employees
By using these methods, organizations can promote a culture of safety, encourage safe behavior, and reduce
the risk of accidents and injuries.

Creating Awareness:
1. Safety Posters: Eye-catching visuals with safety messages
2. Safety Displays: Interactive exhibits showcasing safety practices
3. Safety Pledge: A promise to prioritize safety, signed by employees
4. Awards and Recognition: Honoring safety achievements and milestones
5. Celebrations: Marking safety successes and awareness campaigns
6. Safety Ambassadors: Employee champions promoting safety
7. Safety Training: Regular sessions on safety procedures and best practices
8. Safety Newsletter: A regular publication sharing safety news and tips
9. Safety Slogan: A catchy phrase promoting safety, displayed prominently

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 10. Safety Week/Month: A dedicated period for safety awareness and activities

Awards:
1. Safety Champion Award: Recognizing individual safety contributions
2. Safety Team Award: Honoring team safety achievements
3. Safety Innovation Award: Encouraging new safety ideas and solutions

Celebrations:
1. Safety Milestone Celebrations: Marking accident-free periods or safety achievements
2. National Safety Day/Week/Month: Participating in global safety awareness initiatives
3. Safety Awareness Campaigns: Organized events promoting safety consciousness

Safety Posters and Displays:

1. Safety Reminders: Visual cues promoting safe behavior
2. Hazard Alerts: Warning signs highlighting potential dangers
3. Safety Success Stories: Displaying positive safety outcomes

Safety Pledge:
1. Employee Safety Commitment: A promise to prioritize safety
2. Leadership Safety Pledge: A commitment from leaders to support safety initiatives
These activities aim to engage employees, promote safety consciousness, and foster a culture of safety
within the organization.

Safety Incentive Scheme:

1. Reward System: Recognize and reward employees for safe behavior, reporting hazards, and
contributing to safety initiatives.
2. Points System: Assign points for safety achievements, redeemable for rewards or prizes.
3. Safety Bonus: Offer bonuses for meeting safety targets or milestones.
4. Safety Recognition Program: Publicly acknowledge and reward safety champions.
5. Safety Suggestion Scheme: Encourage and reward employees for submitting safety ideas.

Safety Campaign:
1. Theme-Based Campaigns: Focus on specific safety topics, such as fall prevention or electrical
safety.
2. Posters and Visuals: Display eye-catching posters, banners, and safety signs.
3. Safety Workshops: Conduct interactive training sessions and workshops.
4. Safety Ambassadors: Appoint employee champions to promote safety messages.

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 5. Safety Drives: Organize regular safety awareness drives, such as safety weeks or months.
6. Communication Materials: Distribute safety newsletters, brochures, and emails.
7. Events and Activities: Host safety events, such as safety fairs, quizzes, and competitions.

Examples of Safety Campaigns:

1. "Safety First" campaign
2. "Zero Accidents" campaign
3. "Safety Awareness Month"
4. "Hazard Reporting Initiative"
5. "Safe Behavior Campaign"
6. "Safety Champions Program"
7. "Fall Prevention Campaign"
A well-designed safety incentive scheme and safety campaign can:
1. Encourage employee participation in safety initiatives
2. Increase safety awareness and consciousness
3. Reduce accidents and injuries
4. Improve safety performance and metrics
5. Foster a positive safety culture

Domestic Safety and Training:

Domestic safety refers to the practices and measures taken to ensure a safe and healthy environment
within the home. Training is an essential aspect of domestic safety, as it empowers individuals with the
knowledge and skills to identify and mitigate potential hazards.

