Comprehensive project

Chapter 1:

Introduction to

SAFETY MANAGEMENT

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Overview of industrial Safety

Health and safety of the employees is an important aspect of a company's smooth and
successful functioning. It is a decisive factor in organizational effectiveness. It ensures
an accident-free industrial environment. Companies must attach the same importance
towards achieving high OH&S performance as they do to the other key objectives of
their business activities. This is because, proper attention to the safety and welfare of
the employees can yield valuable returns to a company by improving employee
morale, reducing absenteeism and enhancing productivity, minimizing potential of
work-related injuries and illnesses and increasing the quality of manufactured products
and/ or rendered services.

The Constitution of India has also specified provisions for ensuring occupational
health and safety for workers in the form of three Articles i.e. 24, 39(e and f) and 42.
The regulation of labour and safety in mines and oil fields is under the Union list.
While the welfare of labour including conditions of work, provident funds, employers'
invalidity and old age pension and maternity benefit are in the Concurrent list.

The Ministry of Labour , Government of India and Labour Departments of the States
and Union Territories are responsible for safety and health of workers. Directorate
General of Mines Safety (DGMS) and Directorate General Factory Advice
Services & Labour Institutes (DGFASLI) assist the Ministry in technical aspects of
occupational safety and health in mines and factories & ports sectors, respectively.

DGMS exercises preventive as well as educational influence over the mining industry.
Its mission is the reduction in risks of occupational diseases and casualty to persons
employed in mines, by drafting appropriate legislation and setting standards and
through a variety of promotional initiatives and awareness programmes. It undertakes
inspection of mines, investigation of all fatal accidents, grant of statutory permission,
exemptions and relaxations in respect of various mining operation, approval of mines
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safety equipment, appliances and material, conduct examinations for grant of statutory
competency certificate, safety promotional incentives including organization of
national awards and national safety conference, etc.

DGFASLI is an attached office to the Ministry of Labour and relates to factories and
ports/docks. It renders technical advice to the States/Union Territories in regard to
administration and enforcement of the Factories Act. It also undertakes support
research facilities and carries out promotional activities through education and training
in matters concerning occupational safety and health.

Major Initiatives undertaken by DGFASLI during the 10th Five Year Plan are:-

 Improvement and strengthening of enforcement system for safety and health of
dock workers in major ports.
 Development of safety and health information system and data bank.
 Establishment of Regional Labour Institute at Faridabad.
 Setting up of a National Board on occupational safety and health.

Legislations

The statutes relating to OH&S are broadly divided into three:-

 Statutes for safety at workplaces
 Statutes for safety of substances
 Statutes for safety of activities

At present, safety and health statutes for regulating OH&S of persons at work exist
only in four sectors:-

 Mining
 Factories

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 Ports
 Construction

The major legislations are:-

The Factories Act, 1948

 It regulates health, safety, welfare and other working conditions of workers in
factories.
 It is enforced by the State Governments through their factory inspectorates.
The Directorate General Factory Advice Service & Labour Institutes
(DGFASLI) co-ordinates matters concerning safety, health and welfare of
workers in the factories with the State Governments.
 DGFASLI conducts training, studies and surveys on various aspects relating to
safety and health of workers through the Central Labour Institute in Mumbai
and three other Regional Labour Institutes located at Kolkata, Chennai and
Kanpur.

Mines Act, 1952

 It contains provisions for measures relating to the health, safety and welfare of
workers in the coal, metalliferous and oil mines.
 The Mines Act, 1952, prescribed duties of the owner (defined as the proprietor,
lessee or an agent) to manage mines and mining operation and the health and
safety in mines. It also prescribes the number of working hours in mines, the
minimum wage rates, and other related matters.
 Directorate General of Mines Safety conducts inspections and inquiries, issues
competency tests for the purpose of appointment to various posts in the mines,
organises seminars/conferences on various aspects of safety of workers.
 Courts of Inquiry are set up by the Central Government to investigate into the
accidents, which result in the death of 10 or above miners. Both penal and
pecuniary punishments are prescribed for contravention of obligation and

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duties under the Act.

Dock Workers (Safety, Health & Welfare) Act, 1986

 It contains provisions for the health, safety and welfare of workers working in
ports/docks.
 It is administered by Director General Factory Advice Service and Labour
Institutes, Directorate General FASLI as the Chief Inspector there are
inspectorates of dock safety at 10 major ports in India viz. Kolkata, Mumbai,
Chennai, Visakhapatnam, Paradip, Kandla, Mormugao, Tuticorin, Cochin and
New Mangalore
 overall emphasis in the activities of the inspectorates is to contain the accident
rates and the number of accidents at the ports.

Other legislations and the rules framed there under:-

 Plantation Labour Act, 1951
 Explosives Act, 1884
 Petroleum Act, 1934
 Insecticide Act, 1968
 Indian Electricity Act, 1910
 Indian Boilers Act, 1923
 Indian Atomic Energy Act, 1962
 Building and Other Construction Workers (Regulation of Employment and
Conditions of Service) Act, 1996
 Beedi and Cigar Workers' (Conditions of Employment) Act, 1966 .

National Safety Council of India (NSCI)

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The National Safety Council of India (NSCI) was set up to promote safety
consciousness among workers to prevent accidents, minimize dangers and mitigate
human suffering, arrange programmes, lectures and conferences on safety, conduct
educational campaigns to arouse consciousness among employers and workers and
collect educational and information data, etc. It has launched new initiatives in three
sectors:-

 Road Transportation Safety
 Safety of Health in Construction Sector
 Safety, Health and Environment in Small and Medium Scale
Enterprises(SMEs)

At the international level, NSCI has developed close collaboration with International
Labour Organisation (ILO); United Nations Environment Programmes (UNEP); World
Bank ; Asian Disaster Preparedness Centre (ADPC),Bangkok; World Environment
Centre (WEC), New York; and the member organizations of Asia Pacific Occupational
Safety and Health Organisation (APOSHO) of which NSCI is a founder-member.

The National APELL (Awareness and Preparedness for Emergencies at Local
Level) Centre (NAC) has been established since April 2002 in the NSCI Headquarters
under the MoU with the Division of Technology, Industry & Economics (DTIE) of
UNEP, Paris. It is the first APELL Centre in the world. It has the technical support and
information from UNEP and other international sources and the Ministry of
Environment & Forests, Government of India and the stakeholders. It is dedicated
primarily to strengthen chemical emergency preparedness and response in India
through the use of the internationally accepted APELL process.

Policy

Announcement of the National Policy On Safety, Health And Environment At
Work Place was also a step towards improvement in safety, health and environment at

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workplace performance.

Objectives of the policy were:-

 Continuous reduction in incidence of work related injuries, fatalities, diseases,
disaster and loss of national assets.
 Continuous reduction in the cost of work place injuries and diseases.
 Extend coverage of work related injuries, fatalities, and diseases for a more
comprehensive data base as a means of better performance and monitoring.
 Continuous enhancement of community awareness regarding safety, health and
environment at workplace related areas.

Awards

In order to encourage occupational health and safety, certain awards have also been
instituted by the Government:-

 The National Safety Awards for factories and docks, were instituted in 1965,
to give recognition to good safety performance on the part of the industrial
undertakings and to stimulate and maintain the interest of both management
and workers in accident prevention programmes.
 The National Safety Awards for mines were instituted in 1983, to give
recognition to outstanding safety performances of mines of national-level
which comes within the purview of the Mines Act, 1952.
 The Shram Vir Awards, now known as Vishwakarma Rashtriya Puraskar
were instituted in 1965. These are meant for workers of factories, mines,
plantations and docks and are given to them in recognition of their meritorious
performance, which leads to high productivity or economy or higher efficiency.

Indian Standard on OH&S management systems

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Occupational Health and Safety demands adoption of a structured approach for the
identification of hazards, their evaluation and control of risks in the organisation.
Hence, Bureau of Indian Standards has formulated an Indian Standard on OH&S
management systems. It is called as the IS 18001:2000 Occupational Health and
Safety Management Systems. This standard prescribes the requirements for an
OH&S Management Systems, to enable an organization to formulate a policy, taking
into account the legislative requirements. It also provides information about significant
hazards and risks, which the organization can control in order to protect its employees
and others, whose health and safety may be affected by the activities of the
organization.

