Contents

Plant Safety

Elements of Industrial Safety

Causes and prevention of accidents

Pollution and environmental consideration

 Plant Safety
• Plant safety means continuing and healthy living without
injury inside the plant

• Safety is freedom from harm or the danger of harm

• Safety also deals with improvement in working conditions for

better health

• Plant management is responsible for providing safety in

working conditions and individual safety
 Elements of Industrial Safety
The three elements of industrial safety are:
1. Safety
2. Health
3. Environment
These three are popularly known as SHE

1) Safety
In industry, safety may be considered from mechanical side
(equipments, tools etc.) or from legal angles of workmen’s
compensation and in motivating towards safe work practices for
workers
2) Health
For works which are direct exposure to hazard, appropriate
preventive measures has to be taken in order to avoid any danger
to the safety and health of workers. The preventive measures
should place emphasis on the need to eliminate or reduce the
hazards at the source.

3) Environment
Environmental factors indicate improper physical and
atmospheric surrounding conditions of work which indirectly
promote the occurrence of accidents. The plant operation should
not pollute environment. Even poor house keeping will also result
in the damage of environment.
 Plant Safety Programmes
In a plant safety programme, it is necessary to identify the
possible causes of the accidents, then study them and then take
effective steps for their prevention.
For an effective plant safety programme, following areas should
be covered:
i. Plant layout
ii. Maintenance of the equipments
iii. Equipment requirement
iv. Safety department with proper communication system
v. Fire fighting facilities
vi. House keeping
For a proper safety programme:

1. Seek support from top management

2. Appoint one person in organization to direct safety program
3. All the employee in the plant should be aware of the
programme.
4. Train a new employee with safety programme
5. Promote good house keeping
6. Safety practices should be made effective
 Three phases of Safety programs:
Safety programs will be carried out in 3 phases:
1. Self awareness
This includes educational safety, on-job training, ergonomics, job
safety analysis technique.

2. Safety implementation
This needs the participation of each and everyone in the plant.

3. Safety programme maintenance

This phase has to maintain energy level of the participants, and it
should not deteriorate with time.
 Elements of Industrial Safety
1. Need for Safety
• Safety is necessary for the benefit of employees
• Safety helps to increase rate of production
• It reduces cost of production
• It reduces damage to equipment and machinery
• It prevents death of talented workers who are an asset to the society
2. Organization for Safety
• In an industry, each shop supervisor may be made responsible for
safety in his shop
• Every shop supervisor has to report to the top executive regarding
safety matters
• Safety in industry is mostly taken care by the general foremen or
personal officer
• Safety dept. (with director and no. of persons under him at diff.
levels) is created for the effective function
• Safety committee is also formed
3. Safety Committee
• A safety committee consists of executives, supervisors and shop
floor workers
• The lower level employees get a channel of communication on
safety matters direct to executive level
• It was observed that those organizations which made safety
committees had lower record of accidents
4. Safety Programmes
• It tends to discover when, where and why accidents occur
• It aims at reducing accidents and the losses associated with them
• It begins with the assumption that most work-connected accidents
can be prevented
• It’s a continuous process to achieve adequate safety
• A safety programme involves providing safety equipments and
special training to employees
For a proper safety programme:
1. Seek support from top management
2. Appoint one person in organization to direct safety program
3. All the employee in the plant should be aware of the programme.
4. Train a new employee with safety programme
5. Promote good house keeping
6. Safety practices should be made effective
5. Safety instructions and Training
It involves:
• Induction and orientation of new recruits to safety rules and
practices
• Explaining safety function, during on job training
• Efforts made by the first level supervisors
• Formulating employees safety committees
• Holding of special employee safety meetings
Continues….
6. Educating employees to develop safety consciousness
Some of the measures to develop safety consciousness among workers
are given:
• Display of safety posters and films to remind workers of particular
hazards
• Providing simple and convenient safety devices
• Conduct safety competitions and award prizes to the winners
• Report safety activities to all employees
• Cross-mark all accidents areas
• Conduct safety training lectures periodically
• Explain them on safety theme, until all the employees are feeling of
pride in safe work
• Welcome all safety suggestions
• Make sure employee adopts safety measures from his/her first day
of work
• Layout work areas to reflect safety considerations
Measures of safety in industries/Safety measures
to be taken in industries
Safety measures are taken in industries to prevent accidents and to
improve the productivity.

