MODULE 4

Chapter 1
INDUSTRIAL SAFTY

Factory
It is a place where ten or more persons are working with the help of power and
machines for manufacturing any product.
Accident
It is defined as an event which interrupts the orderly progress of a work in an
industry.
Incidence rate = (Number of injuries / Total number of employees) x 1000

Frequency rate: It is defined as the number of accidents occurred per million

man-hours worked in a year

Frequency rate = (Number of lost time accident / Total number of man hours worked) x 1000000

Severity rate: It is defined as the number of man-days lost per million man-
hours worked, in a year.

Severity Rate = Number of man days lost / Total number of man hours worked) x 1000000

Accident Proneness
It is defined as the continuing tendency of a person to have more accidents as a
result of his characteristics.
Reasons for Accident Proneness
1) Inattentiveness and Day-dreaming
2) Poor eyesight and Lack of stamina
3) Poor adjustment of work
4) Dislike of the supervisor
5) Lack of training and skill to do a work
6) Insufficient intelligence
7) Lack of experience
8) Lack of coordination
9) Lack of health
10) Immature age

Methods to reduce Accident Proneness

i) Select only those candidates with appropriate mental and physical standards for
the job.
ii) Transfer accident prone workers to less hazardous jobs
iii) Impart adequate training
iv) Encourage employees and avoid unnecessary frustrations.
v) Stick to safety rules.

Unsafe acts of Worker

1) Casual behavior of workers

2) Lack of interest and indifferent attitude of workers towards work.
3) Failure to use personal protective devices
4) Lack of experience for the job
5) Longer hours of continuous works
6) Lack of attention and sleep
7) Carelessness and not following safety rules
8) Using unsafe speed
9) Ignorance and lack of training
10) Fatigue, physical defects etc.

Unsafe Conditions in the company

Includes:-
1) Defective equipment/machines.
2) Insufficient safety devices
3) Bad environmental conditions due to inadequate heating, lighting and ventilation
4) Electrical failures
5) Poor housekeeping
6) Long hours of continuous work
7) Improperly guarded equipments
8) Bad environmental conditions
9) Improper disposal of waste disposal
 10) Wrong or faulty layout

Causes of Accidents

Accident may be caused due to

1) Technical causes: Two types a) Mechanical factors

b) Environmental factors

2) Human causes: Caused by the person concerned – Personal factors

a) Mechanical Factors
1) Unsafe mechanical design/construction
2) Hazardous arrangement
3) Improper Machine guarding
4) Unsafe apparel
5) Defective devices
6) Improper material handling
7) Broken safety guards
8) Leaking values
9) Untested boilers and pressure vessels

10) Protruding sharp materials

b) Environmental Factors

1) Too low temperature cause shivering

2) Too high temperature causes headache, swearing etc.
3) Too high humidity causes uncomfort, drowsiness etc.
4) Defective illumination causes eye strain glares etc.
5) Presence of dust, fumes, smoke and lack of proper ventilation.
6) Poor housekeeping
7) High speed of work
8) Noise, bad odour, flash etc.
9) Inadequate rest between working hours
Personal Factors
1) Age
2) Health
3) Lack of knowledge and skill
4) High level of anxiety
5) Non-use of safety devices
6) Improper use of tools
7) Number of dependants
8) Fatigue
9) Carelessness and unsafe speed.
10) Emotional instability.

4 E’S of Accident Prevention Techniques

1) Engineering
 Safety at the design and equipment installation stage
 A good layout should be provided
 The height of the working rooms should be of 3meters
 The floors most be non-skid type
 Reduce the level of noise
 Use personal protective devices
a) Head- helmets, safety caps
b) Face and eye- face masks, shields, goggles etc.
c) Body- aprons, asbestos, suits, safety belts
d) Hand, foot- gloves, pads, safety foot wear.
e) Gas masks
 Inflammable materials should be stored separately from
the store
 Fire extinguishers should be kept in proper condition
2) Education

 Employees should be educated to think, act and work safely

 The safety education involves orientation programmes, displaying chart,
posters, and safety classes at the time of job training etc.
 Formulate safety committees and appoint safety officers
 3) Enlistment

 It concerns the attitude of employees and management towards the safety

programmes and its purpose. It is necessary to arouse the interest in
employees in accident prevention and safety consciousness.
 It includes display of safety posters, providing safety devices, providing
allowance to the workers, hold safety competitions and awards, hold
safety meetings, cross mark accidents, report safety activities to all.