Organizations interested in obtaining licence for OH&S Management System as per IS
18001 should ensure that they are operating the system according to this standard. The
organization should apply on the prescribed preformed ( Form IV ) at the nearest
Regional Office of BIS along with Questionnaire ( Form X ) and the prescribed
application fee. The application shall be signed by the proprietor or the Chief
Executive Officer (CEO) of the organization or any other person authorised to sign on
behalf of the organization. The name and designation of the person signing the
application must be recorded legibly in a space set apart for the purpose in the
application form. Each application must be accompanied by a documented
Occupational Health and Safety Management System Documentation.

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Some Safety tools:

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Chapter 2:
SAFETY MANAGEMENT
IN
TEXTILE INDISTRY

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SAFETY MANAGEMENT IN TEXTILE INDISTRY

Cotton textile industry is the oldest & largest organised industry in India.
Providing direct employment over 20 Lakh people in the country. However the
accident frequently rate in the textile industry is highest & growing at rate in the last
few year . The resent survey has indicated that the accident frequently rate is high as
47-5 in the textile industry , therefore , there is an urgent need to take the action to
reduce the accident in textile industry .

HEALTH HAZARDS-(ACCIDENT)

Among the various health hazard there can be one are more the following
hazard which are likely to course accident or health problems –

1-Engineering hazards

2-Chemical hazards

3-Dust hazards

4-Fire & Explosion hazards

5-Enviramental hazards like heat humidity noise etc.

1-Engineering hazards

The textile machinery used in the most of the spinning mills. They are ordinary heads
through line shots located close to the roof, this type of power transmission expose the

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workers to many patent hazards. Due to contact with moving belts pulleyers shot
breakage of belts other hazards. Since the workers are exposed the m/c of very old
models on which the guards are not adequately provided however the machine of the
latest design have been provided with in wide guards taking in to consideration the m/c
in the space available quite then ignoring the statutory requirements of space between
the machines and the passage for the main material.

The other factors like housekeeping and illumination also are after neglected,
thus resulting in many accident. The need for a defiled survey of all the machine
working in mills identify the potential hazards is very necessary.

2-CHEMICAL HAZARDS-

In textile mill the problem of chemical hazards is mostly faced where the
wet processing activity , bleaching , dyeing , printing etc .Carried out ware the worker
are likely to come in contact with various type of dyes and chemicals(Some times the

atmosphere air jets contaminated with gasses like so2 , sulphite etc which may course
heart disease or mental implances.)

As it like H2SO4, HCl,CH3COOH & alkalies like soda-ash, caustic soda, tri sodium-
phosphate are extensively used .the concussing injuries & injuries of skin if they are
not handled properly varies kinds of dyestuffs are used for dyeing of cloth. There can
cause skin disease called dermatitis while some dye stuffs are carcenajen .It is
therefore necessary for the management to study in details& to provide suitable
handling disease were much lesser in the operatives. Who are working in mills with
modern machinery and fully air-conditioning facilities but of the cotton dust in the
work Environment was much higher then the international standards. The following
are the figures in different department equipment & also the personal protective
equipment to safe guard the health of the workers.

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DUST HAZARDS.

When cotton is pressed in various sequences for being converted in to yarn &
subsequence operation lot of fine dust is generated and in to the working atmosphere.
This cotton dust contains cellulose lignin &if this dust is continuously is hated by the
change of these spooking suffering from dangerous diseases called Byssinoisis . If the
operatives are already having a lung trouble or who are habituated to smoking then
they folly pay to this disease very easily reputedly a survey was conducted on 1241
workers working in this type of textile mills in Bombay continuously for 5 years mills
with reasonably new machineries and with air-conditioning facilities mills with
modern machinery & air-conditioning facilities.

According to these studies even through the faces of Byssinoisis disease were
much lesser on operative who are working in the mills with modern machinery and
fully air-conditioning facilities but quantity of the cotton dust in the work.
Environment was much higher then the international standard.

After the detailed study the researches a worst a remark saying Indian cotton mill
worker is in working in working order total conditions. How alarming the remark the
quality of cotton dust bellow 2 mg/m3 leave makes the textile exerless work under the
health or fitting.

4-FIRE AND EXPLOSION HAZARDS-

In textile industry fire and explosion hazards are also noticed. One of the main
reason for the fire hazards is to the electrical short circuits then the fine accidents takes
place due to the friction in the machine during non-lubrication. In the textile
processing there is always a possibility of the Bloating fibres accumulating on the

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electrical wiring and other equipments which are highly suspect able to the risks.

In this direction the importance of house keeping has to be understood by the
mile management & the cleaning of such layers of accumulated fabrics of to be
remove on regular basis.

The electrical fitting should be also be dust proof so that the fibre interring into
the fitting avoided.

Most of the machines presently is the work on the principles of the pneumatic
systems which necessitate the provision of compressors of the opposite mills where the
sizing activity carried out require steam kept winders pressures cookers etc. They
equipment if not properly maintained & likely to cause explosions. Once there is a
used for symmetric testing of these equipments to minimize such a risks .

The management should endeavour provide the fire fighting equipment least
as per the statutory equipment such that fabrics should be distinguished that the initial
page it self most managements resort economising in the measurement of the fire
fighting equipment and also is the paper maintenance of fire above and suffer huge
lasts to fire accidents.

5-ENVIREMENT HAZARDS LIKE HEAT, HUMIDITY
& NOISE
Humidity fixation activity of the textile manufacturing correct ambient
condition are most essentials for efficient working of textile material upon which a
series of operations of opening & cleaning of fibres in blow room to interlacement of
warp & weft in weaving the fabric should have requisite properties. So that the
material retains its basics shape & size & strength when the atmospheric relative
humidity too low fibres becomes brittle to store lot of static electricity generated due to
friction too high relative humidity also result in poor performance of the material,
hence both low and high relative humidity are therefore essential from several such

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technical requirement the workers are the part of manufacturing process and hence
condition maintenance is the set should not only be comfortable to the process and the
product they should also be comfortable.

The temperature is also required to maintained in the textile manufacturing
activity,

It excessive heat is in the work area, it affects the health of a worker leading to
drop in work out put, therefore there is a need to maintain a suitable temperature to
protect the health of the workers and maximize their efficiency and productivity.

Noise hazard also is faced by the workers enjoyed in the weaving shade which
a quit often able the T.L.V. of 85 is therefore necessary far the mill management to
study this problem in corporate changes in term of avoiding so that the likely damage
caused to the weavers by the way of irreversible loss of bearing is avoided, it is also
found that the textile workers are likely to suffer from humidifier fever due to the used
of polluted air a7 water in the humidification plants which are used for maintained the
controlled condition of temperature and humidity. Hence it is necessary to see that
clean water are provide to humidification plants.

PRINCIPLE OF MACHINE GAURDING-

The principle of m/c guarding are as under-

1.Desing the machine so the it is impossible for an operator to get at the point of
operation or any other hazard point while the machine is working.

2.Desing the machine so that corners and edges are round.

3. Locate m/c control so that the operator will not be in the vicinity of the point of

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operation while actuating the controls.

4.Make the control so that the operator will not have to reach too form move his body
of balance in order to operate the machine.

5. Build power transmission & drive mechanism as integral parts of the machine.

6. Build over load device in to the machine.

7. Design the machine for single point lubrication.

8. Design mechanical instead to manual holding device.

9. Design a mechanical device for feeding to effecting parts so as to eliminate the use
of hands for such operations.

10.Provide fail safe interlocks so that the m/c cannot be started when it is being
founded as unloaded or being locked once provide a grounding system for all electrical
equipment provide standard access plat form and do for inspections and maintenance
of equipment ,

Design component pat of equipments for easy and safe removal and replacement to
facilitate maintenance ,Reduce sources of excess noise vibration heaf etc.

