safety audit : major steel plants - cidm somani.pdf · 2019. 7. 19. · 16-07-2019 1 ravi -09 jul...
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Ravi Kant SomaniExecutive Vice President
Group Head (OHS)
8826301444
SAFETY AUDIT : MAJOR STEEL PLANTS
Chemical & Industrial Disaster Management
(CIDM) Conference 2019The Taj Palace, New Delhi
08-10 Jul 2019
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INTERNATIONAL LABOR ORGANIZATION (ILO) FACTS
1. Millions of workers loose their lives due to accidents
2. 250 million accidents every year
3. 20 million accident per month
4. 685,000 accidents every day
5. 475 accidents every minute
6. 8 accidents every second.
7. Fatality rate in advanced industrialized economies is almost half that of
Central and Eastern Europe, China and India
Providing safe and healthy workplace is the common goal of all countries.
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STEEL PLANTS – PROMINENT HAZARDS
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STEEL PLANTS – PROMINENT HAZARDS
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STEEL PLANTS – PROMINENT HAZARDS
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WORLD STEEL ASSOCIATION (WSA) – SAFETY PRINCIPLES
1. Management is responsible and accountable for safety and health
performance
2. Employee engagement and training is essential
3. Working safely is a condition of employment
4. Excellence in safety and health supports excellent business results
5. Safety and health must be integrated into all business management
processes
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PLAN, DO, CHECK , ACT CYCLE
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What is Safety Audit?
PROCESS OF:
• Verifying the existence and implementation of elements of
Occupational Safety and Health Systems
• Verifying the systems' ability to achieve defined Safety Objectives
IS 14489
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Why Safety Audit?
1. To meet the required local, state and federal health &
safety requirements.
2. To verify the requirements against certain standards
3. To verify the compliance to hazards recognition &
control programs
4. To verify the compliance to company specific
Occupational Safety & Health systems or procedures
5. To identify the gaps in maintaining safe
workplace
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Types & Standards of Safety Audit
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ULTIMATE OBJECTIVE (SAFETY)
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ULTIMATE OBJECTIVE (BUISENESS)
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SEVEN GOLDEN RULES – MISSING IN GENERAL
Seven Golden Rules for implementing Vision Zero in
an industry:
1. Take Leadership – Demonstrate Commitment
2. Identify Hazards – Control Risks
3. Define Targets – Develop Programs
4. Ensure a Safe and Healthy System – be well
organized
5. Ensure Safety and Health in Machines,
Equipment and Workplaces
6. Improve Qualifications — Develop Competence
7. Invest in People — Motivate by Participation
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SAFETY INDEX AUDIT – A CATALYST
A Proven &
Result Oriented
Program !!
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Departmental Safety Index
Reactive
Proactive
Max Score
-100
Max Score
+200
50%
Wtg.
Each
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Reactive Parameters
S. No. Reactive Parameter Evaluation Guidance Max Score
1 Fatal Case 100% for any fatal case -40
2 Lost Time Case 25% for each LTC -30
3 Fire (PI)100% for any fire incident with
production interruption -10
4Dangerous
Occurrence (PI)
100% for any dangerous occurrence
with production interruption-10
5Property Damage
(>10 L Rs100% for any property damage case -10
TOTAL MAX (-VE) SCORE -100
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Pro-active Parameters
S. No. Proactive Parameter Evaluation GuidanceMax
Wtg.
1 Apex Safety Committee
Participation% Rating in Audit 10
2 Departmental Safety
Committee% Rating in Audit 10
3 Potential Incident
Observations
No of PIO X100 / Total Manpower
(Employees)20
4 Near Miss Reporting No of Near-miss reported X
100/Total Manpower (Employees)10
5 Work Permit System % Rating in Audit 20
6 Use & upkeep of
emergency equipments% Rating in Audit 10
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Proactive Parameters (Contd..)
