SAFETY ENGINEERING

SAFETY IN INDUSTRIES AND ACCIDENTS

Group 4
Jaisal Ibhrahim
Lijo Johny
Mariya Johny
 SAFETY IN INDUSTRY
• The modern safety movement started around 1912 with the First Cooperative Safety
Congress and the organisation of the National Safety Council in U.S.A.
• From 1912 to the present time, remarkable advances have been made in reducing
the rate and severity of the accidents.
• Safety results from
❖ Safe plant, processes and operations
❖ By educating and training workers and supervisors regarding safe practices on the
shop floor
 NEED FOR SAFETY

• Increase the rate of production

• Reduce production cost
• Reduce damage to equipment and machinery
• Prevents premature death of talented workers who are asset to the society
• Prevents needless pain and suffering to its employees
 ORGANIZATION FOR SAFETY

• Each shop supervisor is responsible for the safety in his shop. He/she must report to
their top executive as regards safety matters.
• Since the duty of the shop supervisor is to turn out production, he may treat safety as
a second option. So he may be replaced by a personnel officer or general foreman.
• Depending on the growth and hazardousness level in an industry a Safety
Department is created with the Safety Director/ Manager as its chief executive and
number of persons under him at different levels.
 SAFETY COMMITTEE
• A safety committee consists of executives, supervisors and shop floor workers.
• Thus organizations having safety committee has got lower accident records than those
who without safety committee.
• Safety committee aids in developing safety consciousness as well as it is a policy making
body on such safety matters come before it.
• A safety manager/executive requires a degree of firmness and ready discrimination to
exclude personal and union matters in which the safety is merely the pretext for their
hiring. He/she should guard jealously the responsibilities of management and
supervision.
 SAFETY PROGRAMMES

• Tends to discover when, where and why accidents occur.

• Aims at reducing accidents and losses associated with them.
• Begins with the assumption that most work-related accidents can be prevented.
• Does not have an end; rather it’s a continuous process to achieve adequate safety.
• Tries to reduce the influence of personal and environmental factors that cause accidents.
• Involves providing safety equipment and special training to employees.
• Composed of one or more of the following elements
 • A safety programme mainly include 4 E’s

❖ Engineering i.e., safety at the design equipment installation stage

❖ Education of the employees in safe practices
❖ Enlistment. It consist the attitude of the employees and management toward the
programme and its purpose. It is necessary to arouse the interest of the employees
in accident prevention and safety consciousness

❖ Enforcement i.e., to enforce the adherence to safety rules and safety practices
 SAFETY INSTRUCTIONS AND TRAINING

It involves
• Induction and orientation of new recruits to safety rules and practices
• Explaining safety function, during, on the job training
• Efforts made by the first level supervisors
• Formulating employees safety committee
• Holding of special employee safety meetings
• Displaying charts, posters, films etc., to emphasize the need to act safely
 EDUCATION EMPLOYEES TO DEVELOP
SAFETY CONSCIOUSNESS
Measures to develop safety consciousness among workers/employees are as follows
• Display of safety posters and films to remind workers of hazards/accidents
• Providing simple and convenient safety devices
• Providing allowance (in the standard time) to the worker for setting, removing and replacing
any necessary safety devices
• Ask the employee from the first day he starts work to adopt safety measures
• Elaborate on the safety theme until all the employees are safety conscious
• Hold the regular safety meetings
• Layout work areas to reflect safety conditions
 ACCIDENTS
An accident can be defined as an event detrimental to the health
of a man, suddenly occurring and originating from external
source and which is associated with the performance of a paid
job, accompanied by an injury, followed by disability or even
death
 ECONOMIC ASPECTS(COSTS) OF ACCIDENTS
• An accident can be very costly to the injured employee as well as to the employer of the concern
• There are definite costs associated with accident, i.e., direct and measurable costs and indirect,
i.e., somewhat intangible but nevertheless real costs

DIRECT COSTS OF AN ACCIDENT

• Compensation insurance, including payment and overhead cause
• Uncompensated wage losses of the injured employee
• Cost of medical care and hospitalization
 INDIRECT COSTS OF AN ACCIDENT
• Costs of damage to equipment, materials and plant
• Costs of wage paid for time lost by workers not injured
• Costs of wages paid to the injured worker
• Costs of safety engineers, supervisor and staff in investigating, recording and reporting of
accidents and its causes
• Costs of replacing the injured employee
• Cost of lowered production by the substitute worker
• Costs of delays in production due to accident
• Cost of reduction in efficiency of the injured worker when he joins the concern after getting
recovered
 CAUSES OF ACCIDENTS
An accident is an unplanned incident and for each incident there is usually a specific
cause or causes if one could but discover them.
An accident maybe caused due to
❖ Technical causes
Unsafe conditions
o Mechanical factors
o Environmental factors
❖ Human causes
Unsafe acts
o Personal factors
 Technical causes or unsafe conditions reflect deficiencies in plant, equipment, tools,
materials handling systems, general work environment etc.
❑ Mechanical factors
• Unsafe mechanical design or construction
• Hazardous arrangement
• Improper machine guarding
• Unsafe apparel
• Detective agencies or devices
• Broken safety guards
• Protruding nails
• Leaking acid valves
• Untested boilers or pressure valves
❑ Environmental factors
It includes
• Too low temperature to cause a shivering
• Too high temperature to cause shivering and headache
• Too high a humidity to cause uncomfort, fatigue and drowsiness(especially when the
atmosphere is also hot)
• Defective and inadequate illumination causing eyestrain, glares, shadows etc.
• Presence of dust, fumes and smokes and lack of proper ventilation
• Noise, bad odour and flash coming from the nearby machinery, equipment or processes
• Poor housekeeping
 Human cause or unsafe facts by the person concerned are due to his ignorance or
forgetfulness, carelessness, day dreaming etc.
❑ Personal factors
• Age
• Health
• Number of dependants
• Financial position
• Home environment
• Lack of knowledge and skill
• Fatigue
• Emotional instability
• Mental worries
• Day dreaming and unattendiveness
 TYPES OF ACCIDENTS