SUGGESTED STEPS FOR SAFETY MANAGEMET

1.Engineering research.
2.Safety education.
3.Safety audit.
4.Safety promoter.

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5.Safety budget.

REQUIREMENTS FOR GOOD GUARDS-

1-With its primary purpose of protection, it should also facilitate the work.

2-It should fully satisfied the loyal provision and I.S. prescribed. 3- It should be
suitable and effective to the top and the m/c.

4- It should allow for failing and repair.

5- It should with stand wear shocks, vibrations and long use with minimum
maintenance.

6- It should be of free from self hazards.

7- It should be of proper material and contact. 8- It should
be transparent and get durable. 9- It visual watch of
operation necessary

10- It should be fail safe at least it should give warning to stop the machine.

11- It should be interlocking type. It should fulfil special requirement
depending up on its purpose.

MAINTENANCE AND REPAIRS OF GUARDS-

Section of the factories acts states that the guards should be constantly
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maintained and kept to position such maintenance is obviously necessary b/c a m/c
running without guards or with open or broken guards condition the guard removed
damaged or requiring repairs. A guard remove for repair should be replaced at the
earliest possible & mean while temporary guard should be installed guard maintenance
increased the life of a guard and vice-versa the supervisor pay constant attention for
this.

SAFETY PRECAUTIONS OF M/C-

1-Every port of the transmission machinery and other dangerous parts should be made
inaccessible by proper guards. In the case of new machines set screws belts & keys on
moving parts should be covered or otherwise well guards. All gears and too the wheels
which do not require adjustment should be fully enclosed.

2-Suitable and safe belt shifting device should be provide on al machinery.

3-Any examination adjustment lubrication or other operation of moving parts of
machinery which exposes a worker to potential hazards should be carried out only by
adult mole workers who are well trained and while wearing tight fitting clothing.

4-Women and young person must be specially trained b/f being employed on certain
dangerous m/c.

5-On all these machines the beater covers and other openings which proved access to
dangerous parts should be effectively interlocked. Further openings ginning across to
dust chambers should be so forced that while light is admitted to the chambers access
to heater guard is prevented.

6- The lap forming rollers should be equipped with a guard which is addition to
preventing access to the vibrate of the lap rollers should also be interlocked
effectively.

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INTERNATIONAL LABOUR ORGANISATION-

The organic section was established in 1919 . it has more than 130 members become
specialised agency of united nations in 1946 .permanent secretariat international labour
office (Geneva) Director general is I.L.O. International member from countries .
Director general is appointed by the governing body constitution of governing body –

Government representative - 24
Labour representatives - 12
Management - 12
Governing body has its meeting over four months .

OBJECTIVES-

1. International celebration for securing permanent place
2. Eliminating adjustice through improvement of labour conditions
3. To provide technical assistance on labour and social policy .

General conference of I.L.O is convinced annually delegates and annual
conference.

ROLE OF I.L.O IN OCCUPATIONS SAFETY AND HEALTH

1. Standard setting and research
2. Exchange of technical information and research
3. Technical cooperation activities

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1. STANDARD SETTING

• I.L.O. conventions and recommendations model codes of regulation
for code of practices
• Safety and health in dark work
• Safety and health in agriculture prevention of accident due to
electricity
• Guide and manual supplement to code dust prevention enemies
• Guides for labour inspectors accident prevention etc .

2. EXCHANGE OF TECHNICAL EDUCATION-

Issue of application of inquiries report about –

1. Report on safety and health issued during last 10 years.
2. Report on maximum weight carried by workers .
3. Medical inspection of labour.
4. Electrical accident.
5. Directories on safety and health.
6. Catalogue on safety & health film.

CLS-international occupations safety and health information centre (1905).

It has regional office in various countries & permit information
Regarding safety and health one can contribute in the publications by C.L.S.

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3-TECHNICAL CO-OPEATIVE ACTVITIES-

1. Assignment of expert in a centre for measure on safety and health
2. Advising govt. in revising their legislations
3. Provide technical equipment for labour
4. Granting fellowship for training and studies on safety and health organising and
conducting training program and seminars.
5. In addition to above I.L.O. discus matters concerning particular regions, areas,
fields, and industries by organising special conferences.
6. Setting up of committees conducting technical meeting provided opportunities
for advance of study on labour polities at international institute of labour studies
at Zeneva;

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Chapter 3:
PLANT LAYOUT
FOR
INDUSTRIAL SAFETY

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PLANT LAYOUT FOR INDUSTRIAL SAFETY

Before the industrial revolution, the artisan who worked frequently in his home, nearly
utilized fixed position layout, when he worked at his bench all materials were brought to
the bench, along with all the tools, he required. His product was completely fabricates
while the major component in one location, at his work bench.
With the advent of industrial revolution, the machinery has grown in size and
complexity, so that today in factories, it is easier to move materials than to move the
equipments. Although the plant layout is older than the industrial revolution, the tools
devised to solve the problem were hardly improved at all before the turn of the century.
The time 4 motion study thinking brought about some systematic approaches such as
flowchart and operation process chart but only after world war-II, significant slides are
developed and analytical tool useful in salving plan layout problems are adopted.

Whether it is a product layout or process layout there are some advantages of
good plant layout. They are ;
• Reduce worker’ afford and minimizes his manual material handling.
• Reduces the number of accidents and provides for better working conditions
by eliminating congestion.
• Reduces labour costs by increasing productivity output per man hour.
• Reduce indirect manufacturing acts by decreasing scrap and silage due to difficult
handling situations.
• Helps not to allow plant equipment becoming absolute.
• Provides space for future expansion.
• It eliminates wasted aisle spaces.
• Helps easier and reduces frequent quality checks.

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There are many advantages and it is not possible to list them out. However, realization of
advantages much depends upon how active the organization for plant layout and how alert
the layout engineer is, in seeking out certinent information, from various sources.
With the declared policy of Government during 7th five year plan period for productivity, the
plant layout concept, is bound to get a boost. Adequate consideration to safety and health
factors taken at blue print stage will help the realization of advantages. Any neglect of the
factors in the layout can result in permanent condition of work having potential to cause
accidents, ill health, fires and explosions. A latter attempt to apply corrective action may
prove to costly and the cost become prohibitive and improvements may be impracticable
also.

The factories Act 1941 (section 6) and rules provides for submission of plans of new
factories and futures expansions and alternation the existing factories. The section 6 cost
further “requiring the previous permission in writing of the (state) government or the chief
inspector to be obtained for the site on which the factory is to be situated and for the
construction or extension of any factory or class or description of factories” was unsorted by
act 94 of 1976. Further rules have been framed by state Government regarding other
particulars to be shown in plans. As a safety measures lastly Government of Maharashtra in
1984 introduced a ruler enquiring certificate of stability issued by a component person on
respect of every work of engineering construction in prescribed form I-A. The periodic
examination of the work of engineering construction. “Once in a period of five years is also
envisaged. The work of Engineering construction ‘means’ any building, tank, site, scaffold,
platform, chimney, supporting steel work retaining well or any similar structure”. It describe
to note that proper planning of most of the health and amenities and safety provisions
required under the act can be done at layout stage.

With a view to modernize tools for production, the replacement of the existing machineries
with heavy and fast moving on the existing old factory buildings will require rethink while
to consider “floor leading protection” i.e. requiring the display of loads approved by
competent civil engineer for manufacturing and storage areas and also prohibition of greater
load to which such old floorings are certified.

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The safety distances to be maintained at the installations where dangerous petroleum in bulk
is stored above ground in envisaged under the petroleum Act & Rules. Screen walls are also
permitted by the chief inspector of Explosives where the distance specified is not possible
under certain situations.

An Indian standard institution has developed a code of safe practices for layout of cu-
side facilities for industrial plants. Some salient points are enumerated below:-

1. Reads and Fact Paths – Reads in plant yards and grounds are sources of frequents
accidents unless they are carefully laid out, substantially constructed, well surfaced
drained and kept in good conditions.

