CORPORATE

OCCUPATIONAL SAFETY HEALTH

AND ADMINISTRATION [OSHA]

PROFILE
Presented by: Swati V. K.
30/07/2021
KGTTI’s training plan development
Schedule
Time Duration Trainings phase Planned activity Social form/ method Applied media/
material
10:00 10 min Introduction of OSH Trainer elaborates purpose of Presentation PPT
OSHA

10:05 40 min Meaning of OSH Students research on facts and Group work PPT
figures of OSHA Case study Case
Brainstorming
Group discussion

10:45 30 min simulation Trainer displays simulation Group work PPT

Brainstorming Simulation sets
Case study
What is OSHA and its purpose?
❑ Occupational Safety and Health Administration.

❑ With the Occupational Safety and Health Act of 1970,

to ensure safe and healthful working conditions for workers by setting and enforcing standards and by providing
training, outreach, education and assistance's.
Why OSHA?
❑ Number of industrial accidents from 2014 to 2017
Why OSHA?
“Industrial Accidents are caused by chemical, mechanical, civil, electrical, or other process failures due to
accident, negligence or incompetence, in an industrial plant which may spill over to the areas outside the plant
causing damage to life and property.”
What is OSHA compliances?
❑ OSHA compliance is adhering to all the OSHA regulations that apply to your business. This results in a workplace
that is safe from serious hazards that can cause a danger to employees.
What are OSHA requirements
for employees?
Provide a workplace free from serious recognized hazards
and comply with standards, rules and Regulations issued under
the OSH Act.

Examine workplace conditions to make sure they conform to applicable OSHA standards. Make sure employees
have and use safe tools and equipment and properly maintain this equipment.
Hazard factors
Overview
Mechanical Working at over-/ under Hazardous
factors pressure substances

Electrical Vibrations Biological

factors working materials

Thermal Sound Physical burden Severity of

factors work

Climate Radiation Mental load

Lighting Fire, explosions Human beings

Color Animals

Multi-factorial hazards
Hazard factors
Individual work
Define what hazard factors are/ might be relevant to your department/ taught profession and explain where the hazard is
coming from.

Prepare and present your findings in the session.

Preparation time: 10 minutes

Presentation time: 2 minutes per person
Mechanical factors
Overview
Object moves Human moves

Controlled moving Mobile work Uncontrolled moving Dangerous surfaces Fall/ Lacking step
unprotected parts equipment/ mobile parts and shapes security
trans-portation mean
Fire
Requirements and impacts
Oxygen

Fuel Ignition source

Impact Hazard Damages
Heat ▪ Thermal heating ▪ Burns
▪ Spread of fire ▪ Building damage
Smoke ▪ Obstruction of escape and rescue ▪ Stumble
▪ Inhalation of hazardous substances ▪ Poisoning
▪ Contamination ▪ Corrosion and building damage by
contamination
Fire
Fuels classification according to GHS
▪ Explosives
▪ Flammable gases
▪ Flammable aerosols
▪ Oxidizing gases
▪ Gases under pressure
▪ Flammable liquids
▪ Flammable solids
▪ Self-reactive substances
▪ Pyrophoric solids
▪ Pyrophoric liquids
▪ Self-heating substances
▪ Substances which in contact with water emit flammable gases
▪ Oxidizing liquids
▪ Oxidizing solids
▪ Organic peroxides
▪ Substances corrosive to metal
Hazard factors
Group work
Arrange four groups. Each group has to elaborate one factor. Decide independently which group will process which factors.
At the end, all of the following factors need to be elaborated:

▪ Electrical hazards ▪ Physical workload

▪ Explosion ▪ Sound/ Noise
▪ Hazardous substances ▪ Lighting

Elaborate for each factor the following aspects:

▪ Description of factor and its characteristics
▪ Relevance to your work
▪ Kind of hazards and their impacts
▪ Parameters and assessment criterion
▪ If exist: National limits

