Jayakumar.

G
Asst.General Manager (Safety) Rtd
from FACT –Udyogamandal Complex

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 What is a Safety Management System?
Material
safety
Safety
Design Policy
Safety Human
safety Continuous
Improvement
Process
safety

Safety

Drills

No Structure Structure
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What is a Safety Management System?
 “An orderly arrangement of interdependent
activities and related procedures that drives an
organisation’s performance.”
 “A Safety Management System is an integrated
set of work practices, beliefs and procedures
for monitoring and improving the safety and
health of all aspects of your operation.”
Orderly Arrangement - Key Elements of a SMS

Policy
Policy development

Organisational
Organising development

Planning &
Audit
Implementing

Developing
techniques of
Measuring planning,
Performance measuring and
reviewing

Reviewing
Performance
Orderly Arrangement - Key Elements of a SMS

Policy Policy

Organising
Effective health and safety
policies set a clear
Audit
Planning &
Implementing direction for the
organisation to follow.
Measuring
Performance

Reviewing
Performance
Orderly Arrangement - Key Elements of a SMS

Policy
Organganising
Organising An effective management structure
and arrangements are in place for
Audit
Planning &
Implementing
delivering the policy.

Measuring
Performance
An effective management structure
and arrangements are in place for
Reviewing
delivering the policy.
Performance
Orderly Arrangement - Key Elements of a SMS

Policy
Planning

Organising There is a planned and

systematic approach to
Planning & implementing the health
Audit
Implementing and safety policy through
an effective health and
Measuring
Performance
safety management
system.
Reviewing
Performance
Orderly Arrangement - Key Elements of a SMS

Policy Auditing and

Reviewing of
Organising
Performance
Planning &
Audit
Implementing

The organisation learns from

Measuring
Performance all relevant experience and
applies the lessons.
Reviewing
Performance
Safety Management System Interventions
7 components

1. Management leadership
vision, values, commitment
safety goals & objectives
costs of safety performance
2. Responsibility & accountability
defined for management & employees
accountable for performance
4. Safe work practices & procedures
general & job specific
housekeeping
contractors
emergency
5. Safety review & improvement
a Plan / Do / Check / Act process
accident investigation process/
safety audit / inspection process
6. Safety training
Based on needs assessments
Designed & presented effectively
For both management & employees
Results in observable changes in behavior on the job
7. Safety communications
Internal & external
Appropriate for audience
Effectiveness of communication methods
MANPOWER SAFETY
SAFETY POLICY
SAFE WORK PROCEDURES
TRAINING TO PERSONNEL MATERIALS
GIVE PPE’s SAFETY
MOCK DRILLS
SAFE HANDLING
TREM CARDS
PROCESS SAFETY DRIVERS TRAINING
DESIGN SAFETY VECHICLE AUDITS
FAILSAFE CONTROL
SYSTEMS
LATEST DCS CONTROLS
ISO WORK PROCEDURES
HEALTH STUDY OF PLANTS
SAFETY CHECK
ON-SITE & OFFSITE MOCK
DRILLS
WORK PERMIT SYSTEM
CONTINOUS INSPECTION
ENSURE USE OF PPE’s BY
CHECKS
SAFETY AUDITS
SAFETY IMPROVEMENT
RISK ASSESSMENT STUDY
OCCUPATIONAL HEALTH SAFETY COMMITEE
CHECKS MANAGEMENT COMMITMENT
SAFETY DAY CELEBRATIONS
SAFETY MESSAGES DISPLAY
UPKEEP OF SAFETY GADGETS
ENSURE FUNDS FOR SAFETY
DESIGN SAFETY
Safety relief valves FAILSAFE
ARC Valves CONTROL
Vent control valves SYSTEMS
P&I Diagrams Critical instruments
Breather systems Excess flow valves
Fire protection systems Interlocks
Blanketing Trend data
Dyke walls DCS Control
Trip switches
Bypasses
systems
ISO WORK PROCEDURES
 Departmental Procedures
 Apex Manual
 Work Instructions
 Aspect Impact Register
 Management of change
 Risk awareness training programme
 LOPA – Layers of protection analysis
 RB I - Risk based inspection
 Safety Audits
 Safety instrumental systems
 Safety integrety level Analysis
 CALCULATION OF FREQUENCY RATE
 Ther Frequency Rate shall be calculated both for lost time
injury and reportable lost time injury.