2. In a factory heavy truck movement is a normal feature. For heavy duty motor truck
movement roads up to 16 meters wide for two way traffic are required Rectangular
bonds should be avoided by providing amplest radial at curves. Gradients are to be
limited to a maximum of a percent. Provision of ditches to carry drainage water is
also recommended.

3. While laying internal roads at least they should be all meter away from the building
especially at entrances. At loading docks adequate length say twice the length is
desirable to facility to backing of vehicles.

4. Traffic signs and signals regulating speed and movements of vehicles hazardous
locations are very essential stop signs are specified for railway crossing and entrance
to main through fares ‘sound your Horn’ signs are necessary at blind corners of
buildings.

This can prevent road accidents especially then roads have to be built close to the
buildings.
5. Speed breakers with zebra lines should be provided before entrance/exit of plants,
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short curves, blind corners and also before such places where speeding vehicles
would pass a particular hazard to pedestrian traffic or other vehicles moving in the
area (if roads are to be used at night traffic signs should be made out with luminous
materials).

6. Protected footpaths between outside facilities and roads, leading to canteen buildings
and ambulance rooms are also desirable to discover age workers taking short cuts.

7. Parking areas - Good drainage to parking areas are essential and the entries parking
areas should be fenced with barbed wire.

Internal Plant Layout – There is a separate code of safe practice for industrial plant
layout published by Indian Institution Sum 1976, the following are some of the
recommendations.

BUILDING

1. The size of the factory should be determined by taking into consideration of all
possible future expansion although there is not definite area specified for the site of a
factory still as a thumb rule five times of the actual manufacturing area is considered
as a recommended practice.

2. The three common building types are single story multistory and monitor. A No. of
variations in roof construction can be found which provides advantages in ventilation
or lighting. If a given industry is rapid ally changing products designs or process the
rectangular shape is recommended because it is easier to change over. The ‘NFDA
recommendations and ISI codes should be carefully studies before deciding the
type of building.

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SPACES FOR MOVEMENT OF MEN, MACHINES & MATERIALS:-

1. Ample space should be provided between gradated units, such as flames source,
(boilers, building equipment, etc.

2. Aisles should be dearly defined with approved marking, plastic buttons fastened with
metal fasteners to the flour should be used with advantage because of their durability.

3. At least 2 meters radius should be provided for small industrial trucks.

4. A vertical clearance of 2.2 metres is recommended between passage stairways and
overhead structures.

5. Aisles for one day traffic should at least be of one meter wider than the widest
vehicles and for two way traffic should be at least of one meter wide than twice the
width of the widest vehicles. Aisles between 4 to 6 meters. Wide are recinnebded for
new buildings especially when heavy traffic is anticipated.

6. Ramas should have abrasive coatings where slippery floor conditions may exist, sharp
turns into aisles at the top and bottom ramps should avoided. One meter wide square
should be reserved as a walk way where Ramos are meant for use both by truck and
pedestrians.

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STORAGE

1. Ample space for outdoor storage of materials and for disposal areas, separately for
solid waste, should be provided for.

2. The segregation of raw materials storage, processing buildings and storage for semi-
finished and finished products should be provided for to minimize fire and explosion
hazards. Separate storage for highly flammable liquids will reduce fire hazards and
helps easy control of fire if it starts.
3. The plants where handling and storage of substantial quantities

of flammable liquids having flash points below 950C should confirm strictly to
specifications for handling and storing of flammable liquids developed by local
authorities. All the storage tanks installed should confirm to good engineering
practice and provision for relieving excess eternal pressure, grounding insulation,
piping and other appetencies should be provided for
.

4. Regarding compressed gas cylinders, the following precautions should be taken:-

a. Do not stock cylinders near sources of heat or indirect sun.

b. Do no keep cylinders in battery charring room or in all room.

c. Do not allow cylinders to come in contact with electrical apparatus or live wires.

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LIGHTING

Wide variations in the intensity of lighting in the adjacent areas for e.g. A corridor and a
machine shop in which fine work is carried out, can lead to many accident through the
inability of the workers eyes to adjust quickly enough, from one lighting condition to
another. This danger is intensified when operators of trucks, overhead travelling crane
and another vehicle moving at speed are exposed to this hazard shadow son important
objects and spotty illumination conditions tends to reduce safety and working efficiency,
They can be easily corrected. When placing the lamp for general lighting care should be
taken so the lamp and lamp shades be easily approached in normal working conditions so
that they could be cleaned and maintained in good state.

VENTILATION

Modern industry with the complexity of operating & processes are required to use
increasing number of chemicals compounds and substances, many of which may be
highly toxic the use of such materials results in dissemination of fames, gases and mists
in the work-room and contaminates that the air. The protection of worker is needed under
such environments mental exposure.
1. Provision of exhaust ventilation without adequate through results in workers
discomfort, exposure to combustible gases from back drafting and impaired
ventilation. In such situations the system should be well designed for efficient
exhaust ventilation.
2. Ventilation to supply fresh air for respiration, for dilution contaminated air, to
maintain that, heat balance of the body, to prevent discomfort and injury to health
should be also planned at the initial stages of plant layout.
3. Under the statutory provisions of factories Act, 1984 (sections-13) it is required
that effective and suitable provisions in every factory for securing and
maintaining and every workroom-

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A. Adequate ventilation by the circulating of fresh air, and

B. Such a temp. as will secure the workers there in reasonable conditions of comfort
and prevent injury to health.

(30)

AND IN PARTICULAR

Walls and roofs shall be of such material and so designed that such temp. shall not be
exceeded but kept as low as practical.

1. Where the nature of work carried on the factories involves, or is likely to involve,
the production of excessively high temp. such adequate measures are as
practicable shall be taken.
2. It can be include separating the process which produces such temp. by insulating
the hot part sof by other effective neaps.
3. In the Maharashtra Factory Rules 1963 applicable from 1st Aug, 1984, a French
rule 22 (a), is introduced to ensure comfortable temp. conditions inside the
workroom, three is also mention of a number of air changes & also provision for
even distribution, to prevent dead air packets and droughts caused by high inlet
velocities, it is also required to have ventilation openings equivalent to at least
10% of the floor area, located at not more than 1 mt from floor level. There is also
mention that the aggregate area if ventilation should not be less than 15% of the
floor area however, the national building code recommends a minimum of there
air changes per hours if there are no contaminate to be removed from the
workroom.

4. Under section 16 of the factories Act 1948, over cowding shall

a. have to be prevented. This section demands 14 M3 to 16M3 of space for
every worker and for temp. of calculation no account will be taken of any
space between 4.25 mts. Above the floor level. In relation to dry bulb
temp. exceed to that given in the table below as required under
Maharashtra Factor, Rules, 22

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MEDICAL FACILITIES

Location of First-aid rooms near manager’s office for major departments or also to the
person responsible for it. Each first aid station should be equipped with a stretcher for
servicing injured person. The safety colour of code of American standard association
suggests their first aid equipment in the plant be painted in bright green for quick, easy
identification.

Some typical layout drawings taken from plant layout design from james M. Moore
books in incorporated for ready reference.

Lavatory facilities in some plants are Kept operate from locker rooms, but the few
facilities are combined, as is seen lavatory and toilet facilities in larger plants should be
decentralized in order to be conveniently accessible to the workers where the locker
rooms are separate from the lavatory facilities, the former may be placed close to the
employer’s entrance to plant, and time clock should be also known for.

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Chapter 4:
GOOD HOUSEKEEPING
AND
SAFETY MANAGEMENT

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GOOD HOUSEKEEPING TOWARDS PRODUCTIVITY

Good housekeeping and orderliness plays an important role in
productivity and accident prevention drive because it is one of the practical
methods of getting efficient operations, improving morale & reducing the accidents.

Following are the types of accidents caused by bad plant housekeeping.