Safety measures are essential for the welfare of the people working
in the industry and for the overall benefit of the organization.

By incorporating safety measures at various levels, the awareness

on safety will improve. It is possible to prevent accidents. It is
possible to handle emergencies in a better way. There will not be a
breakdown of machines. Employees will be able to work without
being exposed to conflicting conditions.
Following are the safety measures taken in industries:
1. Safety policy
2. Importance of safety
3. Safety & training
4. Protective equipment
Safety Policy

• In order to take safety measures effectively, organizations

should have a safety policy.
• The safety policy statement will give direction to the
management. The management is responsible for the
implementation of safe methods and practices.
• The organization should realize that worker’s health and safety
takes precedence to the job or task to be accomplished. If there
is any threat of safety in the way the worker is performing the
job, there should be concerted effort to finish the task with
least health effect on the worker.
• The procedures implemented in the organization should be
verified, inspected and subjected for improvement if there is
any requirement for the enhancement of safety.
• If a job cannot be done in a safe method, the job should not be
attempted. The place of work should be safe to perform
various tasks. There should be proper lighting, ventilation and
no congestion of things.
Importance of safety

• Training plays an important role to implement safety policies in

an organization. Training brings uniformity among various levels
of employees. There will not be any confusion or conflict. By
imparting training on a regular basis, it is possible to impart the
basic and specific skills to perform the job in an efficient manner.
• It is the responsibility of each and every employee to follow the
guidelines laid by the management.
• Unsafe working conditions should be reported to the supervisory
and management staff.
• Employees should work in a professional way by taking all the
necessary precautions.
Safety & Training

Safety and training in the company should be monitored by the

safety director. Safety director should train foremen so that they will
be able to know the procedures to investigate accidents. Machine
operators should be trained both in the classroom environment and
in the workplace. Training at various levels should comply with the
state and federal regulations. It should be ensured that no employee
will work on unguarded machine.
Protective equipment

In order to ensure the safety of workers, protective gear should be

used. If you are doing welding works, you should use goggles to
protect your eyes. If you are working in a warehouse, you should
wear hard hats and your eyes should be protected.
Usage of helmet, leather coat, apron, gloves and other equipment
is necessary depending on the working conditions.
The helmet should be provided with a focusing light if you are
working in low light or no light conditions.
If you are working in a paint shop, the eyes should be protected.
It is the responsibility of the safety manager that even visitors
will be provided with safety gear.
 THE INDIAN FACTORIES ACT, 1948
Health Provisions
This act prescribes the following provisions for maintaining the
health of the workers:
1.Cleanliness
Following steps should particularly be taken:
• The dust and refuse shall be removed daily
• The floor of every workroom shall be cleaned at least once in
every week
• Effective means of drainage shall be provided and maintained
2.Ventilation and temperature
• Effective and suitable provisions shall be made for securing and
maintaining adequate ventilation
• Walls and roofs should be of such material and so designed that
temperature shall be kept as low as practicable
3. Artificial humidification
• If there is an artificial humidification it shall be of prescribed
standard and created by the prescribed methods
• The water used for such humidification shall be clean and free
from dirt
4. Overcrowding
• No room in the factory shall be overcrowded, for this at least 14.2
m 3 of space for every worker is necessary in the factories built
after the commencement of this act
5. Lighting
• Sufficient and suitable lighting whether natural or artificial or both
shall be maintained at the working place or passages
• All glazed windows and skylight shall be kept clean on both the
inner and outer surfaces
6. Drinking water
Drinking water should be made available to all workers at all
working hours. All such points shall be marked “drinking water” in
a language understood by a majority of workers
7. Bath rooms
A sufficient number of bath rooms shall be provided
8. Latrines and Urinals
• Separate enclosed accommodation for male and female workers
shall be provided. The accommodation shall be adequately
lighted and ventilated.
• One latrine shall be provided for every 20 female workers, and
one latrine shall be provided for 20 to 100 male workers
9. Spittoons
Sufficient number of spittoons shall be kept at convenient places.
 THE INDIAN FACTORIES ACT, 1948
Safety provisions
Following important provisions for safety are provided in the act:
1. Fencing of machinery
Following items shall be properly fenced in every factory:
• Every moving part of a prime-mover, every flywheel;
• Head race and tail race of every water turbine;
• Every part of an electric generator, a motor, or a rotary
convertor etc. should be properly safeguarded
2. Work on or near machinery in motion:
The work on or near moving machinery shall be done by a
specially trained adult male worker wearing tight fitting clothing
3. Devices for cutting off power from running machines in
emergency shall be provided
4. Casing of machinery
Every machine should be properly guarded and encased to
prevent danger
5. Hoists and lifts
• They shall be of good mechanical condition and of adequate
strength
• Every hoist way and lift way shall be sufficiently protected by
an enclosure fitted with gates
6. Lifting machines, chains, ropes and lifting tackles
They shall be of good construction and of adequate strength
7. Revolving machinery
A notice shall be affixed Indicating max. safe working peripheral
speed of every grind stone or abrasive wheel, the speed of the
shaft or spindle upon which the wheel is mounted
8. Excessive weights- No person shall be employed to lift heavy
loads
9. Protection of eyes
10. Precautions against dangerous fumes
11. Precautions against fire
Welfare provisions
Factories Act provides following welfare provisions:
1.Washing facilities
2. Sitting facilities
3. First-aid appliances
4. Canteens
5. Shelter, rest-rooms, lunch-rooms
Working Hours
Following are the provisions for working hours:
1. Hours of work: No adult worker shall be required or allowed to
work in factory more than 48 hours in a week and for more than 9
hours in a day.
2. Holidays: No adult worker shall be required or allowed to
work in a factory on Sunday, unless he has or will have a holiday
for a whole day on one of the 3 days immediately before or after
Sunday.
3. Overtime wages: When a worker works for more than 9 hours
in any day or for more than 48 hours in any week, he shall be
entitled to wages at the rate of twice his ordinary rate of wages in
respect of overtime work.
4. Restriction on double employment: No worker shall be
required or allowed to work in any other factory.
5. Employment for women: No women shall be employed in any
factory except between 6 A.M and 7 P.M
Reporting accidents
Rule 88 of Factories Act, 1948- Notice of certain accidents, states
that, where, an accident occurs, in any factory which causes,
death or any bodily injury, by reasons of which the person
injured is prevented from working for a period of 48 hours or
more, immediately following the accidents or which is of such
nature as may be prescribed in this behalf, the manager of the
factory shall send a notice thereof to such authorities and in such
form and within such time as may be prescribed.
 ACCIDENTS

