MCN 401

INDUSTRIAL SAFETY ENGINERING

MODULE 1
SAFETY AND PRODUCTIVITY

• Safety, quality, and productivity are inextricably linked

• When organizations put better care into maintaining their safety,

quality, and productivity, they are also better able to serve their
customers and protect their employees
Safety
• Improves quality and productivity

• When operations are unsafe, they aren’t well-managed

• Employees will not be motivated nor mindful, and employee churn will be far greater

• Quality and productivity both suffer when employees are under stress, unsatisfied, or
unable to complete their mission

• But when businesses are safe, it frees up employees to focus on their quality and their
productivity

• The safer the organization is, the less frequently the organization will experience large
scale disruption
Quality
• Improves safety and productivity
• Safety is a measure of conscientiousness and proactiveness
• High quality work means better results and better products
• The higher quality the work, the fewer reworks are needed, and the greater
overall productivity is
• When quality is high for a business, it can be assumed that standards for the
business are generally high, including safety equipment, safety software,
and safety processes
Productivity
• Improves safety and quality
• Carelessness is often what begets safety issues
• With the appropriate (and productive) safety processes, safety can be
improved, and quality can be improved as well
• The more productive employees are, the less likely they are to cut corners
on things like safety processes
• The more productive they are, the more likely they are to put extra attention
into the quality of their work
Traditional Barriers to Safety, Quality, and
Productivity
• It’s easy to see that safety improves business outcomes

• Dangerous operations lead to lost time, injured employees, and a loss of

morale

• Nevertheless, many organizations fear that additional safety processes can

take time and money

• While true, it’s time and money well spent; it’s better to spend a small
amount for preventative care than a large amount for an emergency
Traditional Barriers to Safety, Quality, and
Productivity (Cont.…)
• In terms of quality, the primary issue is often expediency

• Companies may feel they have to choose between fast, cheap, or high-quality

• When companies are forced to reduce costs (cheap) and produce quickly (fast)
they need to sacrifice quality

• But sacrificing quality actually ends up driving up time and costs; unsatisfied
customers demand reworks, which can often be upwards of three times the
original budget
Traditional Barriers to Safety, Quality, and
Productivity (Cont.…)
• Productivity must never be seen to be at odds with safety or quality

• Organizations may feel that safety and productivity are mutually

exclusive, and that it’s difficult to maintain a productive office
Accident
• The ordinary definition of the word “Accident” as derived from lexicons is
an unforeseen of an unexpected event.
• The American Safety council has defined accident as “that occurrence in a
sequence of events which usually produces unintended injury, death or the
property damage.
• Heinrich has defined accident as “an unplanned and uncontrolled event in
which the action or reaction on an object, substance, person or radiation
result in personal injury”.
Injury

• An injury or illness is an abnormal condition or disorder. Injuries

include cases such as, but not limited to, a cut, fracture, sprain, or
amputation. Illnesses include both acute and chronic illnesses, such as,
but not limited to, a skin disease, respiratory disorder, or poisoning.
• Accidents are defined as unplanned occurrences which result in
injuries, fatalities, loss of production or damage to property and
assets
• Preventing accidents are extremely difficult in the absence of an
understanding of the causes of accidents
• Attempts have been made to develop a prediction theory of accident
causation, but so far none has been universally accepted
• Researchers from different fields of science and engineering which
will help to identify, isolate and ultimately remove the factors that
contribute to or cause accidents
 Haddon's energy release theory
• accidents are caused by the transfer of energy with such force that
bodily injury and property damage result.
 Intervention that is focused on employee behaviour.

 Identification of external factors that will help understand and improve employee behaviour (from the

 perspective of safety in the workplace).

 Direction of behaviour with activators or events antecedent to the desired behaviour, and motivation of

 the employee to behave as desired with incentives and rewards that will follow the desired behaviour.

 Focus on the positive consequences that will result from the desired behaviour as a way to motivate

 employees.

 Application of the scientific method to improve attempts at behavioural interventions.

 Use of theory to integrate information rather than to limit possibilities.