1. Tripping over the objects haphazardly placed on flour, stairways platforms,
airless,
2. Hitting by objects falling over head.
3. Slipping and falling over grassy and dirty floors.
4. Striking against projecting and pearly placed or piled materials.
5. Falling of improperly supported or piled materials over the bodies.
6. Injuries due to nails or sharp objects lying as floors. Here everybody must keep in
mind that good house-keeping can not be achieved in one day. The same must be
pre-planned in detail and continuously followed u.p Generally we see that
departments are kept clean, if there is a visit of any VIP such as managing
director, the importance of good house-keeping can be stressed by showing
following advantages:
Once the department is kept clean and good house-keeping standards are established,
much loss time and efforts are required to maintain it clean.
i. Bad house-keeping is hindrance for pre planned for increase productivity.
j. There are no chances of materials and parts getting lost or mixed up. Therefore time
which is wasted in search of tools, parts or materials is saved.
k. Sorting of unused materials, spillage and scrap caster.
l. Operator can more freely around machines.
m. Faster traffic with no chances of collision is possible if aisles kept open.
n. Reduced fire hazard, Fire starts or is spread by poor house-keeping conditions. In
textile mill accumulation of fluff is major fire hazard.
o. Low accident rate.
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SUPERVISORS RESPONSIBILITY

It is the responsibility of supervisors to see that departments under his control are kept
clean and orderly in case where certain goods house-keeping standards are established by
the top management, task of supervisor become comparatively simpler. If it is not the
case, supervisor can set up a separate programmes he should keep in mind that to achieve
it, participation of all his employees is essential. He must set up procedure so that
operations can be checked frequently and prompt action taken on deviation or lowering
of standards.
In order to prepare check list to maintain good house keeping we should know
what are the indicators of bad house-keeping.

INDICATORS OF BAD HOUSE KEEPING

1. OBJECTS OR MATERIALS CLUTTERED UPON FLOORS-These are results
of materials falling from machines, tool boxes etc. or dropped during transmit.
Usually maintenance people bring extra materials to attend any breakdown but
they never clear up their work area fully after job is finished.
2. EQUIPMENT OUT OF PLACE – These should be trucks, tools, ladders, potable
welding sets and equipments etc. it must be checked that these are kept at out of
place or not.

3. POOR STORAE PRACTICES:
A. Disorderly piling.
B. Storing the things in aisles.
C. Pilling top high or improperly.
D. Keeping things in aisles, doors, sire exists etc
E. Containers not provided for waste and scrap.
F. System not established to remove waste at periodic interval.
G. Failure to provide mechanical cleaning equipment such as vacuum cleaning
machine.
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4. POOR DISPOSAI SYSTEM:

5. DIRTY WIDOWS LIGHTS ETC. If windows, skylight, ligh fixtures are not kept
clean illuminseium reduces, which increases eyestrain and accident hazard, tube
lights should not be fixed above the machine as it becomes difficult to clean so
there should be fixed between two machine or passages.

6. FIRE HAZARD :- Oil snaked rags and cotton waste must at once. Now we will
see the points which should be included in programme of achieving &
maintaining good house-keeping.

m Cleaning of floors, walls, ceilings, windows, stairs, passage ways, aisles,
lamps and reflectors etc.
l Cleaning of machinery, equipment, tools, trucks elevators, conveyors, hand
and power tools.
a Disposal of scrap, waste etc.
D Provision of separate containers for combustible materials, non-combustible
materials and oil snaked rags.
m Collection of all roughish and waste at regular intervals.
C Arrangement of goods in process, flushed products and waste material.
A Provision of adequate space for materials, portable tools & equipments.

P Stacking and piling on properly marked storage area.

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USE OF COLOUR CODE AS AN AID FOR HOUSE-KEEPING –

Safety Colours :-

a. Red – Red is used to identify the location of equipment used to sight fires.

b. Yellow – Yellow is used to identify hazards the worker should “Watch out for “
when yellow is used with black, in the form of parallel, vertical or parallel
diagonal lines, it points out areas where tripping, follinger striking is likely to
occur.

c. Orange – It is used to mark portions of machines or equipment that might injure
workers.

d. Green- Green is used to identify the location of equipment used in administering
assistance after and accident has occurred.

e. Blue – Blue is used to advise caution.

f. White- White is used in marking ailes, and stock areas are marked with bands of
white. Its may be used to paint waste containers. Dark corner in stairwells &
manufacturing areas may be painted with white to assist good housekeeping.

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INDUSTRIAL SAFETY FOR PRODUCTIVITY IN TEXTILE

Let me first emphasize that sometimes we go with a wrong attitude to work place
and particularly the supervisory staff as well as the line staff always is more
concerned and is made responsible for getting out production. But one must
clearly understand that while one is concerned with his production though his
employees he is earnestly concerned with anything that interfere with the
expected production which is his foremost concern. I mean productivity and
production.

By production one must understand that it does not mean actual making of some
articles but does include handling of materials and delivery of finished product
right up to the consumer. If we enlarge ourselves the operation that it definitely
means not only the maintenance of building or equipment but also operation of
boiler, running of machines etc. further one must also understand that loss of time
on any account is also one of the source of interference with normal production.
The same there is not only an interference in production but also injury to the
person and sometimes damage to the machinery or equipments further, the impact
that we find after a serious accident on the behaviour of those who are working in
that are3a we get so much upset that not only there we find loss in production
because of the accident but also the workers morals is so much effected adversely
that to bring those affected employers back to normal production level it takes
sometimes I am not mentioning here how much time is lost by others also who
come to watch the accident place and are indirectly adversely affecting the
production schedule at some other department.

i also have realized that normally the supervisor is more interested in production
activities rather than accident prevention activities.

How many of us known in fact the causes of production, troubles are practically
the same as those of accidents. Just take an instance , time is lost b/c material is
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not piled properly. Time is lost b/c many aisles are blacked with boxes or material
which should not have been there. Time is lost b/c of wrong type of tool used one
must therefore admit that therefore a supervisors role & concern is not only the
elimination of accidents that result in personal injury but accidents that result is
lost of time, damage to equipment, damage to product and also interference with
planned production procedures.

I have never seen a sign anywhere in any factory or radium any book any
schedule where it was mentioned “Stop, Tomoe for an accident”. This according
to man that there should be no time for accident if it is so, all the time is for
production and anything which goes towards maintaining of the same. In short
people go to their jobs to work and continue to work till the job is properly
performed and their scheduled time assignment is over. If it so, let us think of
safely and production going together.

Here investigation therefore becomes necessary when any accidents occurs & one
must admit that while investigation the cases of accidents, not only the causes that
require me3dical attendance that have to be investigated but also where damage is
caused to man as well as machine the same has to be found out.

M any a time, the supervisor gives the causes so as to enable anyone to determine
at what step the individual concerned was careless. Once we know the step which
was strong it can be ensured that we can prevent similar accidents and avoid
careless steps.

Once we know what step was wrong we should try to know why of the action.
When you know what and why at the happening of the accident then, who
becomes unimportant because all become one to decide further action as to know
how they should avoid such accident. It therefore means corrective action.

1. We can correct a hazard by mechanical means, can eliminate the conditions or

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or change the operation what creates the hazards. We can repair the broken or
defective part or we can put a guard on the dangerous machine part.

2. We can eliminate the cause by assigning people to work. This applies more in
relation to accident – proms workers. It has been found that probability of an
accident can be reduced by a change in the environment.

3. The corrective action can be applied through disciplinary measures. This
method of approach may be tried only when other methods have failed.

4. We can prevent accidents through the method of instruction and appeal which
is the most effective way to get results. Last but not in the least supervisor
must ask himself whether the instructions are being followed and for that he
should ask himself the following questions?

s Have I exhibited an active interest in accident prevention.

H Have I given safe3ty instructions with the same degrees of enthusiasm
and determination as production instructions?
a Have I pointed out to the men the importance of their job to the
finished product and how improper methods can seriously interfere
with the completion of a project?
w Have I previously ignored via lotion of the same instructions that I am
trying to enforce?
t Have I been guilty to do the same thing that I am now trying to correct
others from doing?
Have I given others an opportunity to express themselves?
H Have I been impartial?