S. No. Proactive Parameter Evaluation Guidance Max Wtg.
7 Legal Compliance (Cranes, &
Pressure Vessels)% Rating in Audit 20
8 SOP/SMP Compliance % Rating in Audit 20
9 By-passing & Non-functioning of
Safety Devices/ Equipments% Rating in Audit 10
10 3-Member Need-based Audit % Rating in Audit 10
11 Safety Log Book by Senior Leaders % Rating in Audit 20
12 Accident Reporting & Investigation % Rating in Audit 20
13 Departmental Safety Training % Rating in Audit 20
TOTAL MAX (+VE) SCORE +200
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Rating Flag
100 EXCELLENT
>90 70 50
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Overall Safety Index
83.18 81.81 81.17 80.76 80.3 79.94 79.5 78.51 77.9975.61 74.73 74.71 74.3
67.1463.95
57.99
0
10
20
30
40
50
60
70
80
90
100
P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P16
Safety Index Score-Overall
PLANTS
66.3663.61 62.35 61.53 60.61 59.89 59 57.02 55.98 55.97
51.23 49.45 49.41 48.59
35.41 34.28
0
10
20
30
40
50
60
70
80
90
100
P1 P2 P3 P4 P5 P6 P7 P8 P9 P16 P10 P11 P12 P13 P15 P14
Proactive Safety Index Score
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Score – Proactive Parameters
PLANTS
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Proactive – By-passing or Non-working of Safety Devices
PLANTS
80 8076.67 76.67
73.3370
66.6763.33
6056.67
53.3350
40 40
33.3330
0
10
20
30
40
50
60
70
80
90
100
P1 P6 P11 P7 P4 P2 P3 P13 P5 P8 P16 P14 P10 P15 P12 P9
By Passing & Non Functioning of Safety Devices/Equipments
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Proactive – Departmental Safety Training
PLANTS
83.33 83.3380
76.67
66.67 66.6763.33 63.33
6056.67
50 50 50
43.33
33.33
20
0
10
20
30
40
50
60
70
80
90
100
P2 P5 P1 P3 P9 P7 P11 P10 P6 P4 P16 P8 P14 P12 P13 P15
Departmental Safety Training
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Proactive – Work Permit System
PLANTS
82.5 82.5 82.2277.78
73.33 72.5 72 7267.5 66 66 65.71
62
54.2951.11 50
0
10
20
30
40
50
60
70
80
90
100
P2 P10 P12 P4 P9 P5 P7 P6 P8 P3 P1 P13 P11 P16 P15 P14
Work Permit System
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Hot Spots – P1
68.87
49.45
100
62
76.6773.33
65.71
76.67
0
66 63.33
71.66
100
75
0 00
10
20
30
40
50
60
70
80
90
100
HOT SPOT – P1
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Hot Spot – P2
61.4655.97
52.5 54.29 50
80
68
53.33
62.86 64
50
60
100 100
28.95
00
10
20
30
40
50
60
70
80
90
100
HOT SPOT – P2
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Hot Spot – P3
70.24
59
100
72 73.33 72.73
64
76.67
62.86
73.3366.67 69.23
100 100 100
6.9
0
10
20
30
40
50
60
70
80
90
100
HOT SPOT – P3
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Achievements (Department 1)
30
40
50
60
70
80
90
100
Aug'18 Sept'18 Oct'18 Nov'18 Dec'18 Jan'19 Feb'19 Mar'19 Apr'19 May'19
Reactive Proactive Overall
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Achievements (Department 2)
40
50
60
70
80
90
100
Aug'18 Sept'18 Oct'18 Nov'18 Dec'18 Jan'19 Feb'19 Mar'19 Apr'19 May'19
Reactive Proactive Overall
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Achievements (Sample Organization)
0.55
0.3
0.25
0.150.11
0
0.1
0.2
0.3
0.4
0.5
0.6
Accident Frequency Rate
0.428
0.169
0.0820.046
0.028
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
Total Disabling Injury Index
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Achievements (Group)
2406
1668
943
510
292 268 236
0
500
1000
1500
2000
2500
3000
2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19
Total Accidents
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Indirect Achievements – Responsible for Direct Achievements
• Visible felt leadership for health & safety of workers
• Respectful relationship between line managers and shop floor workers
• Acceptability to safety inputs by line managers and sincere efforts for compliance
• Contractors involvement in reporting deviations/incidents
• Emphasis by Senior Leadership on safety issues in day to day interactions with their
teams
• Significant improvement in compliance status
• A positive sense of demanding safe working conditions by shop floor workers including
contractors
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Who is Responsible for Safety?
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Is Safety First is Must?
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Thanks! Stay Safe!!