Near accident(an accident with no damage or injury)

Trivial
Minor
Serious
Fatal
 ACCIDENT PREVENTION
Accident prevention is essential in order to
• Prevent injury and premature death to employees
• Reduce operating and production costs
• Have good employer-employee relations
• High up the morale of employees

The following conditions are to be implemented for accident prevention

1) Safe workplace layout and working conditions
2) Safe material landing
3) Personal protective devices
4) Safety activities in the organisation
 1) SAFE WORKPLACE LAYOUT AND WORKING
CONDITIONS

LAYOUT
• A good layout and working conditions play a major role in preventing many accidents which
would have otherwise occurred.
• For preventing accidents layout should be such that every employee has enough space to move,
operate and there must be no obstruction. It also must prevent the inrush of hot air/cold air and
draughts to the working place.
• Heights of the working rooms must be 3m and the rooms must be non-skid type, satisfactorily
plane and they must be easily cleaned and absorb sounds.
• Windows must be of adequate dimension to make full use of natural light, doors and gates must
be provided with guards.
• Fire hazards can be reduced by using fire walls to separate compartments.
• A worker operating on a machine must have easy access to the safety switches.
 Working conditions
• Air temperature, air purity, velocity of air, humidity of air and heat radiations between bodies of
different temperature should be controlled.
• Whether natural or artificial, there should be sufficient illumination, of adequate colour of light.
• High level of noise impairs men at work and may even endanger them. To reduce this select
machineries which produces less noise , isolate machineries which produce noise, use silencers
and suitable machine mount to minimise noise and vibrations.
 2) SAFE MATERIAL HANDLING
• Careless handling of materials and components is one of the major source of injury.
• Use mechanical means of conveyance to ensure the safety of men engaged in material handling.
• The transport workers should not be asked to lift more than the permissible load.
• During transport sharp materials, sharp edge tools must be covered properly.
• Containers or vessels employed for the transportation of liquids or small parts etc. should not be
too large, should be light, should not be defective/leaking.
• All material handling equipment should be promptly repaired and adequately maintained on
priority basis.
 3) PERSONAL PROTECTIVE DEVICES
Protection of head
• Safety hard hats, Rubberized hats, Ear protectors
Protection of face
• Face mask, Face shields, Welding helmets
Protection of eyes
• Goggles, Eye cup goggles(against flying objects and against chemicals)
Protection of lungs
• Air line respirators, Cartridge respirators, Oxygen or air breathing apparatus, Gas masks
Protection of other body parts(hand, foot, leg etc.)
• Protective asbestos clothing, Gloves, Safety shoes, Foot guards, Safety body belt, Aprons
 4) SAFETY MEASURES ESSENTIAL IN INDUSTRY

• Provide wire mesh safety to all rotating parts.

• High voltage equipment should be properly fenced.
• Pressure vessels and their component parts should be periodically tested and defective parts
should be replaced.
• Power should be switched off before repairing the equipment.
• Inflammable material should be stored separately and away from the general store.
• Electrical connections and insulation should be checked at regular intervals.
• Enough precautions should be taken to avoid electrical accidents.
• Fire extinguishers must be kept at proper places and at key places.
 ACCIDENT PRONENESS
ACCIDENT PRONENESS can be defined as the continuing tendency of a person to have more
accidents as a result of his persisting characteristics etc. It is perhaps because of peculiar
psychological and physiological make up of certain persons.

Causes of Accident Proneness

o Inattentiveness and day dreaming
o Poor eyesight and hearing and lack of stamina
o Poor adjustment of work
o Emotionally stressed
o Dislike of supervisor, lack of training, proficiency skill to do a work
o Insufficient intelligence, unsafe behaviour(intentionally not using safety precautions)
 Methods to Reduce Accident Proneness
o Depending upon the job conditions select only those applicants who possess appropriate
mental and physical ability.
o Transfer accident prone workers to comparatively less hazardous job situations.
o Impart adequate training to a recruit before putting him on the job.
o Encourage employees working under you and see that the do not get unnecessarily perturbed,
frustrated or emotionally disturbed.
 FIRST AID
• Even after taking all safety precautions accidents occur in factories.
• To take care of such critical situations, factories employ full time, at least a person who has
successfully completed his Red-Cross First Aid course and who can give preliminary treatment
to the injured person. Besides, a first aid personnel can look after who suffer from minor injuries,
sever burns, electric shocks etc.
THANK YOU