Preparation time: 15 minutes in total

Presentation time: 5 minutes per factor
Explosion
Impacts
Impact Hazard Damages
Heat ▪ Thermal heating ▪ Burns
▪ Spread of fire ▪ Building damage
Pressure ▪ Blast wave ▪ Damages to persons
▪ Material damages
Smoke ▪ Obstruction of escape and rescue ▪ Stumble
▪ Inhalation of hazardous substances ▪ Poisoning
▪ Contamination ▪ Corrosion and building damage by
contamination
 Explosion
Guiding questions
▪ Has it been checked whether flammable substances are present in the form of gases, vapors, mists or dusts and whether
an explosive mixture can result from them?
▪ Have measures been defined to prevent or limit the formation of explosive atmospheres?
▪ Have measures been defined to prevent the ignition of this explosive atmosphere?
▪ Have measures been established to limit the effects of an explosion to a harmless level?
▪ Have measures been defined which maintain the measures mentioned above through safety, control and regulation
devices?
▪ Is only that work equipment used in potentially explosive areas that is suitable under the actual operating and usage
conditions?
▪ Are the potentially explosive areas clearly recognizable and permanently marked?
▪ Does a work permit system exist?
▪ Have additional organizational measures for explosion protection been taken?
▪ Are these measures regularly checked by experts?
 Electrical factor
Characteristics and parameter
▪ Danger from electric shock can occur if the current through the human body reaches a dangerous level depending on
the resistances in the accident circuit and the driving voltage

▪ There is a risk of electric shock if the voltage between an active part and earth or the voltage between active parts is
higher than 25 V AC or 60 V DC
Electrical factor
5 Safety Rules
Electrical factor
Guiding questions
▪ Has the work equipment been selected according to the operating conditions and external influences?
▪ Are electrical equipment used as intended?
▪ Is the basic protection available and sufficient?
▪ Has the error protection been implemented and is it effective?
▪ If necessary, is the additional protection available and effective?
▪ Are the protective measures applied and effective in the event of increased electrical hazard?
▪ Is work carried out on active parts only after ensuring that they have been de-energized?
▪ Is work on active parts, the voltage-free state of which cannot be determined, only carried out according to safe
procedures?
▪ Are safety clearances observed when working near live systems?
▪ Has it been ensured that the testing of electrical systems and equipment is carried out before commissioning, after
repairs and at regular intervals?
▪ Is PPE used where necessary?
 Hazardous substances
Guiding questions
▪ Has it been checked whether employees carry out activities involving hazardous substances or whether hazardous
substances arise or are released during these activities?
▪ Has it been checked whether hazardous substances can be avoided by using other processes or can be replaced by
other working substances?
▪ Are safety data sheets available for hazardous substances and preparations?
▪ Is there a list of hazardous substances?
▪ Are hazardous substances and preparations labeled?
▪ Have appropriate protective measures been established?
▪ Are employees in the work area and in neighboring areas protected and informed about hazards and protective
measures?
▪ Has a measurement been carried out on hazardous substances in the air?
▪ Are hazardous substances safely stored and disposed of?
▪ Are there emergency plans for accidents involving hazardous substances?
▪ Are hygiene measures observed when handling hazardous substances?
Sound/ noise
Characteristics
▪ One of the most common workplace hazards
▪ Can damage the hearing and health and impair the physical and / or mental well-being of people
▪ Increased risk of accidents as a result of ignoring signals or as a result of incorrect behavior as a startle reaction to
unexpected noise
▪ Reduction of the work performance
 Sound/ noise
Parameter

Emission Nuisance Exposure

Airborne sound emitted by a Sum of all sound effects at certain depends on the level of nuisance and the exposure time
machine or other sources of noise point in a room and is therefore person-related

daily noise exposure level

LEX, 8h between 80 to 85 dB (A)
peak emission sound pressure level LpC, peak between 135
to 137 dB
 Sound/ noise
Guiding questions
▪ Have measures been taken to reduce sounds that are perceived as noise as much as possible?
▪ Have noise areas been identified?
▪ Are the dominant sources of noise spatially separated or shielded?
▪ Are additional sound sources with a hazard to the hearing taken into account, prohibited or set to a minimum?
▪ Is the noise emission information known for the work equipment?
▪ Are noise emissions taken into account when purchasing new work equipment?
▪ Are measures being taken to prevent sound reflection?
▪ Are employees instructed about noise hazards and protective measures?
▪ Is suitable hearing protection provided?
▪ Are danger signals perceptible despite operational noise?
Physical workload
Forms of active physical workload
Manual load handling
▪ Lift, hold, carry
▪ Pulling, pushing
Work in forced postures (forced postures)
▪ Sit
▪ Stand
▪ Torso flexion
▪ Squat, kneel, lie down
▪ Arms above shoulder level
Work with increased exertion and / or application of force
▪ Activities in hard-to-reach workplaces (climbing, climbing)
▪ Use of the hand / arm system as a tool (knocking, hammering, turning, pressing)
▪ Force / pressure effect when operating work equipment
Repetitive activities with high handling frequencies
Physical workload
Proper postures
 Physical workload
Guiding questions

▪ Is it prevented that physically heavy work is often carried out without changing the load?
▪ Is the muscle work of large muscle groups (arm, legs, trunk) reduced to the absolute minimum?
▪ Are forced and unfavorable postures avoided?
▪ Is a change of the posture (sitting vs. standing) possible?
▪ Is a lot of effort avoided when pushing or pulling loads?
 Lighting
Characteristics

