the ramco cements ltd. jayanthipuram - qcfi

THE RAMCO CEMENTS LTD.JAYANTHIPURAM

1

CementReady Mix ConcreteCement Fiber ProductsCotton and Synthetic YarnSoftware Systems

Total Employees : 15,000

RAMCO GROUP

Shri P.A.C. Ramasamy RajaFounder

(1894 - 1962 )

Shri.P.R.RamasubrahmaneyaShri.P.R.RamasubrahmaneyaRajhaRajha

Chairman & Managing Director

Wind FarmsResearch & DevelopmentDry Mortar PlantsCotton TextilesSurgical.

Turnover : Rs. 6,700 crores

The Ramco Cements Ltd., (formerly Madras Cements Ltd.)Main Plants :

1. RR Nagar Plant near Virudhunagar, TN (2.0MTPA) (Established in 1959)

2. KSR Nagar Plant, Jaggaiahpeta, Andhra Pradesh (3.65 MTPA) (Estd. in1986),

Turnover-662 crores , No. of Employees- 431

3. Alathiyur near Vridhachalam, Tamil Nadu (3.0 MTPA) (Established in 2002)

4. Mathod near Chitradurga, Karnataka (0.3 MTPA) (in Operation since 2000)

5. Ariyalur, Tamil Nadu (5.5 MTPA) (Established in 2009).

Cement Grinding Units :

1. Kattuputtur (0.75MTPA) 2. Valapadi (2.0 MTPA)3. Kolaghat (1.0 MTPA) 4. Vizag (0.95 MTPA)

Packing Units :

1. Nagercoil,TN

2

Management System Certificates

UNIT HEAD

H&S organogram:

WORKS HEAD(SAFETY COMMITTEE CHAIRMAN)

SAFETY OFFICER

ADMINISTRATIVE HEAD

MEDICAL OFFICER SAFETY OFFICER

SAFETYCOMMITTEE

MEMBERS

SAFETYMENTORS

MEDICAL OFFICER

PARAMEDICS LABTECHNICIAN

CONTRACTORSAFETY OFFICERS

5

Safety Committee Members for the Year 2014 – 2016:

S C Chairman -Works - Head S C Secretary -Safety - Head Staff & Officers - 14 Members Workmen - 14 Members Contract Workmen – 4 Members Safety Committee awards are presented to Safety

Committee members for following categories; Highest attendance percentage. Highest no. of points referred by a member.

Safety Committee Members for the Year 2014 – 2016:

S C Chairman -Works - Head S C Secretary -Safety - Head Staff & Officers - 14 Members Workmen - 14 Members Contract Workmen – 4 Members Safety Committee awards are presented to Safety

Committee members for following categories; Highest attendance percentage. Highest no. of points referred by a member.

6

SAFETY COMMITTEE MENTORS

To educate the co-worker, regarding the safety practiceassociated with the work. To inform the unsafe activities & unsafe condition to the

section – in charges & safety dept. To co-ordinate the safety related function. Safety Committee Mentors for the Year 2014 – 2016: Staff - 06 Members Company workmen - 25 Members Contract workmen - 05 Members

First Aiders & Fire Fighters: First Aiders - 72 Members Fire Fighters - 45 Members

To educate the co-worker, regarding the safety practiceassociated with the work. To inform the unsafe activities & unsafe condition to the

section – in charges & safety dept. To co-ordinate the safety related function. Safety Committee Mentors for the Year 2014 – 2016: Staff - 06 Members Company workmen - 25 Members Contract workmen - 05 Members

First Aiders & Fire Fighters: First Aiders - 72 Members Fire Fighters - 45 Members

7

SAFETY COMMITTEE ACTIVITIES To identify and suggest control measures for the

hazards in their area / department. To suggest changes / modifications, if any, to ensure

safe working conditions. To identify the requirement of any specific personal

protective equipment. Review of corrective and preventive actions regarding

the accidents / incidents in the concerneddepartments.

To carry out Internal Safety Audits by SafetyCommittee Members (7 Teams) once in a month. Tosubmit a report on periodical basis on the abovematters to the Top Management.

To identify and suggest control measures for thehazards in their area / department.

To suggest changes / modifications, if any, to ensuresafe working conditions.

To identify the requirement of any specific personalprotective equipment.

Review of corrective and preventive actions regardingthe accidents / incidents in the concerneddepartments.

To carry out Internal Safety Audits by SafetyCommittee Members (7 Teams) once in a month. Tosubmit a report on periodical basis on the abovematters to the Top Management.

8

SAFETY COMMITTEE POINTS STATISTICS2010 - 2016

482494

431

482494

411

300

400

500

600

0

100

200

300

2010-12 2012-14 2014-16

Raised Completed

9 Format

Best Practiceson

Safety

Best Practiceson

Safety

10

SAFETY FLAG HOISTING,SAFETY PLEDGE & SLOGAN

Everyday, Safety Pledge and Sloganby Company employees along withcontract employees.

Every Monday, Safety Flag hoistingand 5 minutes Safety Talk by oneof the Company or Contractemployees.

Everyday, Safety Pledge and Sloganby Company employees along withcontract employees.

