MEPE39-INDUSTRIAL SAFETY ENGINEEING

UNIT 1
UNIT 1

Evolution of modern safety concept- Safety

management functions - safety policy - Safety
Organization - Safety Committee - budgeting for
safety - Behaviour based Safety.
 How safety Evolved?
The first age of safety started with the Industrial Revolution in 1750-1760
and the invention of the steam engine. Most accidents were from the
technology failing, injuring workers and the public. The focus of safety
management was to ensure the technology was safe to use.

Workplace safety concerns began in Europe with the labour movement

during the Industrial Revolution. During this movement, Workers formed
unions and began to demand better working conditions. Government
organizations responded by regulating the workplace and forcing safer
work practices.
How safety Evolved?
1900 :

 Invention and application of new tools for mass production

brought danger.

 Fatality due to industrial accidents were more than the world war .

 Employers ignored the problem as a disabled worker could be

easily replaced and wages were low.

 Workers and managers believed that accidents were inevitable.

 Accident was considered as an "act of god”(it was a time

when people believed that sickness was the result of evil spirits or
a curse of god).
How safety Evolved?
1930 :
Accelerated the upward trend of serious and fatal injuries. The
news papers became interested and published more details
about serious cases which made public interest grew on safety.
1940 :
Safety and productivity was looked as two sides of the same coin.
How safety Evolved?
1941 :-
Organization called American Conference of Governmental
Industrial Hygienists was formed.
1944:-
The Threshold Limit Values for Chemical Substances (TLV®-CS)
Committee was established.
1948:-
Indian full factories act was passed and came into force from
1st April,1949.
1970:-
OSH Administration, USA created NIOSH.
How safety Evolved?
1980:-
Awareness to eliminate or reduce the occupational diseases was
evolved.

1996:-
ISO 14001 environment management system was evolved.

1999:-
The OHSAS 18001 standard was developed to bridge the gap
where no international standard existed for occupational health
and safety.
How safety Evolved?
2010 onwards….

Now, Safety is looked as an integral part of business.

More focus has been made in implementing
successful Safety Management and improve the
safety culture
Evolution of modern safety concept:
Modern system safety is comprehensive and is risk based, requirements
based, functional based and criteria based with goal structured
objectives to yield engineering evidence to verify safety functionality is
deterministic and acceptable risk in the intended operating environment.

Safety is a concept that includes all measures and practices taken to

preserve the life, health, and bodily integrity of individuals. In the
workplace, safety is measured through a series of metrics that track the
rate of near misses, injuries, illnesses, and fatalities.

The goal of System Safety is to optimize safety by the identification of

safety related risks, eliminating or controlling them by design and/or
procedures, based on acceptable system safety precedence.
Concept of Safety

In order to understand the accident causation, it is necessary to consider

what is meant by "safety".
Depending on one's perspective, the concept of safety may have
different connotations, such as:
 zero accidents (or serious incidents);
 the freedom from danger or risks, i.e. those factors which cause or are
likely to cause harm;
 the attitude towards unsafe acts and conditions by employees
(reflecting a "safe" corporate culture);
 the degree to which the inherent risks in industry are "acceptable";
 the process of hazard identification and risk management; and
 the control of accidental loss (of persons and property, and damage to
the environment).
Safety is the state in which the risk of harm by accident to persons or of
property damage is reduced to, and maintained at or below, an
acceptable level through a continuing process of hazard identification
and risk management.
Safety management functions:

An important concept in an effective safety management system is that it is not the sole
responsibility of the company’s safety office – it is the responsibility of everyone within the
company.

Senior managers are responsible for establishing and maintaining the safety management
system. Their roles and responsibilities include:

• Establishing levels of acceptable risk;

• Establishing safety policy;
• Establishing safety performance goals that are in line with other company goals and help set
a direction for improvement;
• Allocating sufficient resources;
• Modifying policies and goals, as necessary.
Safety management functions:

Line managers carry out the instructions of senior management by:

• Implementing safety programs;

• Ensuring that staff receives safety training;

• Ensuring that staff has, and uses, safety equipment;

• Enforcing safety rules;

• Including safety in performance reviews;

• Providing safety coaching to staff;

• Monitoring staff safety performance; and,

• Conducting incident investigations.