▪ Influences on the autonomic nervous system and physiological parameters such as blood pressure, heart rate, core
body temperature or hormone balance
▪ Increase of concentration and attention by higher illuminance levels
▪ Increase of the people's willingness to perform
▪ The influence of illuminance is greater, the higher the proportion of visual requirements and the more difficult the
visual task.
▪ Reduction of the frequency of errors and accidents through higher illuminance levels
Lighting
Guiding questions
▪ Do the rooms have enough daylight?
▪ Are minimum values for illuminance at the workplace being observed?
▪ Is the lighting positively influenced by bright ceilings and walls?
▪ Is emergency and safety lighting available (escape routes, workplaces with special hazards)?
▪ Are glare and reflections avoided?
▪ Are lights arranged in such a way that glare and reflections on table surfaces and screens are avoided?
▪ Are the lights at computer/ display workstations arranged parallel to the main line of sight?
▪ Is flickering avoided?
▪ Do the lamps have the same light color?
Lighting
Lighting systems (according to German standards)
Room-related lighting Workplace-related lighting
Negligible
edge area
Negligible
edge area

Workplace
area

Surrounding
area
Lighting
Guidelines (examples)
Activity/ space Illuminance
Traffic areas and corridors without vehicle traffic at stairs and landings 100 lx
Storage rooms 100 lx
Stairs, machine halls 100 lx
Processing of heavy metal-sheets, casting halls 200 lx
Automotive workshops, procession of light metal-sheets 300 lx
Offices 500 lx
Metal processing accuracy > 0.1 mm 300 lx
Metal processing accuracy < 0.1 mm 500 lx
Quality check, color check, assembly of micro parts 1000 lx
Mental load
Understanding
▪ totality of external factors that affect us mentally
▪ neutral term
▪ combination of requirements arising from work activity and, as such, occurs in all activities
▪ effects can be positive or negative depending on individual’s preconditions and coping strategies

In the changing world of work, mental load is increasing; however, this does not apply to all work activities and all
employees
Mental load
Sources and factors

Work task Work process Work place Social relationships

▪ Attention
▪ Variety
▪ Predictability
▪ Quantity of work
▪ Difficulty level
▪ Sphere of influence
▪ Responsibility
▪ Possibility of decision
▪ Special requirements
Work organization
▪ Duration of the work
▪ Breaks
▪ Shift work
▪ Change of tasks
▪ Work process
▪ Time allowance
▪ Time pressure
▪ Disturbances
▪ Collaboration
▪ Team work/ individual work
Working materials
Working environments
▪ Signal perceptibility
▪ Signal comprehensibility
▪ Work under special hazards
▪ Spatial narrowness
▪ Light
▪ Climate
▪ Noise
▪ Color
▪ Smells
▪ Social contacts
▪ Group behavior/
collaboration
▪ Relationship to the superior
▪ Feedback
▪ Leadership style
▪ Status/ social prestige
▪ Communication
▪ Career possibilities
▪ Performance appraisal
Mental load
Selected coping approaches
Work task
▪ Concept of task orientation
▪ Concept of complete
activities
Work process Work place Social relationships
Work organization Working materials
Working environments
▪ Meaningful subtasks ▪ Orientation at the human ▪ Good organizational climate
▪ Clear determinations of being ▪ Good leadership
processes ▪ Consideration of the human- ▪ Mutual respect
▪ Time management machine-interface
▪ Process management ▪ Optimal conditions for
information perception and
processing
 Risk assessment
General rules

▪ Orient on the requirements and circumstances of your organization

▪ Get a systemic idea of the hazards

▪ Clarify how the hazard can be eliminated or reduced

▪ Required for every executed activity and every workstation

▪ Consider specific hazards caused by the local circumstances of non-stationary workstations

▪ Have a proper documentation in place

▪ Involve the employees

Risk assessment
When to perform

▪ Prior to starting the activities

▪ In the event of essential changes in operations

▪ At regular intervals

▪ After incidents and accidents

Risk assessment
Risk estimation matrix according to Nohl
Risk assessment
Step 4 - Hierarchy of measures
1. Avoid, eliminate, reduce hazard source;
Change characteristics of the source
Range of the measures

2. Technical measures
(physical separation at the source)

3. Organizational measures
(physical/ temporal separation of factor and human)

4. Application of PPE
(physical separation at the human)

5. Behavior-related measures
Risk assessment
Case study

The driver of a tractor wanted to leave the

drivers cabin. When he went down the steps,
his phone rang and he wanted to get it from
the pocket of his jacket.