Key Areas of Domestic Safety and Training:

1. Fire Safety:
- Fire prevention and extinguishing techniques
- Emergency evacuation procedures
2. First Aid and Emergency Response:
- Basic life support and first aid techniques
- Response to common injuries and illnesses
3. Food Safety and Hygiene:
- Proper food handling and storage techniques
- Prevention of foodborne illnesses
4. Home Maintenance and Repair:
- Safe use of tools and equipment

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 - Prevention of accidents and injuries
5. Electrical Safety:
- Safe use of electrical appliances and outlets
- Prevention of electrical shocks and fires
6. Fall Prevention:
- Identifying and mitigating fall hazards
- Safe mobility and balance techniques
7. Poison Prevention:
- Safe storage and handling of chemicals and medications
- Prevention of poisoning incidents
8. Water Safety:
- Safe use of water appliances and fixtures
- Prevention of drowning and water-related accidents

Training Methods:
1. Workshops and Seminars
2. Online Courses and Tutorials
3. Demonstrations and Hands-on Training
4. Safety Drills and Simulations
5. One-on-One Coaching and Mentoring
By providing domestic safety training, individuals can:
1. Reduce the risk of accidents and injuries
2. Ensure a safe and healthy living environment
3. Develop essential life skills and knowledge
4. Enhance their overall well-being and quality of life

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 UNIT- III
SAFETY AUDIT AND ACCIDENT INVESTIGATION

TOPICS Components of safety audit, types of audit, audit methodology, audit checklist and report –
review of inspection, remarks by government agencies, consultants, experts perusal of
accident and safety records, formats, Concept of an accident, reporting to statutory
authorities–principles of accident prevention–accident investigation and analysis.

DURATION (9 HOURS)

Safety Audit:
A systematic examination of a workplace or process to identify hazards, assess risks, and evaluate the
effectiveness of existing safety measures.

Types of Safety Audits:

1. Compliance Audit: Verifies adherence to regulatory requirements.
2. Risk-Based Audit: Focuses on identifying and mitigating potential hazards.
3. Process Audit: Evaluates specific processes or procedures.
4. Management System Audit: Assesses the overall safety management system.

Accident Investigation:
A thorough examination of an incident or accident to determine its root causes, identify contributing factors,
and implement corrective actions to prevent recurrence.

Steps in Accident Investigation:

1. Initial Response: Secure the scene, provide medical attention, and notify authorities.
2. Data Collection: Gather evidence, statements, and documentation.
3. Analysis: Identify root causes, contributing factors, and safety deficiencies.
4. Recommendations: Develop corrective actions and improvements.
5. Implementation: Put recommendations into practice.
6. Follow-up: Monitor and evaluate effectiveness.

Benefits of Safety Audits and Accident Investigations:

1. Improved Safety Performance
2. Reduced Risk and Liability
3. Enhanced Compliance
4. Increased Employee Awareness
5. Better Decision-Making
6. Reduced Costs and Downtime

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By conducting regular safety audits and thorough accident investigations, organizations can:
1. Proactively identify and mitigate hazards
2. Reduce the likelihood and impact of accidents
3. Improve overall safety performance and culture
4. Ensure compliance with regulatory requirements
5. Enhance their reputation and credibility

Components of a Safety Audit:

1. Pre-Audit Planning:

- Define scope and objectives

- Identify audit team and roles

- Develop audit checklist and protocol

2. Documentation Review:

- Examine safety policies and procedures

- Review incident reports and records

- Evaluate training programs and records

3. Site Inspection:

- Observe workplace conditions and practices

- Identify hazards and risks

- Evaluate physical controls and safeguards

4. Interviews and Surveys:

- Talk to employees, supervisors, and management

- Gather information on safety perceptions and concerns

- Assess safety culture and awareness

5. Observation of Work Practices:

- Watch employees perform tasks and activities

- Evaluate adherence to safety procedures

- Identify potential hazards and risks

6. Equipment and Machinery Inspection:

- Examine condition and maintenance of equipment

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 - Evaluate guarding and safety devices

- Check for proper use and operation

7. Emergency Preparedness and Response:

- Evaluate emergency plans and procedures

- Assess training and preparedness

- Review incident response and reporting

8. Regulatory Compliance:

- Verify adherence to relevant laws and regulations

- Evaluate permits and certifications

- Review compliance records and reports

9. Audit Findings and Recommendations:

- Document audit results and findings

- Provide recommendations for improvement

- Prioritize and categorize recommendations

10. Follow-up and Closure:

- Track implementation of recommendations

- Verify effectiveness of corrective actions

- Close out audit findings and recommendations

By including these components, a safety audit can provide a comprehensive evaluation of an organization's
safety management system and identify areas for improvement.