Safety management functions:

Employee acceptance of the safety management system and safety programs is

essential for success and can be achieved by having employees:

• Help develop and establish safety programs;

• Participate on safety committees:
• Follow established procedures and not take short cuts;
• Assist in investigations;
• Report hazards and incidents; and,
• Provide feedback to managers.
Safety and Health Policy
 Became mandatory as per sec-7A sub Sec-3 of
factories act 1948(from amendment in 1987)

 It is the starting point for all the activities in safety

management program
 Policy should do three things
1. It should affirm long range purpose.
2. It should commit management at all levels to affirm
and reinforce this purpose in daily decisions.
3. It should indicate the scope left for discretion and
discussion by lower level management
Safety and Health Policy should
cover following areas
• Management intention
• Scope of the activities covered
• Responsibility
• Accountability
• Staff safety assistance
• Safety committee

For effective safety policy, it must be

• Prepared by safety professional
• Signed by management and
• Published in all departments including office in local
language and common language
The Health and Safety Policy
should contain:
• Declare intension and commitment of the top
management to health, safety and environment and
compliance with all the relevant statutory requirement.

• Organizational setup to carry out the declared policy

clearly assigning the responsibility at different levels.

• Arrangements for making the policy effective.

In particular the Policy should
specify:
• Arrangement for involving the workers.
• Intention of taking into account the health and safety
performance of individual at different levels while
considering their career advancement.
• Providing a resume of health and safety performance
of the factory in its Annual report.
• Relevant techniques and methods, such as safety
audits and risk assessment for periodical assessment
of the status on health, safety and environment and
taking all the remedial measures.
• Arrangements for informing, educating and
training and retraining its own employees at
different levels and the public, wherever required
A copy of the declared Health and Safety policy signed by
the occupier shall be made available to the

• Inspector having jurisdiction over the factory

• The Chief Inspectorate of Factories
The Policy should be made widely
known by:
• Making copies available to all workers including
contract workers, apprentices transport workers,
suppliers etc.
• Displaying copies of the policy at conspicuous places;
and
• Any other means of communications in language
understood by majority of workers.
When to revise Safety Policy?
• Whenever any expansion or modification having
implications on safety and health of persons at work is
made.
• Whenever new substances or articles are introduced
in the manufacturing process having implications on
health and safety persons exposed to such substance
Safety Policy of L&T:
Safety Policy of BlueStar:
Safety Organizations
• Type A organization - Line Organization
• Type B organization – Safety Director
• Type C organization - Safety Committees
Type A organization - Line Organization

Line function : decision making area in an organization

which is in daily operations
Safety: line function

Advantage:
safety function is part of the day by day activities of every
personnel in an organization.
Disadvantage:
- The supervisor personnel occupied with production
problem find difficult to action
- Chief executive should be safety minded.
Type A organization - Line Organization
Type B organization – Safety Director
Safety : staff function
Advantages : safety provisions can be successively implement
Type C organization- Safety
Committees
- For better cooperation and involvement of employees in
safety activity
- Employees like to participate in decision
making concerning their safety and health.
- contributes to the safety promotional activities through
group efforts
- Recognition to employees who contribute in
safety activities
- Encourages closer relation between management
and employees
- Statutory requirements(section 41G and factory rules)
Type C organization- Safety
Committees
- For implementation of various safety programs, it
will be necessary to have standing committees which
form the policies and indicate the course of action to
be taken.
- These committees will advise the safety engineering
department for achieving a better performance in
safeguarding the men, machines and materials
- The employees representatives must also be included
as members in these committees so that they can
present the view of workers and come with their ideas
and suggestions.
Type C organization- Safety
Committees
Types of Safety Committees
• Central safety committee
• Departmental safety committee
• Safety sub committee
• Area safety committee
Central safety committee
Functions :

• Plant level safety education, accident investigation,

selection and development of PPE’S and other safety
promotional activities.
• Advisory body on safety policy.
• Frequency-meet once in 3 months