Every Monday, Safety Flag hoistingand 5 minutes Safety Talk by oneof the Company or Contractemployees.

11

5 – MINUTES SAFETY TALK• 5–Minutes Safety Talk is

being conducting on eachand everyday at all sectionsof plant premises.

• Creating awareness on theparticular risky job beforegoing to do that work.

• 5–Minutes Safety Talk isbeing conducting on eachand everyday at all sectionsof plant premises.

• Creating awareness on theparticular risky job beforegoing to do that work.

12

HELMET COLOUR CODING SYSTEMCompany Workmen

Electrician

Visitor

Staff and Officers

Contract Workmen

Safety Members &Mentors.

Company Workmen

Electrician

Visitor

Staff and Officers

Contract Workmen

Safety Members &Mentors.13

In view of better visibility at the place like tunnel, conveyorgalleries and also during poor visibilities due to climaticconditions, we have issued safety reflective jackets for ourentire company employees, contract workmen, visitors, etc.

IMPLEMENTATION OF REFLECTIVE JACKETS

14

SAFETY SHOES

Ensuring to wear safety shoe and Helmet for allcompany employees, contract workers (Men &Women) and apprentices.

In this regards, Process dept. - High Ankle Heat Resistant shoe Electrical &

Instrumentation - Electrical Shock Proof shoe Others - High Ankle General Safety shoe

Ensuring to wear safety shoe and Helmet for allcompany employees, contract workers (Men &Women) and apprentices.

In this regards, Process dept. - High Ankle Heat Resistant shoe Electrical &

Instrumentation - Electrical Shock Proof shoe Others - High Ankle General Safety shoe

15

LOTO SYSTEM All electrically connected equipments to ensure that they are properlyisolated for hazardous or potentially hazardous electrical energy sourcesduring servicing and or maintenance and properly protect against re-energization.

16

INJURY -FREE MAN-HOURS DISPLAY BOARDInjury-free Man-hours board displayed near prayer assemblypoint. Everyday Injury-free Man-hours are updated.

OUR SAFETY RECORDINJURY FREE WORKING

OUR SAFETY RECORDINJURY FREE WORKING

17

WORK PERMIT SYSTEM Work Permit System is being followed while carrying the

following hazardous work activities in a safe manner:

Hot work (Grinding, welding, gas cutting & brazing)Work at height Confined space entry Electrical works Jam clearance Belt conveyors VRM/VRPM mill entry ESP maintenance and Inspection Excavation Barrel cutting

Work Permit System is being followed while carrying thefollowing hazardous work activities in a safe manner:

Hot work (Grinding, welding, gas cutting & brazing)Work at height Confined space entry Electrical works Jam clearance Belt conveyors VRM/VRPM mill entry ESP maintenance and Inspection Excavation Barrel cutting

18

EMERGENCY PREPARDNESS ANDRESPONSE

Totally in our plant, 20 areas are identified as potentialemergency areas like HSD Storage, HFO Storage, CoalStorage, Gas Cylinders Storage, Magazines, etc.

We are having a well equipped OHC at our premises to takecare of any injuries.

First Aid will be given to the injured person and based on hiscondition he will be shifted to Jaggayyapet TownHospital/Vijayawada Hospitals through our company ACAmbulance.

Totally in our plant, 20 areas are identified as potentialemergency areas like HSD Storage, HFO Storage, CoalStorage, Gas Cylinders Storage, Magazines, etc.

We are having a well equipped OHC at our premises to takecare of any injuries.

First Aid will be given to the injured person and based on hiscondition he will be shifted to Jaggayyapet TownHospital/Vijayawada Hospitals through our company ACAmbulance.20

SAFETY CONTROL MEASURES PROVIDED:

The flammable storage areas are fenced at specifiedsafe distance. 300 Nos. of suitable fire extinguishers and fire buckets

are provided near these storage areas. Fire hydrant lines are provided near the storages. DSPA (Dry Sprinkler Powder Aerosol) is installed in

Fine Coal Bin to control the fire, once temp reaches90OC. Smoke detectors are installed at All Buildings and

Underground Cable tunnels & alarms will be displayedat CCR for continuous monitoring. CCTVs are installed at all the Coal hoppers top & Coal

Mill Bag house top for continuous monitoring.

SAFETY CONTROL MEASURES PROVIDED:

The flammable storage areas are fenced at specifiedsafe distance. 300 Nos. of suitable fire extinguishers and fire buckets

are provided near these storage areas. Fire hydrant lines are provided near the storages. DSPA (Dry Sprinkler Powder Aerosol) is installed in

Fine Coal Bin to control the fire, once temp reaches90OC. Smoke detectors are installed at All Buildings and

Underground Cable tunnels & alarms will be displayedat CCR for continuous monitoring. CCTVs are installed at all the Coal hoppers top & Coal

Mill Bag house top for continuous monitoring.21

EMERGENCY MITIGATING EQUIPMENTSSL No. EQUIPMENTS Nos.

1 Fire Tender 01

2 No. of Fire Extinguishers 300

3 No. of Fire Hydrants points 1213 No. of Fire Hydrants points 121

4 Smoke Detectors 427

5 Self Contained Breathing Apparatus 04

22

EMERGENCY MITIGATING EQUIPMENTSSL No. EQUIPMENTS Nos.