Types of Audits:

1. Compliance Audit: Verifies adherence to regulations and standards.

2. Risk-Based Audit: Focuses on identifying and mitigating potential hazards.

3. Process Audit: Evaluates specific processes or procedures.

4. Management System Audit: Assesses the overall safety management system.

5. Internal Audit: Conducted by internal auditors to evaluate organizational processes.

6. External Audit: Conducted by external auditors to provide an independent evaluation.

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Audit Methodology:

1. Pre-Audit Planning: Define scope, objectives, and audit protocol.

2. Document Review: Examine relevant documents and records.

3. Site Inspection: Observe workplace conditions and practices.

4. Interviews and Surveys: Gather information from employees and management.

5. Data Analysis: Evaluate data and identify trends and patterns.

6. Reporting and Follow-up: Document findings and track corrective actions.

Audit Checklist:

1. Safety Policies and Procedures

2. Training Programs and Records

3. Incident Reporting and Investigation

4. Risk Assessment and Control

5. Emergency Preparedness and Response

6. Equipment Maintenance and Inspection

7. Compliance with Regulations and Standards

8. Employee Participation and Involvement

9. Continuous Improvement and Review

10. Management Commitment and Leadership

Audit Report:

1. Executive Summary: Overview of audit findings and recommendations.

2. Introduction: Background and scope of the audit.

3. Findings and Observations: Detailed description of audit results.

4. Recommendations and Action Plan: Proposed corrective actions and timeline.

5. Conclusion and Follow-up: Summary of audit results and follow-up activities.

6. Appendices: Supporting documents and evidence.

By using a structured audit methodology, checklist, and report, organizations can ensure a comprehensive
and effective safety audit process.

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Review of Inspection:

1. Purpose: Evaluate the effectiveness of the inspection process.

2. Scope: Review of inspection procedures, checklists, and reports.

3. Methodology:

- Document review

- Interviews with inspectors and management

- Observation of inspection activities

4. Criteria:

- Compliance with regulations and standards

- Adherence to inspection procedures

- Effectiveness of inspection checklists

- Quality of inspection reports

- Timeliness and frequency of inspections

5. Findings and Recommendations:

- Identify strengths and weaknesses of the inspection process

- Provide recommendations for improvement

- Prioritize and categorize recommendations

6. Implementation and Follow-up:

- Track implementation of recommendations

- Verify effectiveness of corrective actions

- Review and update inspection procedures and checklists

Types of Inspection Reviews:

1. Internal Review: Conducted by internal auditors or quality teams.

2. External Review: Conducted by external auditors or regulatory agencies.

3. Peer Review: Conducted by peers or industry experts.

Benefits of Inspection Review:

1. Improved Inspection Effectiveness

2. Enhanced Compliance

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 3. Increased Efficiency

4. Better Decision-Making

5. Reduced Risk and Liability

By regularly reviewing the inspection process, organizations can ensure that their inspection activities are
effective, efficient, and compliant with regulatory requirements.

Remarks by Government Agencies:

1. Regulatory Compliance: Comments on adherence to safety regulations and standards.

2. Enforcement Actions: Notes on any enforcement actions taken due to non-compliance.

3. Recommendations for Improvement: Suggestions for enhancing safety practices.

Remarks by Consultants:

1. Best Practices: Comments on alignment with industry best practices.

2. Risk Assessment: Evaluation of risk assessment and mitigation strategies.

3. Safety Management System: Assessment of the overall safety management system.

Remarks by Experts:

1. Technical Expertise: Comments on technical aspects of safety practices.

2. Industry Standards: Evaluation of adherence to industry standards.

3. Innovation and Improvement: Suggestions for innovative safety solutions.

Perusal of Accident and Safety Records:

1. Accident Reports: Review of accident reports and investigation findings.

2. Safety Incident Reports: Examination of safety incident reports and near-miss reports.

3. Safety Performance Metrics: Analysis of safety performance metrics and trends.

Formats:

1. Checklists: Standardized checklists for evaluating safety practices.

2. Audit Reports: Detailed reports on safety audits and assessments.

3. Scorecards: Visual representation of safety performance metrics.

4. Dashboards: Real-time display of safety performance data.

5. Spreadsheets: Tabular format for tracking and analyzing safety data.

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By considering remarks from government agencies, consultants, and experts, as well as reviewing accident
and safety records in various formats, organizations can gain a comprehensive understanding of their safety
practices and identify areas for improvement.