Governing body:
Chairman : production head/ unit head
Members : respective head of department, 3
representatives from various unions
General secretary: safety head
Departmental Safety Committee
Function : Implement the various safety measures
Frequency : Once in a three months

Area Safety Committee

Function :
To identify potential hazards with in the area/section and
implement the remedial steps with a time bound
programmers and continuously monitoring and safety
measures
Frequency : Once in a month
Safety sub committee
Function :
The four elected worker’s representatives nominated from
the works committee visit the shop for safety survey and
finding safety problems
Frequency : once in a week, along with safety officials
Safety Budget
• Managing health and safety at work is an important
part of good business management, and the right
investments in health and safety can be really beneficial
and make a difference to the success or failure of an
organization.

• The safety budget is used for funding all activities

that make Safety Management System (SMS) reach the
highest standard of safety.

• It is important role of the safety engineer to make

sure that budgets are well set and give the right return
on investment.
Safety Budget
• This may be reducing accidents, injuries and sickness
absence rates, compliance with obligations and raising
health and wellness to help create a more productive
workforce.

• Health and safety is a cost, but it should still give a

return that the organization will benefit from.
How Budget is set?

What works well in most organizations is a combination

of both top down and bottom up budgeting, as it draws
on top management knowledge of company goals and
available resource and on lower and middle
management knowledge of day to day operations.
Budget is Responsibility
• Things sometimes are beyond your working reach.
Taking the charge of the safety department wherein you
are responsible for the safety of your people, no one will
know better than you when is the right time to upgrade
your safety.
• But just because the company’s budget does not have
much scope, even though there were certain products in
your mind that you wanted to acquire for your workforce,
YOU COULDN’T DO IT. That is when you realize the
importance of a Proper Safety Budget.
• Therefore, a safety budget should specifically be set
out to allocate funds for any future improvements that
may arise from recommendations made from safety
monitoring activities, risk assessments and accident
investigations.
The four main activities that
require funding
1. Development of safety procedures - Through
reviewing and updating this procedure regularly for
further improvement and making sure that they
comply with safety standards
2. Training - Suitable training must be provided to
staff to enhance their Awareness of the safety
requirements. Depending on the nature of the the
task, the level of safety management training
required will vary from safety general safety
familiarization to export level for safety specialist.
3. Oversight
4. Managing Safety database
The four main activities that
require funding
3. Oversight - Funding for monitoring safety
performance and performing safety audits to
provide a better look at the human performance
errors. Helping to improve man- machine
interactions to reduce the rates of accident and
incident for the airline.

4. Managing Safety database - Improving safety

depends heavily on the ability to collect and
analyze safety data and to use that information to
develop safer systems and take corrective actions
before incident occur
Safety Budget
• Capital Expenditure –
1. Money spent by a business or organization on
acquiring or maintaining fixed assets, such as land,
buildings, and equipment.
2. Based on input form the legal non compliance, risk
assessment, safety audits, accident investigations
etc , for improving the safety standard need to buy
new equipment/ modification of the
equipment/major work procedure

• Revenue Expenditure -
Safety Budget
• Revenue Expenditure –
A revenue expenditure is an amount that is expensed
immediately— thereby being matched with
revenues of the current accounting period.
Safety Budget
Safety Budget
Wearable technology
Introduce smart technology like sensors, wearable tech
devices, smart communication devices, GPS tracking, it
allows the health and safety of workers to be reliably
tracked and monitored, for their benefits.
Ergonomic Interventions
Analyze the atmosphere around your workforce by
introducing the right software to learn about the trends of
your workforce injuries and illness through available data &
plan for its elimination by proper training.
Workplace Design
There is an undeniable link between workplace safety and
workplace design. Aim to make sure the layout is
ergonomically designed &meets the industry standards &
regulations.
Leadership Development
Recognize & reward leaders for their previous year
achievements for maintaining the zero accident scores.
Understand the resources they need in the upcoming year
to maintain safety at the workplace.