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Lacking back to the Textile industry again which is tradition bound and old, the
role of supervisors therefore have to be changed now with the bringing on of
modern machinery & equipments. The worker will have to adjust himself to the
changing screen and changing machine, though the place might remain the same.
The skill that will be required for performing the work will require added vig our
& with that a definite will, to not only tive high production but work safely and
also to achieve maximum, for this let us all work where we take production and
safety together for both are inseparables.
Accident prevention is a continuous process and at times non-rewarding
and even non-attractive. The attitude therefore of each and every individual is
required to be changed because each and every one is not directly but indirectly
affected and if we do not involve individuals noting can enable us to prevent
reduction in accidents. that will to work therefore with a desired objective to work
safely has to be developed amongst all concerned, as production and safety is
equally important, skilled persons though have skills, their skills can be of use
only when they are on work and work safely their safe working helps each one to
get desired objective of increased production.
Another prang that i would like to stress is that sometimes we feel in the
textile industry that accidents are caused because they are God willing; it is the
God who prevents accidents or causes accident. I do appreciate that certain things
are destined but that one must also appreciate that it is our own bad judgement
that creates such a situation where accident occurs. The Textile worker is
cooperatively less educated and his reflex action at times fail, with the result, the
lost minute prevention of accident cannot be avoided.
As stated earlier human error causes accidents and if we glance through past
record in total industry is India a reheating fact come out as can be seen on the
analysis of accident.
1. Human causes – 88% (Unsafe practice, lack of fore sight, wrong attitude
etc.)

2. Mechanical failure – 10% (Plant condition, tool or equipment failure).

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3. Acts of God – 02% (Weather, floods, cyclones etc.).

(Source- Training Manual, National Productivity Council, June 1978
Edition).

As stated earlier if we really look at the productivity problem the Textile
machinery that is provided by the Manufactures have many safety aspects and
infect all the world over, one can honestly say that safety is much higher in
Textile industry as compared to hazardous chemical industry or petrochemical
industry leave apart the fine chemical industry the machinery what has been
provided is world-wide acknowledged to be safe for working and the accidents
occurs only when many a times mechanical fault takes place, safe devices are not
kept in proper working conditions or that someone works in hazardous and unsafe
manner I can only opine as a silent observer that there is still scope for
improvement & that one can work with safety for production only when the
desire, the will & the decision to work safely is there.

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Chapter 5:
STATUTORY SAFETY
REQUIREMENTS IN TEXTILES
INDUSTRY

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STATUTORY SAFETY REQUIREMENTS

1. All openers sketchers, combined openers and sketchers, Lap machine, hard
waste breakers, cleaners, blenders, hoppers feeders and similar machine.

a. All machines given above shall be driven by separate motors or from
separate counter shafts provided with the fast and loose pulleys and
efficient belt shifting devices.

b. In above machines the beater covers and doors which give access to any
dangerous part of the machine shall be filled with effective interlocking
arrangements, which shall prevent the covers and doors being opened till
the dangerous parts of the machine come to rest and also prevent the
machine being restored till the covers and doors are closed.

c. In all machines named above the opening giving access to the dust
chamber shall be provided with permanently fixed fencing, which shall,
while admitting light, yet prevent contact between any part of a persons
body and beater grid bars.

d. Provided that in case of similar machines run at higher speed and provided
with an automatic lap starter mechanism, the m/c shall be immediately put
out of use, no sooner this machine goes out of order for any reason and the
same shall not be decommissioned till the automatic mechanism is
repaired and placed back in efficient working order.

2. CARDING MACHINE :-
• All cylinder doors shall be secured by an automatic locking device which
shall prevent the doors being opened until the cylinder/cylinders ceased to
revolve and shall render it impossible to restart the machine, until the door
is closed.
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• Access to the licker-on cylinder from the back and the sides shall be
positively prevented so long as the licker in cylinder is rotating, by
suitably designed and placed guards.

3. DRAWING FRAME –
1. The gearing for driving the draft rollers on drawing frames

shall be effectively guarded by a cover which shall be so interlocked that it
cannot be raised until the m/c is stopped and the machine can not be
restarted until the cover is closed.

4. SPEED FRAMES-
Hand stocks shall be filled with automatic locking arrangements which shall
prevent the doors giving access to the jack box wheels being opened while the
machinery is in motion and shall render is impossible to restart the machine
until the doors are closed.

5. COMBERS AND SIMILAR MACHINES –
a. The gearing shall be effectively guarded by cover which shall be so inter
locked that it cannot be raised until the m/c is Stopped and the machine
cannot be restarted until the covers closed.
b. A fixed guard of a suitable design shall be provide which would prevent
access to the draw-box rollers in motion.

6. SELF ACTING MOLES-
The drive shall be from countershaft which shall be provided with fast and
loose pulleys and efficient belt shifting devices.

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7. PROCESS HOUSE MACHINERY-
a. In respect of calendaring mangles roller, printing machine, mercerizing.
Soaping, stentering, singeing, shrinking, washing and similar m/cs all such
machines shall be provided with an efficient nip guard along the whole
length on the intake side of each pair of bowls and similar parts, as would
prevent access to the point of contact of the rollers or bowls. Provide, that,
in the cause of those machines in respect of which it is not possible to
provide efficient “nip” guards on account of the corrosive action of
chemical used in the process or on account of the size of the material
passing through the bowls, efficient fixed guard shall be provided on
either side of the machines as would positively prevent any access to the
point of contact of the rollers or bowls. Provided further that in respect of
rollers or bowls of such m/s with ends of lesser diameter, the nip” guards
shall have flattened ends on either side to prevent access between the
guard and the roller or bowl ends moving in.
b. In respect of felt calendaring machines of any type, dangerous intake points
between moving felt of belt and the central or other guide drums shall be
securely fenced from the front & also from the sides, of such intake points
as are accessible from working floors or platforms.

8. SHEARING AND CROPPING MACHINES –
The dangerous moving author blades shall be provided with on efficient
interlock arrangement as would prevent the complete cover or guard to be
opened until the cutter blade has come to rest and would also make it
impossible to restart the machine until the cover or guard is closed.

9. SINGEING MACHINES –
Effective arrangement such as solenoid valve or other effective device shall be
provided to cut of instantaneously supply of any type of gas or electricity to the
machine, in case of failure of power to the machine. .

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Chapter 6:
SAFETY IN
THE COTTON AND
ALLIED FIBRES INDUSTRY

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SAFETY IN THE COTTON AND ALLIED FIBRES INDUSTRY

MUTES:-

This machinery has become absolute and safety aspects are not covered.

RING FRAMES :-

Whilst more modern machines are driven by individual electric motors integral
with the machine it self, older types of grams may still be driven by flat belts and pulleys
from overhead line shafting or they may have been converted to individual motor drives
should be adequately guarded, upto a height of seven feet from level.

GEARING :-

The main gearing on all machines should be in cases. On old machines this is achieved
by the addition of inner panels to the existing guards but on more modern machine
encasement is generally provided by the maker where there are access doors they should
preferably be interlocked.

SIZING MACHINES:-

These machines take the yarn threads from a series of Warper’s beam and
combine them to produce a weaver’s beam. During through the machine a cost of size is
applied to the warp threads to impart added strength for the weaving process. Sizing m/sc
is also known as taps or slashed sizing machines. Early modes of sizing m/cs have drying
unit consisting of two steam heated cylinders whereas later machines have a multi
cylinders arrangement.
The two cylinders on earlier machines are of different sizes and can be positioned
very close together so that a dangerous trap is created between them unless the clearance
between the cylinders is grater than 150 mm. guarding should be provided. On some
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modern multi-cylinder sizes the cylinders are also closely spaced. Efficient guarding
should be provided on these machine if the clearance between the cylinders is less than
(150 mm) or 6”. All gearings & and belts and pulleys should be effectively quarded.
Gearings includes side shafts bevel gears, measuring motion gears wheels driving the
headstock rollers.
All projections on accessible rotating parts should be effectively guarded. In
particular, attention should be given to the set screws on the muff couplings on the side
shafts. It is also advisable that this and other revolting shafting be sleeved or otherwise
protected.
Serious accidents have occurred at the trap between the drag and measuring
rollers of the head stock when persons have attempted to correct faults while the machine
in motion. A guard should be provided and should be maintained in position at all times
except when the machine is on crawl speed. (20 feet per minute).
On modern machines with multicylider drying unit site gearing belts and pulleys
and shafting are usually enclosed. The rollers at the head stock revolves rapidly, and
permanently fixed guarding or interlocked guarding should be provided to prevent access
to the trap between these rollers. Any interlocked guarding should insure that for all
speeds other than crawl, the power supply to the machine cannot set in motion until the
guard is close. The crawl speed should be as low as practicable and should not excess
1000 millimetres per second (20/min.). in addition the only control for the crawl speed
should be at the head stock should be designed so that it has to be continuously held in
the on position. An additional sale-guard on these machines is the provision of the strip
boar or wine set at the front of the machine which when operated ensures that the power
supply to the machine is in erupted.