6 Fire portable trolley mounted pump 01

7 Emergency assembly point 06

8 Emergency siren 04

9 First Aid Boxes 32

10 Surveillance Cameras 122

23

MOCK DRILLSMajor Mock Drills are conductedyearly once at Plant & Mines.Minor Mock Drills yearly thrice atplant. After completion of Mockdrill, observer’s comments arediscussed and implemented.

24

Year Major Minor

2014-15 1+1 3

2015-16 1+1 3

Mock Drills

Year Major Minor

2014-15 1+1 3

2015-16 1+1 3

Observation report for Major Mock drill

23.05.2014

11.02.2015

25

SAFETY PPE EXHIBITION ROOM

To inculcate safety awareness / PPE to the new comers andvisitors, we have a Safety PPE Exhibition Room.

26

SAFETY SUGGESTION BOX

The objectives of the Suggestion Scheme are:To encourage innovations, creativity and value addition byindividual employees for overall improvement.To improve safety culture, quality, productivity, profitabilityand service through employee participation.

27

• Created Road Safety Awareness among the Jaggaiahpetpeople and also conducted Road Safety Campaign near JPTbus stand and Toll Gate on National Highway, 02.01.2016.

ROAD SAFETY WEEK CELEBRATIONS

28

45th - NATIONAL SAFETY WEEK CELEBRATIONDETAILS

Safety Message by Sri P B Gopalakrishna, President(Mfg.) and all Div. Heads on 04.03.2016

29

SAFETY PROCESSIONOrganized Safety Procession withSafety Slogans speaking out withloudspeaker by our Div.Heads, All HODs, SafetyCommittee Members & Mentorsalong with all employees andcontract workmen inside thefactory premises on 04.03.2015

Organized Safety Procession withSafety Slogans speaking out withloudspeaker by our Div.Heads, All HODs, SafetyCommittee Members & Mentorsalong with all employees andcontract workmen inside thefactory premises on 04.03.2015

30

PPE EXHIBITION INAUGURATIONOn the eve ofNSW, Inauguration of SafetyExhibition by our Unit Head.

31

PPE EXHIBITION EVALUATION

• PPE Exhibition evaluated byDy. Chief Inspector ofFactories and Inspector ofFactories Vijayawada.

32

VALEDICTORY FUNCTION HIGHLIGHTSSri MOHANA RAO, Dy. Chief Inspector ofFactories, Vijayawada is invited as Chief Guest for thevaledictory function on 10.03.2015 and deliveredvaluable speeches and explained the need for safety atworkplace, while travelling and other places.

33

Sl.No.

Awards Achieved /Awarded by

2014-15 2015-16

1 Mr. Rambabu Won first prize intelugu Slogans atState level Safetycompetitions

Won third prize inEnglish Slogans atState level Safetycompetitions

Awards & Rewards

Won first prize intelugu Slogans atState level Safetycompetitions


2 Mr.Sivasubramanyam Won third prize inEnglish Essay writingat State level Safetycompetitions

34

BEST MANAGEMENT AWARD to Sri P R Ramasubrahmaneya Rajha, Chairman & Managing Director, RamcoCements Limited and the award is being received by Sri P B Gopala Krishna, President-Mfg., Sri M.Chidambaram, Vice President - Admn, Sri T. Sridhar Reddy, AVP - Works and Sri E. Alwar, DGM - Personnel on theoccasion of MAY DAY on 01.05.2016.

SAFETY PROMOTIONAL ACTIVITIES

Safety Flash Display

For the newly joined employees and contractworkmen, safety awareness is inculcated by showing thesafety practices / appliances at Safety PPE ExhibitionRoom.

Safety News Letter sharing

Accident case studies sharing


For the newly joined employees and contractworkmen, safety awareness is inculcated by showing thesafety practices / appliances at Safety PPE ExhibitionRoom.



36

Safety arrangements & precautions takenwhile carrying out following criticalactivities:

i. Additive Hoppers cleaning work

ii. Cement silos cleaning

iii. Preheater Cyclones Jam removal




37


The following safety arrangements are made for Additive Hoppers cleaning/ Jam removal work as shown in drawing.

01- Platform with handrail provided in straight portion with ladderarrangement for the workmen to go inside the hopper and clean bystanding on the platform with safety belt arrangement.

02- Jhula with winch arrangement was made to clean in bottom area.

03- Workpermitt is taken for confined space entry.

04.Only trained employees / supervisor are engaged for this work.

05. One person is placed at hopper top to observe the cleaning work withrope arrangement.

The following safety arrangements are made for Additive Hoppers cleaning/ Jam removal work as shown in drawing.

01- Platform with handrail provided in straight portion with ladderarrangement for the workmen to go inside the hopper and clean bystanding on the platform with safety belt arrangement.

02- Jhula with winch arrangement was made to clean in bottom area.

03- Workpermitt is taken for confined space entry.

04.Only trained employees / supervisor are engaged for this work.