“An industrial accident may be defined as an event,

related to health of a man, sudden occurring and
originating from external sources, and which is
associated with the performance of a paid job,
accompanied by an injury, followed by disability or
even death”.
 Economic Aspects of Accidents
The following are the cost associated with the accident:
1. Direct cost of accident
2. Indirect cost of accident

Direct cost includes:

• Cost of medical care and hospitalization
• Compensation insurance, including payment, and over head cost
• Uncompensated wage loss of the injured employees
Indirect Cost occurs due to:
• Loss of time of injured person
• Loss of damage to equipment, materials and plant
• Loss of wage paid to the injured worker
• Cost of replacing the injured worker
• Loss of delay in production due to accident
 Types of Industrial Accidents
1. Machinery accidents
2. Non-machinery accidents

Machinery Accidents
These type of accidents occur due to inadequate safeguard of
machines. These accidents can be reduced by providing safe
guard on belts, gears, etc. and proper design and arrangement of
machines.
Non-machinery Accidents
These accidents occur due to personal reasons of the employee
and poor infrastructure.
Factors of Non-machinery accidents are:
i. Age
Accidents are more frequent with younger person due to
inattentiveness, and lack of experience.
ii. Experience
Rate of occurrence of accidents for more experienced worker is
less than that of the people with less experience
iii. Physical condition
Experiments have proved that minor illness like sore throat, cold,
headache, etc. are responsible for accidents to a large extent.
These small frequent illness are responsible for lowering general
health.
iv. Production rate
In order to achieve higher production rate, the speed of the
employee become higher. Due to this pressure, accidents occur.
v. Atmospheric condition
Normally accidents occur, at a temperature less than 20◦C, Rate
of accident increases after 34◦C due to heat. Above 34◦C, rate of
accident increases considerably.
vi. Illumination
Dim illumination raises accident frequency. In day light, accident
frequency is less compared to artificial illumination.
vii. Fatigue
Fatigue is responsible to reduce the power to work, and the
pleasure taken in the work is reduced. The certain factors of
fatigue are repetition of the work, tension, stress.
 Causes of Accident
An accident is an unexpected incident, though we can identify the
certain causes for the occurrence of accident