Concept of an Accident:

- An unexpected event that results in injury, illness, or damage to property, equipment, or the
environment.

- Can be classified into different types, such as:

- Work-related accidents

- Occupational diseases

- Environmental accidents

Reporting to Statutory Authorities:

- Mandatory requirement to report accidents to relevant authorities, such as:

- Occupational safety and health administrations

- Environmental protection agencies

- Labor departments

- Principles of reporting:

- Timeliness

- Accuracy

- Completeness

- Confidentiality

Principles of Accident Prevention:

- Identify hazards and assess risks

- Implement controls and safeguards

- Monitor and review safety performance

- Continuously improve safety practices

- Employee participation and training

Accident Investigation and Analysis:

- Systematic process to determine the root causes of an accident

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 - Identify contributing factors and safety deficiencies

- Develop recommendations for corrective actions

- Implement changes to prevent recurrence

- Types of investigations:

- Preliminary investigation

- Detailed investigation

- Root cause analysis (RCA)

Analysis Techniques:

- Fishbone diagram (Ishikawa diagram)

- Fault tree analysis (FTA)

- Event tree analysis (ETA)

- SWIFT analysis (Structured What-If Technique)

- Barrier analysis

By understanding the concept of an accident, reporting requirements, principles of accident prevention, and
investigation and analysis techniques, organizations can effectively manage safety risks and prevent
accidents.

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 UNIT- IV
ENVIRONMENTAL SAFETY

TOPICS Air pollutants – Pollution sources – Effects of air pollutants on human beings, Animals,
Plants and Materials- water pollutants-health hazards-sampling and analysis of water-water
treatment - Hazardous waste management, waste identification, characterization and
classification technological options for collection, treatment and disposal of hazardous
waste.
DURATION (9 HOURS)

Air pollution is the contamination of air due to the presence of substances called pollutants in the atmosphere
that are harmful to the health of humans and other living beings, or cause damage to the climate or to
materials.

Types of Air Pollutants

- Gases: ammonia, carbon monoxide, sulfur dioxide, nitrous oxides, methane and
chlorofluorocarbons.

- Particulates: both organic and inorganic.

- Biological molecules.

Effects of Air Pollution

- Diseases: respiratory infections, heart disease, chronic obstructive pulmonary disease (COPD),
stroke, and lung cancer.

- Allergies:

- Death: air pollution can cause death to humans; it can also cause harm to other living organisms
such as animals and crops, and may damage the natural environment.

Sources of Air Pollution

- Human activities: fossil fuel power plants, oil and gas sites, manufacturing facilities, waste
incineration, furnaces and other types of fuel-burning heating devices, motor vehicles, trains, marine
vessels and aircraft.

- Natural phenomena: dust from natural sources, methane, radon gas, smoke and carbon monoxide
from wildfires, vegetation, volcanic activity

Air Pollutants:

1. Particulate Matter (PM): Small particles that can be inhaled

2. Nitrogen Oxides (NOx): Contribute to smog and acid rain

3. Sulfur Dioxide (SO2): Contributes to acid rain

4. Volatile Organic Compounds (VOCs): React with other pollutants to form smog

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 5. Carbon Monoxide (CO): Toxic gas that can cause respiratory problems

6. Ozone (O3): Ground-level ozone can cause respiratory problems

7. Lead (Pb): Toxic metal that can cause developmental problems

Pollution Sources:

1. Fossil Fuel Combustion: Vehicles, power plants, industrial processes

2. Industrial Processes: Mining, smelting, refining

3. Agricultural Activities: Livestock, fertilizers, pesticides

4. Waste Management: Landfills, incineration

5. Natural Sources: Wildfires, volcanic eruptions

Effects on Human Beings:

1. Respiratory Problems: Asthma, bronchitis, lung cancer

2. Cardiovascular Disease: Heart attacks, strokes

3. Neurological Problems: Cognitive impairment, neurological damage

4. Cancer: Lung, throat, nasal passages

5. Birth Defects: Low birth weight, premature birth

Effects on Animals:

1. Respiratory Problems: Similar to humans

2. Neurological Problems: Behavioral changes, neurological damage

3. Reproductive Issues: Birth defects, reduced fertility

4. Habitat Disruption: Changes in food chains, ecosystems

Effects on Plants:

1. Visible Damage: Leaf damage, reduced growth

2. Reduced Crop Yields: Economic impacts

3. Changes in Species Composition: Shifts in plant communities

4. Increased Susceptibility to Disease: Weakened plant defenses

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Effects on Materials:

1. Corrosion: Damage to metals, buildings

2. Deterioration: Damage to textiles, paper products

3. Discoloration: Staining, discoloration of surfaces

4. Reduced Lifespan: Premature aging of materials

Water Pollutants:

1. Physical Pollutants: Sediments, temperature changes

2. Chemical Pollutants: Heavy metals, pesticides, industrial chemicals

3. Biological Pollutants: Bacteria, viruses, protozoa

4. Nutrient Pollutants: Excess nitrogen, phosphorus

Health Hazards:

1. Waterborne Diseases: Cholera, typhoid, dysentery

2. Cancer: Linked to arsenic, chromium, and other pollutants

3. Neurological Problems: Mercury, lead, and other heavy metals

4. Reproductive Issues: Hormone disruption, birth defects

Sampling and Analysis of Water:

1. Sampling Methods:

- Grab sampling

- Composite sampling

- Continuous monitoring

2. Physical Parameters:

- Temperature

- pH

- Turbidity

- Conductivity

3. Chemical Parameters:

- Heavy metals (e.g., lead, mercury)

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 - Nutrients (e.g., nitrogen, phosphorus)

- Organic compounds (e.g., pesticides, industrial chemicals)

4. Biological Parameters:

- Bacteria (e.g., E. coli, total coliform)

- Viruses

- Protozoa

5. Analytical Techniques:

- Spectroscopy (e.g., UV-Vis, ICP-MS)

- Chromatography (e.g., GC, HPLC)

- Microbiological assays (e.g., culturing, PCR)

By understanding water pollutants, their health hazards, and the methods for sampling and analysis, we can
effectively monitor and manage water quality to protect human health and the environment.

Water Treatment:

1. Coagulation and Flocculation: Remove dirt and other suspended particles

2. Sedimentation: Separate heavy particles from water

3. Filtration: Remove remaining suspended particles and contaminants

4. Disinfection: Kill bacteria, viruses, and other microorganisms

5. Storage and Distribution: Store treated water and distribute to consumers

Types of Water Treatment:

1. Physical Treatment: Filtration, sedimentation, flotation

2. Chemical Treatment: Coagulation, disinfection, stabilization

3. Biological Treatment: Activated sludge, trickling filters, lagoons

Water Treatment Processes:

1. Activated Carbon Filtration: Remove organic compounds and improve taste and odor

2. Reverse Osmosis: Remove dissolved solids and other impurities

3. Ultraviolet (UV) Light Disinfection: Kill bacteria and viruses

4. Ion Exchange: Remove heavy metals and other inorganic compounds

5. Distillation: Purify water through vaporization and condensation

Water Treatment Technologies:

1. Membrane Bioreactors (MBRs): Combine biological treatment with membrane filtration

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 2. Advanced Oxidation Processes (AOPs): Use oxidizing agents to remove organic compounds

3. Nanofiltration/Ultrafiltration: Use membranes with small pores to remove impurities

4. Biological Aerated Filters (BAFs): Use biological treatment with aeration and filtration

By using various water treatment processes and technologies, we can remove contaminants and pollutants
from water, making it safe for drinking, industrial use, and environmental discharge.