Employee Relationship
Where there is complacency, there is a greater risk for
injuries and accidents. Identify ways to improve manager-
workers relationships by increasing transparent
communication, listen to safety related feedback from the
workforce. Regularly provide the required training.
Behavior Based Safety
Behaviour based Safety

Behaviour Based Safety (BBS) is a process aimed at

reinforcing daily behaviour by employees and leaders
through safety observations, reducing the risks of accidents
in the workplace. It is fundamental to assure that upper
management and leaders are committed, as well as that the
frontline team is on board.
How to implement a behaviour based safety (BBS) program

To implement an effective behaviour-based safety program,

your organization should establish a culture of safety that
follows these steps:
1. Observation

How employees perform their tasks on a daily basis is

assessed at this stage. So-called “observers” need to be
employees trained on conducting safety assessments in the
workplace and have to be experienced in the tasks they are
observing;

It is important that the entire organization be aware of what

the observation period will be so that the situation is not
qualified as a “trap” by workers.
2. Checklist

A checklist form can help to orient the observer by

focusing on employees’ actions, approaches and
attitudes

This checklist ought to have questions associated with

the context of a behaviour-based safety program. Some
topics covered could include employee actions and
decisions related to ergonomics, personal protective
equipment (PPE), tools and equipment, work area,
procedures, protection from falls and use of chemical
products.
3. Feedback

Feedback should be given during and/or after the observation. Praising

good behaviour encourages people to continue to use these practices.
Likewise, the observer may want to interrupt and correct undesired or
unsafe behaviour as it occurs in order to break the barriers of bad habits.

Encourage observers to maintain clear communication with workers,

keeping records on what led these professionals to use unsafe behaviour.
This can result in a lack of resources that have yet to be covered by your
company.

After observation is done and all feedback is shared, the observer should
send comments on the period to the appropriate team, which will
take actions to guarantee that good behaviour continues.

It is important to remember that the goal of a BBS program is to correct

rather than to punish unsafe behaviours.
4. Targets

As with any program, applying targets is essential to

guaranteeing its efficacy. Some targets that can be applied to
your program include reducing potentially accident-causing
incidents or getting 100% of employees to use their personal
protective equipment (PPE) correctly.

Here it is important that targets be measurable and tangible.

Having manageable targets along with an action plan is sure
to increase the chances for success in a BBS program and will
guarantee that everyone is engaged.
Benefits

The main benefits of a BBS program are:

 Shared vision of a “zero accident” culture;
 Significant reduction in accidents;
 Engagement by employees and teamwork;
 Positive reinforcement instead of assigning responsibility
for mistakes;
 Consolidation of an efficient culture of safety;
 Direct and active involvement and support from upper
management and at other managerial levels.
Final considerations

With a BBS program, your entire organization, from

management to frontline employees, are constantly being
observed to discover trends in unsafe behaviours.

The main goal of a BBS program is to provide positive

reinforcement of safe practices while also identifying unsafe
behavioural standards. Whenever necessary and in an effort
to reduce or avoid accidents, actions suited to fundamental
changes are generated, continually enhancing the
occupational safety management system.

By changing behaviour, employees begin to better understand

the risks to which they are exposed and the attitudes that
they need to take to avoid accidents and other deviations
from safety.
What is behaviour based safety process?

Behaviour Based Safety is a program designed to influence

employee actions toward safer outcomes, ideally by
preventing an accident or injury before it occurs.
Implementing a behaviour based safety program is the most
comprehensive way for companies to promote safety,
eliminate hazards and prevent injuries.

What is Behavioural safety in the workplace?

Behavioural safety focuses on fixing the unsafe actions of
workers which are a result of the system they work in, not
the other way around, and by concentrating on the workers
actions, behavioural safety turns the hierarchy of controls on
its head as behaviour modification programs favour PPE and
training as the main .
Theory of industrial accident prevention

The accident triangle, also known as Heinrich's triangle or

Bird's triangle, is a theory of industrial accident prevention.
It shows a relationship between serious accidents, minor
accidents and near misses and proposes that if the number
of minor accidents is reduced then there will be a
corresponding fall in the number of serious accidents.
What is your action