05. One person is placed at hopper top to observe the cleaning work withrope arrangement.

38

i. Additive Hoppers Safety arrangement

39


The following safety precautions are taken for Silos cleaning:

1. Work permit is taken for confined space entry.2. All feed equipments of Cement silo are electrically isolated .3. Open the Silo Inspection doors – 2 Nos.4. Focus lamp arrangement is made from Silo top.5. Clean the loose cement from bottom bin.6. Jhula with winch arrangement is made as shown in photo for

cleaning silo inside walls from top to bottom.6. Safety belt and other required PPEs are used.7. For rotation of Jhula support rope tied & for moving up and

down, winch arrangement is used.8. Two persons are placed at Inspection doors to observe the work.9. Only trained employee / supervisor is engaged to carryout this

work.

The following safety precautions are taken for Silos cleaning:

1. Work permit is taken for confined space entry.2. All feed equipments of Cement silo are electrically isolated .3. Open the Silo Inspection doors – 2 Nos.4. Focus lamp arrangement is made from Silo top.5. Clean the loose cement from bottom bin.6. Jhula with winch arrangement is made as shown in photo for

cleaning silo inside walls from top to bottom.6. Safety belt and other required PPEs are used.7. For rotation of Jhula support rope tied & for moving up and

down, winch arrangement is used.8. Two persons are placed at Inspection doors to observe the work.9. Only trained employee / supervisor is engaged to carryout this

work.40


JHULA ARANGEMENT41

While Cyclone Jamreleasing work , no one is

allowed to stand opposite &below to the cleaning area

for safe work practice.Ensuring the all doors are

in closed condition.


Platform

Platform

Floor

Thermocouple

Draft Point

42

Reasons for Cyclone Jam

1.Refractory failure there by blocking the Material flow

2.Coating formation & dislodging

3.Overheating

4.Foreign material (dispersion plates & immersion tube

segments)

Indication for Cyclone Jam

1.Cone material temp slowly decreasing

2.Cone draft also slowly decreasing

3.Next stage gas temp increasing simultaneously

Reasons for Cyclone Jam

1.Refractory failure there by blocking the Material flow

2.Coating formation & dislodging

3.Overheating

4.Foreign material (dispersion plates & immersion tube

segments)

Indication for Cyclone Jam

1.Cone material temp slowly decreasing

2.Cone draft also slowly decreasing

3.Next stage gas temp increasing simultaneously43

Precaution to avoid further build up

1.If the difference between gas & material temp is

>50°C, Popup alarm will appear on the CCR

monitor.

2.Simultaneously, if the cone draft comes to

zero, interlock gets activated to stop the feed

immediately so as to reduce the material built-up in

the cyclone.

Action to be taken during Cyclone Jam Releasing

1.Ensure the Vent fan in running condition.

2.Well trained & high skilled personnel are only

deployed for clearing the jam.

Precaution to avoid further build up

1.If the difference between gas & material temp is

>50°C, Popup alarm will appear on the CCR

monitor.

2.Simultaneously, if the cone draft comes to

zero, interlock gets activated to stop the feed

immediately so as to reduce the material built-up in

the cyclone.

Action to be taken during Cyclone Jam Releasing

1.Ensure the Vent fan in running condition.

2.Well trained & high skilled personnel are only

deployed for clearing the jam.44

3. Work Permit is raised by the concerned Section In-

charge.

4. No man power is allowed below the rest of the floors.

5. Barricade is arranged at the Inlet and Outlet as well as

Cooler DPC area to control movement of personnel.

6. All relevant PPE are used.

7. Jam releasing is followed from bottom to top of the

cyclone.

8. At the time of cleaning, only one door is opened & rest

are ensured in closed condition.

9. No Manhole doors allowed to open.

10. After jam clearance, all the doors are opened one by

one to check the free passage.

3. Work Permit is raised by the concerned Section In-

charge.

4. No man power is allowed below the rest of the floors.

5. Barricade is arranged at the Inlet and Outlet as well as

Cooler DPC area to control movement of personnel.

6. All relevant PPE are used.

7. Jam releasing is followed from bottom to top of the

cyclone.

8. At the time of cleaning, only one door is opened & rest

are ensured in closed condition.

9. No Manhole doors allowed to open.

10. After jam clearance, all the doors are opened one by

one to check the free passage.45

From Period To Period No ofDays

Accident Free Million ManHours*

01-04-2013 13-11-2015 947 9.51

The longest accident free period (Continuous covering thethree years, assessment period 2013-2015)

•Also we are monitoring incident -free man-hours & we achieved >1 millionthrice from 2014 to 2016.

46

HSE TrainingsTraining need identification (TNI) for employees and contractors.

Training needs are identified by concerned HODs / Divisional Heads foremployees and contract workmen for the financial year concerned atthe beginning of the year.

Training matrix for Employees & Contractors.

Training matrix

Training effectiveness is measured through feedback.

HSE TrainingsTraining need identification (TNI) for employees and contractors.


Training matrix for Employees & Contractors.

Training matrix

Training effectiveness is measured through feedback.

47

Training Particulars.

Sl.No.