DRIVE TO SPINDLES:-

On the earliest machines the spindles where driven by endless narrow bands which in
turn were driven by two tin rollers. Later, machine employed a single tin roller and
jockey pulley system and the bands were replaced by wider tapes. Some modern

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machines have pulleys instead of a tin roller and some designs employ an endless driving
belt to the spindles. Where there are two tin rollers on intake between them is created on
the underside for which suitable guarding should be provided Numerous accidents have
occurred when operatives have attempted to replace bands and tapes which have come
off the jockey pulleys whilst the machines were in motion.
Accidents have also happened, when persons have attempted to repair and replace broken
bands and tapes again with the machines running this work should of course only be done
when the machinery is stationery.

FANS:-

Most ring frames are provided with a broken and extraction system the fan is
usually mounted at one end of the frame and is either provided with ducting on the outlet
is covered with grid bars. The shape and size of the ducting or the spacing of the grid bars
should prevent all access to the fan blades.
Travelling cleaners are also provided on many frames. These are carried around the
frame on elevated track and the fan unit is situated above the trackers. There have been a
number of accidents when persons have climbed up to the clean or perform other
maintenance on the unit. Guarding should be provided for the fan bladder.

OPEN END SPINNING MACHINES :-

This is an entirely new for of yarn production and special machines have been
manufactured for the purpose. They are all relatively modern and the transmission belts
and pulleys and gearing are generally encased. The doors forming part of the encasement
should be interlocked or secured so that they can not be rapidly opened by unauthorized
persons the spinning units are driven by a continuous flat belt usually protected by the
front sections of the units.
When a section is hinged open for process work the belt is still protected but if a
section is completely removed for repair the belt is exposed. In such circumstances
temporary guarding should be provided.

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WINDING MACHINES :-

Belts and Pulleys: - Modern machines are usually driven by individual electric motors
integral with the machines themselves so that and pulleys are encased. Earlier m/cs were
commonly driven by flat belts and pulleys from overhead line shafting or they may have
been concerted to individual motor drive; guarding should be provided in all cases to
prevent access to these belts and pulleys. Secondary belt and pulleys drives and those to
ancillary motions such as conditioning through and conveyers should also be adequately
guarded.
Gearing – All gearing should be satisfactorily guarded where it is at all accessible. On
modern machines the gearing is usually completely encases.

Shafting – All shafting should be satisfactorily guarded where it is accessible, This can
be achieved by fixed guarding, tunnel guards or loose sleeking is the recommended
practice.

TRAP B/W DRUM & PACKAGES:-

A large number of accidents occur at the trap between the rotating drum and the yarn
packages, especially at cone and these winding machines. The majority of these accidents
take place during the removal of a full package and its replacement by an empty tube.
The package holder is moved away from the drum for this purpose and injury results if
the operative lowers the package holder on to the rotating drum whilst his band is
between the parts. Alternatively the package holder may drop unintentionally due to
mechanical failure. Training in the safe operation of these machines in therefore
essentially. This has to be compiled with excellent preventive maintenance. Accident also
occur during the removal of waste yarn from the rotating drum. Friction injuries are
caused by contact with the drum or the operatives fingers may be cut by the moving yarn.
Waste removal should only be permitted when the drum is stationary. Too much
accumulation of yarn waste should be discouraged.

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DOUBLING MACHINES

Ring doubling machines are very similar to ring or moving m/cs except that there
is no drafting zone. The hazards and precautions to be observed are similar to these
described for ring frames.

BACK BEAMING MACHINES –

These machines transfer yarn from a number of packages held in a creel and lay
the threads of yarn side by side on a warp on back beam for spun yarns the beam is
usually driven by frictional contact with a revolving drum up to the immediate post-war
years these machines ran at approximately 1.5 mtr./sec. (100 yds/min). A relatively slow
speed, The threads are brought per the beam barrel to the wound on so that the in take
between the beam barrel and the drum is at the underside and away from the operatives
normal working position at the front of the machines. On more recent machines speeds
have been considerable increased and 14 metres/sec. (900 yds/min) is not unknown the
drum on the high speed machine rotates the beam in the opposite directions and for
winding on the threads are brought under the beam barrel. The intake between the beam
barrel and the drum is therefore, on the upper side and towards the operative. A number
of serious accidents have occurred at the in running trap and a barrier should be provided
which prevents access to the trap when the machine is in motion or a device should be
filled which ensures that the machine is stopped promptly should a person approached the
trap.
The photo electric guard is the most usual form of protection for the intake
between the beam barrel and drum. The photo electric system should be self monitoring
and should be designed to fail to safety another form of protection is a hinged barrier
which prevents access to the trap when is lowered. Both these types of guards really on
efficient breaking systems and has to be maintained in good state of repairs. Attention
must be given to the guarding of belts and pulleys and gearing.

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SECTIONS WORPING MACHINES :-

If threads of yarn were assembled directly from a bobbin creel on to a weavers beam then
to achieve sufficient threads the creel would have to be an impracticable length sction
warping is a technique by which the total number of threads required are assembled in
stages on intermediate drum before final transference on to the weaver’s beam.
Accidents have occurred at the traps between the ends of the drum lags and the
machine frame work and at the revolving projections of the beaming off motion guarding
should be provided for these parts as well as for all gearing and shafting. On some
modern machines a trip bar remitized bar is provided; the displacement of which causes
the machine to stop promptly the additional safeguard efforts some protection against the
possibility of being trapped by the yarn as it is wound on to the drum or beam.

DRY TAPING MACHINES:-

These machines also take the yarn threads from a series of warper’s beams and combine
them to produce a weaver’s beam, but in this case no size is applied the head stock
arrangement is, however, very similar to that on sizing machines and effective guarding
should be provided.

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SAFETY IN THE COTTION AND ALLIED
FIBERSINDUSTRY OPENING PROCESS

SAFGUARDING DESIGN AND MAINTENANCE: -

Whatever type of material is chosen, the guard should be rigid and
substantial construction. Guards should be secured in position and regular and frequent
checks should be made, to ensure that they are properly maintained and kept in position.
The various sections of guards are better kept in position by bolts or rivets so that these
sections can not be easily removed by unauthorized persons, wing nuts or similar
fastening are unsuitable for this purpose. On many machines guarding is by enclosure
with hinged access doors. Secure locking devices should be fitted to these doors and
measures should be taken to ensure that they are kept in the closed and locked position
whenever the machinery is in motion.