1. Technical Causes
(i) Mechanical Factors
(ii) Environmental Factors

2. Human Causes
(i) Personal Factors
1. Technical causes
Technical causes are due to deficiencies in plant, equipment,
tools, material handling system and general work environment.
Mechanical Factors
 Improper installation of equipment
 Improper material handling
 Overloading of material in equipment
 Leaking acid valve
 Untested boilers or pressure vessels
 Unsafe mechanical design or construction
Environmental factors
Environmental factors indicate improper physical and
atmospheric surrounding conditions of work which indirectly
promote the occurrence of accidents.
Environmental factors include:
 Low temperature causes shivering
 High temp. causes headache and sweating
 Inadequate illumination causes eye strain, glares, shadows, etc.
 Lack of proper ventilation, presence of dust, fumes and smoke
 Lack of break hours between working hours
2. Human Factors
• Age
• Health
• Lack of knowledge and skill
• High anxiety level
• Fatigue
• Carelessness
• Inattentiveness
 Prevention of Accidents

Accident prevention is basic necessary in an industry in order to:

i. Increase morale of employee
ii. To have good employer-employee relation
iii. To reduce operation and production cost
iv. To prevent injury and pre medical death of employee
Methods Used
1. Safe work place layout
To prevent accidents, the layout should have:
• Enough space for employee to move and operate
• Preventive measures to control cold/hot air and draughts at the
workplaces
• Clear passage ways between working places, roads, tracks and
alleys.
• Height of the ceiling should be above 3 meters height, for
adequate lighting, ventilation etc.
• Floors should be non skid type, satisfactorily plane.
• Gates and doors should be provided with safeguards
• A worker operating on the machine should have easy access to
the safety switches provided on the machine/near the
workplace.
2. Safe working conditions
• In a closed room, air temp., air purity, velocity of air, humidity
of air, and heat radiations between bodies of different temp.
should be controlled
• Proper ventilation must be provided
• Sufficient illumination should be provided
• Higher level noise in the workplace disturbs the workers and it
should be controlled (E.g.- Motors, pumps should be mounted
on heavy bases, Keeping sound sources away from reflecting
surfaces etc.)
3. Safe material handling
• Do not overload handling equipment
• Keep aisles free
• Different passage for workers and handling equipment
• Keep floors clean
• Emergency switches or controls should be provided
 3. Personal Protecting devices/Equipment (PPE)
Certain sensitive parts of the body and their respective PPEs are:
Body Part Effect PPE
Eye Sensitive to bright light, particles, Goggles, Shields, Dust screen, Wire
dust, fumes mesh
Ear Sensitive to noise and sound Ear plug, cushion, helmet

Face Sensitive to particles, chemical Welders helmets, Hoods

liquids/gases, flying objects

Arms, hand & Sensitive to accidental hitting, Fingers cots, Gloves

fingers insertion of rotating part
Head and neck Sensitive to flying objects, Head safeguard, Hard hats, Protective
accidental hitting caps, Helmet
Respiratory Sensitive to chemical fumes. Dust Respirator, Gas mask, Hoods
system and poisonous gases
Protection of Sensitive to heat and cold, sensitive Firefighter clothing
skin body against to electric shock
fire
Foot and leg Sensitive to falling objects, nails, Safety shoes, Guards
sharp edges and chemicals
5. Prevention of electrical accidents
• Electrical connections and insulations should be checked at
regular intervals
• High voltage equipment and other machines which cant be
properly guarded should be fenced
• Power should be switched off before repairing the equipment
• All the active wires should be isolated and insulated properly
6. Good house keeping
• Clean and neat work area
• Clean and clear passages
• Proper illumination
• Clean, well drained and well maintained road
• Clearly marked aisles in factories or warehouses wherever
mechanical equipment such as fork lift trucks, pallet jacks,
tractor-trains etc. are used
7. Eliminate/reduce accident proneness
Accident proneness is the continuing tendency of a person to
have more accidents as a result of his persisting character.
Methods to reduce:
• Impart adequate training to new employee before putting him
on job
• Encourage the employee
• Transfer accident prone worker to comparatively less
hazardous job situation
• Check whether he is mentally disturbed or emotionally weak
and encourage him