Trainings 2014-15 2015-16

1 Internal Trainings 24 272 External Trainings 2 13 Training Participants Company 392 3784 Training Participants Contractors 786 8164 Training Participants Contractors 786 8165 Total Training Hours 1995 21076 Training Hr. individual per employee per annum 3.37 3.647 Training Hr. Contractor individual per employee

per annum0.42 0.49

8 % covered Employees 90.74 90.219 % Covered Contract workforce 89.82 86.87

48

HIRAC & SOPHIRAC for the plant and its critical maintenances.

Nearly 200 No. of activities are considered for HIRAC covering plant &mines operations & critical maintenance activities. There are reviewed:

• annually or• any change in the activity or• any change in process / technology up-dation or• project activities

HIRAC procedureSample HIRAC

Standard Operating Procedures exist for all critical and regular activities.

• 232 Nos. of SOPs are made across the plant and or being followed.• 252 Nos. of work instructions are prepared and also being followed.

Sample SOPSample work instruction

HIRAC & SOPHIRAC for the plant and its critical maintenances.




Standard Operating Procedures exist for all critical and regular activities.


Sample SOPSample work instruction49

The pre-medical check procedure for employees

After receiving the request from Personnel Department for examination, consent is obtained from thecandidate for medical examination followed by :

Physical examination of the candidate to:identify any visible physical abnormalities ,anthropometric measurements are registered

Clinical lab investigations which includes:Blood for Sugar ,Lipid profile,Urea, Creatinine,Liver function tests andRoutine blood parameters like Hb%, Blood Group and RhTyping, TC, DC, ESRUrine – CompleteECG,X Ray Chest,Audiometry and Spirometry at our OHC itself.

Vision testsAfter the investigations the fitness details ‘ Fit/Unfit” is sent to Personnel department for further action .

The pre-medical check procedure for employees





50

Fatal Accident occurred on 14-11-2015

Welded Angle

Base of Bin

51

End

Sl.No

Type of Workers 2014-15 2015-16

1 Regular 436 421

2.0 Workforce & Man hours Worked.

2.1 Average No. of workers in Factory.

1 Regular 436 421

2 Contract 602 568

3 Total 1038 989

52

Sl.No

Type of Workers 2014-15 2015-16

1 Regular 1068720 899360

2.2 Man hours worked by all workers includingover time worked.

2 Contract 2782760 2584200

3 Total 3851480 3483560

53

Type 2014-15 2015-16

Nearmiss 5 3

High Potential Near miss 0 0

First – aid cases 7 5

LTI (Lost Time Incident) 0 0

Fatality 0 1

3. Reportable incident and F.R.

Fatality 0 1

Man hours lost due to LTI 0 0

Severity Rate 0 1.72

Frequency Rate 0 0.28

No. of Dangerous occurrences as perfactory act

0 1

54

From Period To Period No ofDays

Accident Free Million ManHours*

01-04-2013 13-11-2015 947 9.51

4. The longest accident free period (Continuous coveringthe three years, assessment period 2013-2015)

•Also we are monitoring incident -free man-hours & we achieved >1 millionthrice from 2014 to 2016.

55

5. HSE Policy

5.1. H&S policy.

Included in IMS policy.

5.2. Level at which policy has been in force.

IMS policy is in force from 01-01-2010.

5.3. Description of practices for H&S policy achievement ofobjectives.

By our best safety practices. Some of the best practices areshown in next slides.

5.4. IMS policy is made know to employees of your employees by

Daily in the morning, at assembly point near Time Office, IMSPolicy is chanted by all the gathering. And also displayed atvarious sections.

5. HSE Policy

5.1. H&S policy.

Included in IMS policy.

5.2. Level at which policy has been in force.

IMS policy is in force from 01-01-2010.

5.3. Description of practices for H&S policy achievement ofobjectives.

By our best safety practices. Some of the best practices areshown in next slides.

5.4. IMS policy is made know to employees of your employees by

Daily in the morning, at assembly point near Time Office, IMSPolicy is chanted by all the gathering. And also displayed atvarious sections.

56

6. Review of HSE performance by top management

6.1. OHSMS certification.

Certified by Bureau of Indian Standards (BIS) since 2010.

6.2. Review of top management on H&S performance

• Safety data is reviewed in monthly review meetings by topmanagement.

• Safety related points are discussed in Safety Committee Meetingonce in a month by Committee Chairman, including the pointsraised by internal audit teams of the committee.

• Management Review Meetings are conducted on half-yearly basiscovering OHSMS activities.

• Mock drill observations are reviewed immediately after the drilland in the next mock drill period also.

6. Review of HSE performance by top management

6.1. OHSMS certification.

Certified by Bureau of Indian Standards (BIS) since 2010.

6.2. Review of top management on H&S performance

• Safety data is reviewed in monthly review meetings by topmanagement.

• Safety related points are discussed in Safety Committee Meetingonce in a month by Committee Chairman, including the pointsraised by internal audit teams of the committee.

• Management Review Meetings are conducted on half-yearly basiscovering OHSMS activities.

• Mock drill observations are reviewed immediately after the drilland in the next mock drill period also.

57

6. Review of HSE performance by topmanagement

6.3. The action taken by top management on those reports &its implementation

• Non-conformities (NCs) / Opportunities for Improvements(OFIs) raised by internal / external auditors are immediatelylooked into. The status is reviewed in Management ReviewMeetings.