He slipped off from the last step and rolled

over his ankle on the uneven ground.

The steps were wet from a rain shower.

Risk assessment
Case study
Range of the measures 1. Adding further steps

2. Increasing step security by using non-slip material for the steps

3. None

4. Using ankle-deep safety shoes

5. Instruction on slip hazard due to wet conditions and on parking tractor on

even ground
KGTTI’s training plan development
Competences to be acquired
A competence is the capability to apply or use a set of related knowledge, skills, and abilities required to successfully
perform "critical work functions" or tasks in a defined work setting.
Rotating Elements Jamming Simulators (Hand Safety)

This Kit is used to demonstrate the importance of Hand Safety in Rotating machines and parts Simulate
hand crushing/ jamming
resulting in injury/ lacerations
This Kit has the following drives/conveyors
• Flat Belt Conveyor, Chain and Sprocket Conveyor, V Belt Conveyor, Gear drive
 Pneumatic Force Simulation Kit

Here the user experiences the following

•Machine is fast
•Machine is Strong
•Impact of Residual pressure

This simulation kit lets you experience the power for pneumatic cylinder and air pressure. This kit is completely pneumatically operated
using hand valves and pneumatic cylinders
Hand Safety in Press Simulation / Electrical Safety Devices Simulator

This Kit is used to demonstrate performance of electrical safety devices

such as sensors, safety light curtain, emergency stop buttons, importance
2 hand push buttons and tower signal lamps
Here a pneumatic cylinder will be operated by using these safety devices.

This kit combines 2 requirements mentioned in the RFQ

Hand Safety in Press Simulation while Working in Hydraulic Press and

pneumatic cylinder using simulation working model
Safety Shoes and Helmet Safety

This Kit is used to demonstrate the importance of wearing safety shoes and helmets .
Here a heavy object is dropped on the shoe. Here we will place a regular shoe and a
Industrial Standard Safety Shoe and check the impact on both type of shoes.
Bench Drill Jamming / Handling of the cutting Tools Simulator

This Kit is used to demonstrate the risks involved in operating drilling machine with gloves.
Here we will use a hand glove and insert in the slot.
The glove will get jammed in drill bit
&
Additionally this kit has a mechanical (manual) set up that educates the use of gloves while
working with cutting tools
Industrial Safety Belt Simulator

This Kit lets the person to experience the shock of falling and explains the
importance of wearing the safety belts properly
Hand Grinder Accidents and Collision Simulator

▪ This Kit lets the user to experience the impact when a grinding machine hits wall or any
obstructions.
The user will hold the handle connected to the grinder. He will experience the force/impact
when the wheel collides with the obstruction fixed in the sides.
This Kit is Electrically operated.
 Accidents in CNC Machines Simulator

This Kit lets the user to experience the importance of closing door in a CNC machine. If
the component is not loaded properly and machine is started without closing the door
the component may hit the operator
Here a soft component is tied to a rope and the rope is connected to a rotating
element(motor). When the kit is switched on the component moves uncontrollably
This Kit is Electrically operated.
 Machines & Loose Clothing Accidents Simulator

This Kit lets the user to experience the jamming of shirt or apron when working in
machines. Here a shirt/apron is jammed in between the set of rollers. This also
demonstrates the jamming force
Uncontrolled Hose Accident Simulator

This Kit lets the user to experience the accidents that may happen from remaining air
pressure in Pneumatic hose.
Loose and unfixed Pneumatic hose will move uncontrollably and may cause injury to the
user.
Lifting Weight Simulator / Ergonomic Hazards

This Kit lets the user to experience miscalculations while lifting an object.
Here we will use 4 different material with different specific gravity / volume but with same weight. Also it explains the
importance of ergonomic safety.
Pulling & Pushing Logic

Pushing Pulling

Here the user will experience pushing and pulling a loaded trolley
 Floor Slipping/Tripping and Falling Simulator

This Kit lets the user to accidents that may occur while slipping/tripping and falling
Here he will experience different ways by which he may trip and fall, which includes walking on uneven surface, on a set ball transfer unit,
falling due to obstruction, bolts, nuts and screws scattered on floor, set of conveyor rollers and lastly walking around loose wires/cables.
 Staircase Slipping/Tripping and Falling Simulator

This Kit lets the user to experience accidents that may occur while using stairs.
Step will have different surface finish and with different angle.
It also teaches the importance of using hand rails
 Step ladder Safety Simulator

This Kit lets the user to experience accidents that may occur while using stepladders

1. While working with ladders if the hinges are not locked properly then he may fall
2. While working with ladders if floor lever/surface is uneven then he will fall