 Planned interventions designed with the feelings and attitudes of the individual employee in mind
Management’s Role in Safety
• Management of an organization, the business owner(s),
managers, supervisors, etc., provides the leadership, vision,
and resources needed to implement an effective safety
program.
• Being at the top of the organization, management must
embrace and communicate a few basic principles:
• Make worker safety a core organizational value.
• Provide sufficient resources to implement and maintain the safety
program once it is developed.
• Visibly demonstrate and communicate their safety commitment to
workers.
• Set an example through their own actions.
• According to OSHA, management leadership of a safety program
can be broken down into four action items.
• Item 1: Communicate your commitment to a safety
program.
• A clear, written policy helps you communicate that safety and
health are primary organization values – as important as
productivity, profitability, service quality, and customer
satisfaction. After all, without safety, none of these other things
can happen.
• Item 2: Define program goals.
• By establishing specific goals and objectives, management sets
expectations for everyone on their team and for the program
overall. The goals and objectives should focus on specific actions
that will improve workplace safety and health. Establish realistic,
measurable goals for improving safety and emphasize preventing
injury and illness rather than focusing on incident rates.
• Item 3: Allocate Resources.
• Management has the authority to provide the resources needed
to implement the safety program, pursue program goals, and
address program shortcomings when they are identified.
• To do this effectively, management must integrate safety and
health into the planning and budgeting process.
• Estimating the resources needed to establish and implement the
program and allowing time in workers’ schedules for them to fully
participate in the program are two critical components to an
effective safety program.
• Remember to include all of the following when considering what
safety resources your company needs: capital equipment and
supplies, staff time, training, PPE and Safety Data Sheets.
• Item 4: Expect performance.
• Management leads the program effort by establishing roles and
responsibilities and providing an open, positive environment that
encourages communication about safety and health.
• They will identify a front line person or persons (even a safety
committee) to be responsible for safety performance.
• That person or committee charged with safety responsibility will
need to make plans, coordinate activities, and track progress.
• Providing positive recognition for meeting or exceeding safety
goals aimed at preventing injury and illness (e.g. reporting close
calls or near misses, attending training, conducting inspections) is
also a crucial management function.
Safety Responsibilities for Supervisors

• Supervisors are responsible for a great deal of what goes on day to

day in the workplace;

• it's not just a position that solely assigns tasks.

• Supervisors must ensure a safe and healthful workplace for

employees.

• Employees must be able to report unsafe or unhealthful workplace

conditions or hazards to a supervisor without fear of reprisal.
• Conduct Orientation and Training of Employees:
• Train and instruct employees so they can perform their work safely.
• Know what personal protective equipment is needed for each task
and how this equipment must be properly used, stored and
maintained.
• When there are mandated safety training courses, ensure that your
employees take them and that they are appropriately documented.
• Enforce Safe Work Practices:
• to enforce safe work practices and procedures; failure to do so is an
invitation for accidents to occur.
• Workers must be encouraged to identify unsafe or unhealthful
workplace conditions or hazards and absolutely not be disciplined for
doing so!
• Correct Unsafe Conditions:
• Supervisors' must take immediate steps to correct unsafe or unhealthful
workplace conditions or hazards within their authority and ability to do so.
• When an unsafe or unhealthful workplace condition or hazard cannot be
immediately corrected, the supervisor must take temporary precautionary
measures.
• Supervisors must follow-up to ensure that corrective measures are
completed in a timely manner to address the hazard.
• Prevent Lingering Unsafe or Unhealthful Workplace Conditions or
Hazards:
• Many near miss incidents are caused by unsafe or unhealthful workplace
conditions or hazards.
• It's the supervisor's responsibility to train and periodically remind
employees of what to look for and how to correct or report unsafe
conditions or hazards.
• If a hazard is identified, the supervisor must act.
• Investigate Workplace Accidents:
• Supervisors are responsible for conducting accident investigations and for
ensuring that all occupationally injured employees report to the Occupational
Medical Service (OMS) immediately.
• The OMS will document and treat any acute injuries.
• All facts and opinions regarding the cause of the accident must be compiled and
documented on the Workers Compensation Forms (CA-1 or CA-2).
• Supervisors must review the circumstances, sign and submit the forms within 48
hours.

• Promote Quick Return to Work:

• Employees must be encouraged to return to work as soon as possible.
• The longer an employee is away from work, the less likely he or she will actually
return.
• When possible, light or limited duties should be identified and considered, to
assist in returning the employee to work.
Employee’s Responsibilities
• Workers are responsible for their own safety on the job.
• This means that you have the right to refuse to do any act or operate any tool, appliance, or
equipment when you have reasonable cause to believe that to do so would put you in danger.
• It is your responsibility to wear proper clothing for the job site and to use the PPE provided by
your employer or required for your job.
• As a worker, you should keep the following personal responsibilities in mind:
• Not remove any safety equipment from machines or equipment. This includes shields from
grinders, mixers, etc.
• Adequate instruction about a piece of machinery or equipment before you use it.
• Make sure that no machine, equipment, or tool is used in a way that would cause injury to
someone else.
• Make sure that there are safe entrances to and exits from the workplace.
• Make sure that the work area is safe for the movement of workers, equipment, and materials.
• Wear protective eyewear when using grinders and other equipment that may be hazardous to
the eyes
Role of unions in safety
The health and safety of workers is a priority for unions in the workplace. In most
organizations, union workers from health and safety committees tasked with identifying,
controlling and reporting workplace hazards. The duties of unions should include:
• Surveying membership on their workplace health and safety concerns
• Conducting investigations of injuries, illness, and near misses
• Monitoring workplace conditions
• Educating members and leaders about specific health and safety issues
• Filling and following up on OSHA(Occupational Safety and Health Administration)
complaints
By forming health and safety committees, unions demonstrate to both workers and
employers their commitment to improve their commitment to improving working
conditions and protecting workers on the job. Though many employers feel the burden of
the safety belongs to them, unions have the right to form these independent committees
to serve as a watchdog for workers
Role of Governments in Safety
• In order to ensure industrial safety, government has made numbers of legislations
like, the Factories Act 1948, Indian Electricity Act 1884, Mines Act 1952, Indian
boilers Act 1923, Workmen’s compensation Act, Petroleum Act 1934 which
governs the safety of personnel and equipment in industrial units in the country
• To assure safety to workers and eliminating chances of damage to machinery and
equipment, Indian Standards Institute has done commendable job
It lays down:
(i) Safety precautions to be taken during manufacturing operations
(ii) Requirements for effective maintenance of tools and equipment
(iii) Standards for proper layout, proper lighting and ventilation of factory building
(iv) Standards and specifications of safe industrial operations and practices
(v) Safety codes for handling acids and other chemicals
(vi) Safety requirements for personal protective equipment’s
Safety Organizations
The purpose safety organization in any activity is to assist management in the
development and operation of a program designed to protect the employees and
to increase production by the prevention and control of accidents which involve
any of the elements of production, i.e, manpower, material, machinery tools,
equipment and time.
Types:-
a) Line Organization
Very common type that delegates safety
responsibilities which parallel the supervisors
production assignments, both as to control of
personnel and the physical conditions in the
work area
• President – The president directs policy of the plant and has overall responsibility for
safety of workers as well as responsibility for production
• General Manger – The general manager is delegated authority from the president to
carryout accident prevention functions. He, in turn, delegates authority to supervisors
according to their position and control in production process
• Superintendent – The superintendent carries on the safety program within his
department or unit
• Foreman – The foreman supervises worker safety and conducts job instruction training to
improve worker efficiency
Advantages – Integrates safety as part of production
Disadvantages – In Service safety training is seldom given
Supervisors, occupied with other production problems, may have little
opportunity to acquire special knowledge needed to accomplish a high
standard of safety performance
b) Staff Organization
Staff organization consists of a line organization with specialized personnel to
advise and assist all management levels. This includes a safety director, production
engineer, and other specialized personnel reporting directly to the general manager
Advantages:
• Safety director has specialized experience in the
organization and operation of an accident prevention
Program
• In Service training program has made possible
Disadvantages:
• Cost of added personnel (Safety director,
stenographic help, office supplies). Does not fit small
Plants
• Tendency of management and supervision to
neglect responsibility for safety, leaving it to the safety
director
Safety officer
A safety officer, also known as an occupational health and safety officer, is a key professional
in the work environment. Safety officers provide safety management, advice, monitoring, and
reporting in the workplace, and engage staff in programs that ensure safe practice in the
workplace.
Responsibilities of safety officer
• Identify and assess hazards, risks and control measures for a specific operation or process.
• Conduct ongoing review of operations and processes to identify potential hazards, risks and control
measures that should be implemented to reduce these risks, including all costs involved in
implementing such measures.
• Assess and document hazards, risks and controls in a manner consistent with established procedures
and practices.
• Set up and supervising temporary work areas.
• Supervise the safe handling, storage & disposal of hazardous materials.
• Supervise the operation of any potential hazards in the workplace.
• Improve workplace safety and employee productivity by transitioning from manual safety procedures
to digital safety management systems.
• Ensure that all company employees meet all OSHA requirements.
• Provide OSHA training if necessary.
• Ensure that health, safety, and environmental policies are followed.
• Investigate workplace accidents and injuries and refer them to the proper authorities.
 Safety committee
A safety committee includes employees from different departments in the
organization who are responsible for identifying potential workplace hazards,
developing strategies to mitigate or eliminate them, and promoting a safety culture
throughout the workplace.

Representation in Safety Committees

An effective safety committee should be large enough to broadly represent the

workforce. It should include employees from all levels of the company, from the
custodial staff to upper management.
Functions and Duties of a Safety Committee

• Developing written safety programs

• Promoting safe work practices
• Facilitating safety training
• Performing workplace inspections
• Carrying out accident investigations
• Acting as a point of contact between employees and management
• Reviewing injury and illness records
• Increasing awareness about workplace safety issues
• Identifying hazards and recommending appropriate control measures