• Safety related points raised by internal audit teams of thesafety committee are prioritized. The status is reviewed bySafety Committee Chairman.

• Safety Mentors are nominated and are involved in propagatingthe safety awareness among employees / contract workmen.The discrepancies if any are discussed in Safety Committee bySafety Committee Chairman.

6. Review of HSE performance by topmanagement

6.3. The action taken by top management on those reports &its implementation

• Non-conformities (NCs) / Opportunities for Improvements(OFIs) raised by internal / external auditors are immediatelylooked into. The status is reviewed in Management ReviewMeetings.

• Safety related points raised by internal audit teams of thesafety committee are prioritized. The status is reviewed bySafety Committee Chairman.

• Safety Mentors are nominated and are involved in propagatingthe safety awareness among employees / contract workmen.The discrepancies if any are discussed in Safety Committee bySafety Committee Chairman.

58

7. HSE Organization

7.1 The organizational set up and responsibilities at variouslevels and arrangements for implementation of H&S policy.

Specific Key Performance Indicators (KPIs) related to occupational safetyare assigned to all levels of the employees of the organization.

7.2 H&S organogram

7.3 Safety KPI for every employee in order to achieve H&SObjectives and its measurability

Specific Key Performance Indicators (KPIs) related to occupational safetyare assigned to all levels of the employees of the organization andreviewed annually by top management.

Suitable rating is given for the number of incidents and man-days lostdue to injuries, based on that evaluation one time payment / bonus isgiven.

7. HSE Organization

7.1 The organizational set up and responsibilities at variouslevels and arrangements for implementation of H&S policy.

Specific Key Performance Indicators (KPIs) related to occupational safetyare assigned to all levels of the employees of the organization.

7.2 H&S organogram

7.3 Safety KPI for every employee in order to achieve H&SObjectives and its measurability

Specific Key Performance Indicators (KPIs) related to occupational safetyare assigned to all levels of the employees of the organization andreviewed annually by top management.

Suitable rating is given for the number of incidents and man-days lostdue to injuries, based on that evaluation one time payment / bonus isgiven.

59

UNIT HEAD

H&S organogram:

WORKS HEAD(SAFETY COMMITTEE CHAIRMAN)

SAFETY OFFICER

ADMINISTRATIVE HEAD

MEDICAL OFFICER SAFETY OFFICER

SAFETYCOMMITTEE

MEMBERS

SAFETYMENTORS

MEDICAL OFFICER

PARAMEDICS LABTECHNICIAN

CONTRACTORSAFETY OFFICERS

Back60

Sl.No

NameRegular/Contract

Designation QualificationWorking

Since1 Sri PB

GopalakrishnaRegular Sr. President

(Mfg.)B Tech (Mech.) Decembe

r 20082 Sri M Chidambaram Regular Vice President

(Admn.)B. Com, FCA January

20143 Sri T Sridhar Reddy Regular Asst. Vice

President(Works)

B Tech (Mech.) April,2008

4 Sri S Raja KesavaPrasad

Regular Deputy GeneralManager (OHS)

MBBS, PGC inIndustrial

Health

April,2008

7.4 H&S Personnel

4 Sri S Raja KesavaPrasad

Regular Deputy GeneralManager (OHS)


Health

April,2008

5 Sri AVSatyanarayana

Regular Sr. Manager(Mech.) /

Safety Officer

B Tech (Mech.),Diploma inIndustrial

Safety

August,1995

6 Smt K VPadmavathi

Regular Asst Officer –Nursing

GNM August,1994

7 Sri SM VarunChakravarthy

Regular Deputy Officer-Paramedical(Pharmacist)

B.Sc,D .Pharamacy

June,2009

61

Sl.No


Designation QualificationWorking

Since8 Sri G Raja

SekharRegular Asst Officer -

Paramedical (LabTechnician )

DMLT March,2013

9 Sri P S ChNaresh Kumar

Regular Jr Officer –Paramedical(Pharmacist)

B.Sc, D .Pharamacy

May,2013

10 Sri MVVRamana


B.Sc ,D .Pharamacy

Apr, 2014

7.4 H&S Personnel

Sri MVVRamana

Jr Officer –Paramedical(Pharmacist)

B.Sc ,D .Pharamacy

11 Sri K Laxmaiah Contract Safety Officer ofThermax Limited

DME, Diploma inIndustrial Safety

July 2016

12 Sri S Kabeer Contract Safety Officer ofPetron

DCE, Diploma inIndustrial Safety

January2016

Visiting Doctors:• Dr S Vamsi Priya MD (Obg & Gynec) visits our OHC twice in a week• Dr Kanakalingeswara Rao BHMS visits our OHC once in week• Dr MD Nagaeswara Rao BDS Visits our OHC once in a week62

8. HSE Trainings.8.1 Training need identification (TNI) for employees and contractors.


8.2 Training matrix for Employees & Contractors.

Training matrix

8.3 Training effectiveness is measured through feedback.

8. HSE Trainings.8.1 Training need identification (TNI) for employees and contractors.


8.2 Training matrix for Employees & Contractors.

Training matrix

8.3 Training effectiveness is measured through feedback.

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8.HSE Trainings.8.4 The induction method followed for employees, contractworkforce, experts, Govt. Officials and others.