4) Enforcement

 To enforce the employees to obey the safety rules and safe practices.
 If the safety practices are violated, penalties are given.
Safety Organization

Employees at all levels should be involved in practicing safety procedures.

Role of Management

Management should:

1) Provide a safe and healthy place to work including safe equipment and tools,
inspection system etc.

2) Provide adequate training and supervision to develop safe work habits among
workers

3) Organizing safety activities like investigation of accidents, first aids etc.

4) Make it clear to all levels of supervision and workers that management is behind
the safety program

Role of Safety Officers

 Short term and long term planning of safety activities

 Monitoring safety performance continuously
  Advising managers in matters relating to safety
 Supervision of the work of safety committees
 Conducting safety inspections and accident investigations.
 Overall direction of activities to prevent accidents

Role of trade unions

Members of trade unions should participate directly or through representatives in safety

inspections, in formulating safety rules and making recommendations.

Emergency Preparedness and Response

Preparedness for emergencies is a tool for bringing people – staffs, community

representatives, local authorities, together to allow effective communication on risk and
planning for emergency response.

A fast and effective response to an accident can limit injury to the people as well as
damage to the property and environment.

Response participants can be developed including -Fire and police departments, public
health authorities, transport companies and emergency health services.

Emergency response plan should cover Criteria for triggering alarm signals
Clear reporting procedures
Adequate emergency equipments
Communication equipments that can reach all
participants

Precautions to be observed while working in Hazardous Environment

1. All machine parts likely to cause accidents must be guarded properly.

2. While overhead cranes are operating, sufficient precautions are to be taken.
3. High pressure units like boilers, pressure vessels etc should be installed away from
the main concentration point and proper safety valves and alarms should be
provided.
4. Give proper rest time to the workers during their working time
5. The workers should be properly trained
6. The work should be allotted according to the physical and mental abilities of the
workers.
7. Proper lighting has to be given.
8. The ground should be kept clean without oil and dirt
9. Machines should be correctly loaded with proper speed and feed.
10.Posters indicating safety measures and slogans should be displayed at salient points.
11.Fire extinguishers are to be installed
12.Ample exits should be provided.
Precautions to be observed while handling Electrical Equipments

Various safety rules under Indian Electricity Act, 1923 are:

1. All the electrical supply lines and apparatus should have sufficient strength and
meet specific power ratings.
2. Service lines are provided with suitable cut out devices.
3. Bare electrical conductors should be inaccessible to human contact and switches are
to be given.
4. First aid boxes, fire extinguishers are to be provided.
5. Every electrical appliance should have name plate indicating rated voltage, power,
ampere etc.
6. Only authorized and licensed electricians should do the work.
7. Every installation should be periodically tested.
8. Proper earthing should be given.
9. Proper clearance has to be given
10.Lightening arrestors and electrical surge protections has to be given if necessary.

Safety Provisions in the Factory Act 1948

1. Every moving part of machinery should be safe guarded by casing and fencing
2. Only trained adult male worker wearing tight fitting clothing should be allowed to
work near moving machinery.
3. No women or young person shall be allowed to clean or lubricate moving
machinery.
4. Devices for cutting off power shall be provided.
5. Every hoist and lift shall be of good mechanical construction and strength, protected
by an enclosure fitted with gates.
6. All parts including working gears, chains, ropes etc. shall be of good construction
and strength and examined in regular intervals.
7. Detailed information should be affixed on every revolving machinery, indicating
speed and load.
8. No person shall be employed to lift or carry heavy loads which cause injury.
9. The workers should be provided with suitable goggles and screens to protect eyes.
10. Proper fire exits should be present.
11.Proper safety valves, pressure gauges etc must be given and examined regularly.
12. Pits and openings in floors should be properly covered.