Hazardous Waste Management:

1. Waste Identification: Determine if waste is hazardous based on its characteristics and composition.

2. Waste Characterization: Analyze waste to determine its physical, chemical, and biological
properties.

3. Waste Classification: Classify waste based on its level of hazard and regulatory requirements.

Technological Options for Collection:

1. Drum Collection: Collect waste in drums or containers.

2. Bulk Collection: Collect large quantities of waste in bulk containers.

3. Vacuum Collection: Use vacuum trucks to collect waste.

Technological Options for Treatment:

1. Chemical Treatment: Use chemicals to neutralize or remove hazardous components.

2. Physical Treatment: Use physical processes like filtration or centrifugation to remove

contaminants.

3. Biological Treatment: Use microorganisms to break down organic hazardous waste.

4. Thermal Treatment: Use heat to burn or vaporize hazardous waste.

Technological Options for Disposal:

1. Land Disposal: Dispose of waste in landfills or surface impoundments.

2. Incineration: Burn hazardous waste to reduce volume and toxicity.

3. Recycling: Reuse or recycle hazardous waste materials.

4. Secure Landfill Disposal: Dispose of hazardous waste in landfills with special liners and controls.

Other Options:

1. Waste Minimization: Reduce waste generation through source reduction and recycling.

2. Waste Exchange: Exchange hazardous waste with other facilities for treatment or disposal.

3. Energy Recovery: Recover energy from hazardous waste through combustion or gasification.

By using these technological options, we can manage hazardous waste in an environmentally responsible
and sustainable manner.

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 UNIT- V
POLLUTION CONTROL AND FACTORIES ACT

TOPICS Pollution control in process industries like cement, paper, petroleum - petroleum products
textile-tanneries-thermal power plants – dying and pigment industries. Tamilnadu Factories
Rules1950 under Safety and health chapters of Factories Act1948.–Tamilnadu Safety
Officer Rules 2005.

DURATION (9 HOURS)

Pollution Control and Factories Act

The Air (Prevention and Control of Pollution) Act, 1981, is the primary law governing pollution control and
factories in India. The key aspects of this act are:

Objectives:

The main objective of this act is to preserve air quality and control air pollution.

- Regulatory Mechanism: The act provides a regulatory mechanism that requires polluting industries
to seek consent from the concerned State Pollution Control Board (SPCB) prior to operation.

- Enforcement: The act empowers the State Governments to declare any area or areas within the state
as an ‘air pollution control area’ for the purpose of the act.

- Penalties: The act prescribes penalties for non-compliance, including imprisonment and fines.

Key Provisions

- Section 37: Imprisonment for up to 3 months and/or a fine of up to Rs. 10,000 for contravention of
the act.

- Section 40: Vicarious liability for companies, making whoever was in charge at the time of the
commission of the offence liable.

- Section 41: Offences by government departments, making the head of the department liable.

Limitations

- Outdated: The act has not been substantially amended since its enactment, despite significant
changes in the understanding of air pollution.

- Inadequate Enforcement: The act relies on criminal prosecution as the primary tool for
enforcement, which has been found to be inefficient.

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 - Lack of Funding: The act does not provide for stable funding for the SPCBs, compromising their
ability to engage in critical air quality management tasks.

Pollution control measures in various process industries:

1. Cement Industry:
- Air pollution control: Bag filters, electrostatic precipitators, and scrubbers to reduce particulate
matter and gaseous emissions.
- Water pollution control: Treatment of wastewater and recycling of process water.
- Solid waste management: Utilization of waste materials in cement production.
2. Paper Industry:
- Air pollution control: Electrostatic precipitators, fabric filters, and scrubbers to reduce particulate
matter and gaseous emissions.
- Water pollution control: Treatment of wastewater, recycling of process water, and reduction of
chemical usage.
- Solid waste management: Recycling of paper waste and utilization of biomass residues.
3. Petroleum and Petroleum Products:
- Air pollution control: Scrubbers, electrostatic precipitators, and vapor recovery units to reduce
gaseous emissions.
- Water pollution control: Treatment of wastewater, oil spill prevention, and containment
measures.
- Solid waste management: Proper disposal of hazardous waste and recycling of materials.
4. Textile Industry:
- Air pollution control: Scrubbers, electrostatic precipitators, and fabric filters to reduce particulate
matter and gaseous emissions.
- Water pollution control: Treatment of wastewater, recycling of process water, and reduction of
chemical usage.
- Solid waste management: Recycling of textile waste and utilization of biomass residues.
5. Tanneries:
- Air pollution control: Scrubbers, electrostatic precipitators, and fabric filters to reduce particulate
matter and gaseous emissions.
- Water pollution control: Treatment of wastewater, recycling of process water, and reduction of
chemical usage.
- Solid waste management: Proper disposal of hazardous waste and recycling of materials.
6. Thermal Power Plants:
- Air pollution control: Electrostatic precipitators, scrubbers, and fabric filters to reduce particulate
matter and gaseous emissions.
- Water pollution control: Cooling tower blowdown treatment and reduction of chemical usage.
- Solid waste management: Proper disposal of ash and utilization of fly ash in cement production.
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 7. Dyeing and Pigment Industries:
- Air pollution control: Scrubbers, electrostatic precipitators, and fabric filters to reduce particulate
matter and gaseous emissions.
- Water pollution control: Treatment of wastewater, recycling of process water, and reduction of
chemical usage.
- Solid waste management: Proper disposal of hazardous waste and recycling of materials.

These industries employ various pollution control measures, including:

- Process modification and optimization
- Use of cleaner technologies and fuels
- Installation of air and water pollution control devices
- Waste minimization and recycling
- Regular monitoring and maintenance of pollution control equipment

Tamil Nadu Factories Rules 1950 under Safety and Health Chapters of Factories Act 1948

The Tamil Nadu Factories Rules 1950 is a legislation that outlines the safety and health guidelines for
factories in Tamil Nadu. The rules are formulated under the Factories Act 1948, which is a social legislation
enacted for occupational safety, health and welfare of workers at workplaces. Here are some key points
about the Tamil Nadu Factories Rules 1950:

- Applicability: The rules are applicable to all factories, including state and central government factories, in
Tamil Nadu.

- Safety Committee: The rules mandate the formation of a safety committee in factories where 250 or more
workers are employed, or where any process or operation declared to be dangerous under section 87 of the
Act is carried out.

- Functions of Safety Committee: The safety committee is responsible for assisting and cooperating with
the management in achieving the aims and objectives outlined in the health and safety policy of the occupier,
dealing with all matters concerning health, safety and environment, creating safety awareness amongst all
workers, undertaking educational, training and promotional activities, and reviewing the implementation of
the recommendations made by it.

- Amendments: The rules have been amended several times, with the latest amendment being made in 2021.
The amendments aim to ease the compliance process by making it digital and reducing the time and cost
involved.

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- Key Provisions: The rules cover various aspects of factory safety and health, including the appointment of
safety officers, health officers and factory medical officers, reporting of accidents and diseases, safety
training and education, and inspection and enforcement.

- Penalties: The rules prescribe penalties for non-compliance, including fines and imprisonment.

Tamil Nadu Safety Officer Rules 2005

The Tamil Nadu Safety Officer Rules 2005 were established under the Factories Act of 1948.

Here are some key points about the rules:

- Duties, Qualifications, and Conditions of Service: The rules outline the duties, qualifications, and
conditions of service for safety officers in factories.

- Appointment of Safety Officers: The rules require factories to appoint safety officers who meet
the specified qualifications and conditions.

- Safety Courses: The rules recognize safety courses from institutes or colleges recognized by
AICTE, UGC, or DGFASLI.

- Amendments: The rules have been amended several times, with the latest amendments aimed at
enhancing safety standards in workplaces.

Key Provisions

- Safety Committee: The rules require factories to constitute a safety committee where 250 or more
workers are employed or where any process or operation declared to be dangerous under section 87
of the Act is carried out.

- Qualifications and Conditions of Service: The rules specify the qualifications and conditions of
service for safety officers, including educational qualifications, experience, and training.

- Duties of Safety Officers: The rules outline the duties of safety officers, including ensuring
compliance with safety provisions, conducting safety audits, and reporting accidents and incidents

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