Employees – 2 man-daysContract Employees – 1 man-day (Safety)Government officials / Others – While sending inside safety induction

/ Safety manual reading.8.5 Maintaining of individual training records.

Training matrix

8.6 HSE training to drivers (Internal& External Vehicles).

• Trainings are being given for internal drivers at par with employees.• For External drivers, while entering from gate induction being given.• Training programme conducted for local auto drivers by external

faculty while Road Safety Week 2015 at our premises.

8.HSE Trainings.8.4 The induction method followed for employees, contractworkforce, experts, Govt. Officials and others.

Employees – 2 man-daysContract Employees – 1 man-day (Safety)Government officials / Others – While sending inside safety induction

/ Safety manual reading.8.5 Maintaining of individual training records.

Training matrix

8.6 HSE training to drivers (Internal& External Vehicles).

• Trainings are being given for internal drivers at par with employees.• For External drivers, while entering from gate induction being given.• Training programme conducted for local auto drivers by external

faculty while Road Safety Week 2015 at our premises.

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8.7Training Particulars.

Sl.No.

Trainings 2014-15 2015-16

1 Internal Trainings 24 272 External Trainings 2 13 Training Participants Company 392 3784 Training Participants Contractors 786 8164 Training Participants Contractors 786 8165 Total Training Hours 1995 21076 Training Hr. individual per employee per annum 3.37 3.647 Training Hr. Contractor individual per employee

per annum0.42 0.49

8 % covered Employees 90.74 90.219 % Covered Contract workforce 89.82 86.87

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9 MOCK DRILLMajor Mock Drills are conductedyearly once at Plant & Mines.Minor Mock Drills yearly thrice atplant. After completion of Mockdrill, observer’s comments arediscussed and implemented.

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Year Major Minor

2014-15 1+1 3

2015-16 1+1 3

Mock Drills

Year Major Minor

2014-15 1+1 3

2015-16 1+1 3

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Observation report for Major Mock drill observations –

Report - 23.05.2014.docMock drill observations - Report – 11.02.2015.doc

Observation report for Major Mock drill observations –

Report - 23.05.2014.docMock drill observations - Report – 11.02.2015.doc

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10. Accident / Incidents Reporting

10.1 Method of reporting system in the organization

Reporting System

10.2 Reporting Path

Reporting System

10.3 RCA (Root cause analysis) is conducted on all incidents.


10.1 Method of reporting system in the organization

Reporting System

10.2 Reporting Path

Reporting System

10.3 RCA (Root cause analysis) is conducted on all incidents.

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10.4 Leading the RCA process

* Safety Officer with Concerned Section in-charge.* Preliminary Incident Investing Team (PIIT) if appointed by Top

Management for investigation for the particular incident

10.5 Extension for incompletion of CAPA points does not get closed asper target dates provided

Take the reasons for not closing CAPA and with properjustification the dates are extended by appropriate authority,such as:

* Safety committee chairman* Top management for Non-conformities / Opportunities for

Improvements raised by internal & external auditors


10.4 Leading the RCA process

* Safety Officer with Concerned Section in-charge.* Preliminary Incident Investing Team (PIIT) if appointed by Top

Management for investigation for the particular incident

10.5 Extension for incompletion of CAPA points does not get closed asper target dates provided

Take the reasons for not closing CAPA and with properjustification the dates are extended by appropriate authority,such as:

* Safety committee chairman* Top management for Non-conformities / Opportunities for

Improvements raised by internal & external auditors

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11. HIRAC & SOP11.1 HIRAC for the plant and its critical maintenances.




11.2 Standard Operating Procedures exist for all critical and regularactivities.


Sample SOPSample work instruction

11. HIRAC & SOP11.1 HIRAC for the plant and its critical maintenances.




11.2 Standard Operating Procedures exist for all critical and regularactivities.


Sample SOPSample work instruction71

11. HIRAC & SOP11.3 Job Safety Analysis (JSA) & Job Safety Observation (JSO)system.

Job Safety Analysis sample copy

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12.Contractors Safety Management.12.1 Evaluation of contractors

While selecting the contractor, their previous history of accident-free man-days isconsidered as one of the criteria for evaluation.

12.2 The frequency of contractor’s safety performance monitoring

• Monthly once for Labor supply contract and• Job contractor after completion of the job.

While awarding Job contract to Contractor, we issue General safety conditions tobe followed. If any violation is observed, particular contract workmen is sent outfrom duty for specific period and suitable penalty is also imposed to the concernedContractor.

12.3 Deployment of qualified safety person by contractors:

2 Nos. of qualified Safety Officers are deployed presently by 2 Nos. of majorcontractors.

12.Contractors Safety Management.12.1 Evaluation of contractors

While selecting the contractor, their previous history of accident-free man-days isconsidered as one of the criteria for evaluation.

12.2 The frequency of contractor’s safety performance monitoring

• Monthly once for Labor supply contract and• Job contractor after completion of the job.

While awarding Job contract to Contractor, we issue General safety conditions tobe followed. If any violation is observed, particular contract workmen is sent outfrom duty for specific period and suitable penalty is also imposed to the concernedContractor.