 FA = Number of Lost time injury X 1,000.000

Man Hours worked

 FB = Number of Reportable Lost time injury X 1,000.000

Man Hours worked
 If the Injury does not cause loss of time in the period in which it occurs but in
a subsequent period , the injury should be included in the FR of the period in
which the loss of time begins.
 If an Injury causes intermittent loss of time , it should only be included in the
FR once , that is when the first loss of time occurs.
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CALCULATION OF SEVERITY RATE
 SA = Mandays lost due to Lost time injury X 1,000.000
Man Hours worked

 SB = Mandays lost due to RLTI X 1.000,000

Man Hours worked

Since SB is based on the lost time injury reportable to

the statutory authorities , it should be used for official
purpose only. In all other case severity case should be for
comparison purposes.

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Calculation of Mandays lost shall be
based on the following
 a) Man-days lost due to temporary total disability.
 b) Man-days lost according to schedule of charges for
death and permanent disabilities as given in Appendix
A. In case of multiple injury , the sum of of schedule
charges shall not be taken to exceed 6000 man-days.
 C) Days lost due to injury in the previous periods , that
is , if any accident which occurred in time in the
period of still causing loss of time in the period under
review , such loss of time is also to be included in the
period under review.
 d) In the case of intermittent of time, each period
should be included in the severity rate for the period
in which the time is lost. 24
 e) If any injury is treatment as a lost time injury in one
statistical period and subsequently turns out to be a
permanent disability , the man-days charged to the
injury shall be started from the Schedule charge for the
injury when permanent disability becomes known.

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 Incidence Rate
 It is the ratio of the number of injuries to the number of
persons during the period under review. It is expressed
as the number of injuries per 1000 persons employed.
 Lost time IR = No. of Lost time injuries X 1000
Average number of persons employed

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Sl Description of Injury % Loss of Equivalent
No earning capacity Man Days
lost
PART – A : TOTAL DISABLEMENT

1 Death 100 6000

2 Loss of Both Hands 100 6000

3 Loss of a Hand or foot 100 6000

4 Double amputation through leg or thigh 100 6000

5 Loss of sight 100 6000

6 Very severe facial disfigurement 100 6000

7 Absolute Deafness 100 6000

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Sl Description of Injury % Loss of Equivalent
No earning capacity Man Days
lost
PART – A : PARTIAL DISABLEMENT-AMPUTATION CASES, Upper limbs

1 Amputation through shoulder joint 90 5400

2 Amputation below shoulder 80 4800

3 Loss of thump 50 1800

4 Loss of four fingers of one hand 100 3000

AMPUTATION CASES – LOWER LIMBS

5 Amputation of both feet 90 5400

6 Loss of all toes 40 2400

7 Amputation at Hip 90 5400

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 CLASSIFICATION OF INDUSTRIAL ACCIDENTS
 CLASSIFICATION ACCORDING TO AGENCY

1 Machines Prime Movers , Steam engines, Combustion

2 Transmission
Machinery
3 Metal Working
machines
4 Wood and Associated
machines
5 Agricultural
Machines
6 Mining Machines
7 Lifting Machines
8 Wheeled means of
transportation
engines
Shafts, Belts, Cable pulleys, chains, gears
Power presses, Lathes, Milling Machines,
Abrasive wheels, Mechanical Shears
Circular saws, Moulding machines, Overhand
planes
Reapers, Threshers
Drilling and Boring Machine, cutting machine
Cranes, Lifts, winches
Tractors, Lorries, Trucks

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 CLASSIFICATION OF INDUSTRIAL ACCIDENTS
 CLASSIFICATION ACCORDING TO AGENCY
9 Pressure vessels Boilers , Gas cylinders
10 Furnaces Blast furnace, Kilns
11 Refrigerating Plants
12 Electric Hand tool
13 Ladders
14 Scaffolding
15 Explosives
16 Flying objects
17 Radiations
18 Working Environment
19 Open Cast mining
20 Improper guarded
agency
21 Hazardous arrangement

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“And the end is
that the workman shall live to enjoy the fruit of
his labour:
that his mother shall have the comfort of
his arm in her old age:
that his wife shall not be an untimely widow:
that his children shall have father
that cripple and hopeless wrecks who were once
strong men shall no longer be the by product of
industry” ---- JHUNKE

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Thank you

Jayakumar.G
Asst.General Manager(Safety)-Retd
From FACT
Mob: 9446333370
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