12.3 Deployment of qualified safety person by contractors:

2 Nos. of qualified Safety Officers are deployed presently by 2 Nos. of majorcontractors.

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12.Contractors Safety Management.

12.4 Frequency of contractor getting involved in safety meetings.

Monthly once. 2 Nos. of qualified Safety Officers who are deployed by 2Nos. of major contractors, attend the Safety Committee Meetings along withother committee members.

12.5 The method adapted to encourage contractors safetyperformance

Conducting Safety training to all contract employees and taking thefeed back from them with questionnaire.

12.Contractors Safety Management.

12.4 Frequency of contractor getting involved in safety meetings.

Monthly once. 2 Nos. of qualified Safety Officers who are deployed by 2Nos. of major contractors, attend the Safety Committee Meetings along withother committee members.

12.5 The method adapted to encourage contractors safetyperformance

Conducting Safety training to all contract employees and taking thefeed back from them with questionnaire.

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Sl.No.

Audits 2014-15 2015-16

1 Internal

No of Observation 221 210

Compliance % 95 96

13 Safety Audits.

Compliance % 95 96

Variance% 5 4

2 External

No of Observation 25 18

Compliance % 100 100

Variance nil nil

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14.Occupational Health.14.1 Dedicated OHC & Dedicated Staff

Sl.No


Designation Qualification

1 Sri S RajaKesava Prasad

Regular Deputy General Manager(OHS)


Health2 Smt K V

PadmavathiRegular Asst Officer –Nursing GNM


Regular Deputy Officer-Paramedical (Pharmacist)

B.Sc,D .Pharamacy


Regular Deputy Officer-Paramedical (Pharmacist)

B.Sc,D .Pharamacy

4 Sri G RajaSekhar

Regular Asst Officer -Paramedical(Lab Technician )

DMLT

5 Sri P S ChNaresh Kumar


B.Sc, D .Pharamacy

6 Sri MVVRamana


B.Sc ,D .Pharamacy

Visiting Doctors:• Dr S Vamsi Priya MD (Obg & Gynec) visits our OHC twice in a week• Dr Kanakalingeswara Rao BHMS visits our OHC once in week• Dr MD Nagaeswara Rao BDS Visits our OHC once in a week76

Facilities Available at our OHC:

ECG (12 Lead)machineDefibrillatorFoetal DopplerWell equipped clinical lab with Semi Auto analyzer300 mA X ray Machine( Allengers)Digital AudiometerSpirometerMultiparamonitorSurgical equipment for handling minor injuries and minor casesOxygen ConcentratorSuction apparatusNebulizerWell equipped AC Ambulance

Facilities Available at our OHC:

ECG (12 Lead)machineDefibrillatorFoetal DopplerWell equipped clinical lab with Semi Auto analyzer300 mA X ray Machine( Allengers)Digital AudiometerSpirometerMultiparamonitorSurgical equipment for handling minor injuries and minor casesOxygen ConcentratorSuction apparatusNebulizerWell equipped AC Ambulance

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14.2 The pre-medical check procedure for employees





14.2 The pre-medical check procedure for employees





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14.3 The frequency of re-medical checkup for employees?

• Once in a year for all regular employees and contract workmen.• Specific health surveillance tests carried out for food handlers and drivers at regular intervals

(once in 6 months) or even before based on the health condition.

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14.4 Ensuring of contractor workforce medical prior to deploymenton job

After receiving the request from Personnel Department examination, consent is obtained from thecandidate for medical examination followed by:

Physical examination of the candidate to :identify any visible physical abnormalities ,anthropometric measurements will be registered

Clinical lab investigations relevant to the job the person is going to handle like: Motion,Urine,Blood examination for Food handlersBlood test, Audiometry andVision for Drivers

After the investigations the fitness details ‘ Fit/Unfit” will be sent to personnel department forfurther action.

14.4 Ensuring of contractor workforce medical prior to deploymenton job

After receiving the request from Personnel Department examination, consent is obtained from thecandidate for medical examination followed by:

Physical examination of the candidate to :identify any visible physical abnormalities ,anthropometric measurements will be registered

Clinical lab investigations relevant to the job the person is going to handle like: Motion,Urine,Blood examination for Food handlersBlood test, Audiometry andVision for Drivers

After the investigations the fitness details ‘ Fit/Unfit” will be sent to personnel department forfurther action.

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15.SAFETY PROMOTIONAL ACTIVITIES


For the newly joined employees and contract workmen,safety awareness is inculcated by showing the safetypractices / appliances at Safety PPE Exhibition Room.




For the newly joined employees and contract workmen,safety awareness is inculcated by showing the safetypractices / appliances at Safety PPE Exhibition Room.



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Sl.No.

Awards Achieved /Awarded by

2014-15 2015-16

1 Mr. Rambabu Won first prize intelugu Slogans atState level Safetycompetitions


16 Awards & Rewards

Won first prize intelugu Slogans atState level Safetycompetitions


2 Mr.Sivasubramanyam Won third prize inEnglish Essay writingat State level Safetycompetitions

Best Practice82

Thank you..Thank you..

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the ramco cements ltd. jayanthipuram - qcfi

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