In cases where a section of guard has to be removed frequently from a machine to
afford access, it is good practice to fit interlocking devices to ensure that the machine
cannot be set in motion when the section in grid, the section cannot be removed when the
m/c is in motion. This aspect should always be considered at the design stage since
modification after the machine has been installed may be technically difficult and even
impracticable.
Interlocking devices should be so constructed that they can not be readily
tempered with or defeated and if a component of the interlocking mechanism should fall,
the m/c should not be capable of being set in motion. Unfortunately many interlocking
devices, both mechanical and electrical do not meet this standard. Certain electrical limit
switches can be easily defeated by depressing the contact button and some modern
machine suffer from this short coming. Inter locking arrangements which are not reliable

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are known as ‘fail to danger type’, & those which are reliable are known as ‘fall safe
type’. Accidents which continue to occur, have confirmed the need for regular inspection
and testing of all interlocking devices, and the immediate repair of any defects brought to
light by such inspection. If a component part of an interlock is removed, or if it is
detective or damaged, access to the dangerous part will sooner or later be gained it is
strongly recommended that such inspections should be carried out at regular intervals by
a responsible person, and that at regular intervals by a responsible person, and that a
record of the result and any section taken should be kept. The factories 1948 Act requires
set screws bolts, or keys on revolving part to the sunk, in case or otherwise effectively
guarded to prevent danger. It also requires all gearing which does not need frequent
adjustment whilst in motion to be completely in-cased unless it is as safe as if it were
completely in cased. This is a legal requirement placed not only on the makers of m/c but
also on agents or importers of machines.
Any other dangerous parts of m/cs are required to be guarded in accordance with
sections of the factories Act 1948 (amended) whilst this obligation is placed on the
factory occupier, it is desirable that provision for the necessary guarding be made at the
design stage and guarding supplied with machine at the time of sale. If the executive are
aware requirements, they can intend machineries with necessary gadgets/guards.

TRANSMISSION MACHINERY:-

Transmission machinery includes the shafting, pulleys and belts by which
machines are driven. Where machines are driven from line shafting it should be realized
that is quite contrary to low to approach the shafting (if unguarded) for any such purposes
as oiling, greasing or the mounting of bolts while the shafting is in motion. The law is
quite clear on the matter either the shafting is on motion should be securely fenced or
they should be so placed as to be equally safe. If as is contumely, safety by position is
relied upon, then positional safety must be maintained. Overhead shafting in motion must
not be approached for any purpose, save for such very rare emergencies as may be
covered by section of the factories (section 22). It should be clearly understood that

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lubrication of transmission machinery and the mounting of belts in certain specified
continuous process has no application to the Textile Industry.
A requirement of the factories Act is that a driving belt, when not in used, should
not be allowed to rest or ride on any revolving shaft forming part of the transmission
machinery Either the belt should be removed or, particularly if it is one which is
frequently out of use, a suitable belt perch should be provided. If such precautions are not
taken there is risk of the belt wrapping around the shaft. Driving belts should not be
manipulated when the machinery is in motion except by means of a pole and then only
when the line shaft is sleeved on a belt perch provided.
Where overhead main driving belts or ropes are used these should be provided
with a tough guard below to prevent the accidental contact by operatives and to offered
protection in the case of belt breakages.
Groups of machines are often driven from line shafting in turn driven from one
motor which may be mounted on the floor at the higher level. The drive from this motor
to the line shafting should be adequately guarded there, this is at all accessible.
Take large extent the flat belt and pulley drives from line shafting have been
superseded by individual drive where
Each machine has its own motor. It is a legal requirement that the belts and pulleys or
drives of any m/c should be fully guarded. Vee-belt drives running on grooved pulleys
and toothed belt drives are particularly dangerous.

BELT CONVEYERS:-

They are commonly used in textile mills. There are traps between the intakes of the belt
and head and tail pulleys, there are also trape between the idler roller or tension pulleys
and the belt. Where closed guards are not possible or smaller conveyers, close fitting nip
guards are recommended.

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BELTS AND PULLEYS:-

Where use is made of external belts and pulleys, fender guards or individual guards are
necessary Fender guards or individual guards are necessary fender guards should be high
enough to prevent person reaching the dangerous in running nips of the belts, pulleys and
the guards should securely fixed in position. Individual guards should completely in cases
the drives.

GEARING:-

All gear wheels should be guarded so as to prevent access to the dangerous parts. This is
usually achieved by complete e3ncasement. The standard is on visage under 140
conventions. On modern machinery gearings is often totally enclosed behind locked
doors, the key being held by a responsible person in charge of the opening ranges.

FEED ROLLERS:-

After the preliminary opening of the fibre, pairs of fluted of spiked rollers feed the
material to a variety of beaters. Access to the in running nip of these feeder should be
prevented by a fixed guards secured to the framework of the machine for textile
machinery the extension do batter covers could be considered.

BEATERS AND CYLINDERS:-

Contact with these moving parts produces the most serious type of injury access is gained
either by lifting the beater or cylinder voter or the desk door, often to clear a blockage b/f
the beater or cylinder has come completely to rest. In most cases frequent access is
required and an interlocking arrangement should be fitted which makes it impossible to
open the cover door until the beater or cylinder has stopped and prevents the beater or

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cylinder being started until both the cover and door are closed. All the parts of this
interlocking mechanism should be secures by rivets and not by set screw which can be
easily removed.
Many accidents results from faculty interlocking mechanism a number of these
rely on a sliding belt of such a length that either one end must be in a whole in the beater
cover or the other and on a whole in the beater pulley alternatively a special disc
mounded on the beater shaft can be used instead of a pulley. If the relative distance of the
cover and pulley or disk is not maintained or the belt is not long enough, the mechanism
will not function correctly. It is absolutely imperative that these mechanism are correctly
designed and properly maintained where only infrequent access is required, covers should
be secured in position so that they cannot be readily removed by unauthorized person.
Master bolting for older machines should be considered. Fibre may be transferred
from one m/c to another by pneumatic means and it is necessary to have inspection
panels in the turning for clearing any brakeage if such a panel is placed with in arms
length of the beater a most serious accident could occurs. Pad locks or other locking
arrangements for these panels with the key hold by a responsible person is not a reliable
method of ensuring that the panel is always closed when the machine is in motion.
Similarly securing the panel is place by bots or wing nuts ha proved unreliable as the
incidence of accident has shown. The only safe guard is to position the opening beyond
forms length from the beaters. Vision panels should also be placed in a similar position.
Opening which permit access to the beater should be blanked off. Eq. with
soldered or riveted panels.
On some machines access to the beater is also possible though openings in the
side frame work. Covers over such openings should be secured in position unless access
to the beater is prevented by grid bars.

LAP ROLLERS:-

Accidents have occurred at the lap end when a new lap is being started. On
manually doffed machines the operative must truck the fibre lap around the slip roller. A
trap is crated between the slip roller and the revolting lap rollers. No injury is linked to

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result until the racks are lowered and pressured is exerted on the slip roller. An
interlocking lap guard should be filleted which will prevent access to this traps ones
pressure has been applied.
BASIC PRINCIPLES

INTRODUCTION

Around 30% of the total number of accidents in our country are due to moving
machinery, and they are avoidable by hashing properly designed, well placed and rigidly
anchored machine guarding. The textile industry accounts for a longer percentage of
accidents due to moving machinery. Accidents due to moving machinery are move
beavers and also results at time in death and permanent, total and petal disablement.

Where guards are need?

1. Where it is likely or remotely possible for any person present in the factory to
come in contact with any moving part of the machinery.

2. In order to prevent particles or broken parts of any machinery flying and injuring
any person present in the factory. The guards are needed for the following
machinery parts.

a. Transmission machinery.

b. Moving parts of the machinery 4.

c. Point s of operation hazards. The statutory requirements of guarding
provision incorporated under section 21 of factories Act and schedule I of
Rule 57 of Maharashtra Factory Rules for textile industry.
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Specifications of guards:-

a. Guards should form as part of machine.

b. Guards must protect not only the operator but also others who work in the
environment or engage in inspection, supervision and also who attend to machines
occasionally for repair oiling and those who come for supplying raw materials for
removing finished parts from the and around the machine.

c. To remove the efficiency of operations.

d. Guards should be fool proof.

e. Design of guards should provide case of carrying out repairs oiling etc.

f. Secured anchorage should be ensured.

g. Guards should not themselves be cause for accidents. should cover up the
statutory requirements envisaged under the factories Act and provision.

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Opening in machine guards:

a. Reasons for providing opening in machine guards :

· For entrance to the materials to be processed and/or taking out the
processed materials (ex. power press).

· For allowing the operators to the job during process at the point of
operation (ex. Power Press).

· For allowing the operators to the job during process at the point of
operation (ex. Sheering Cropper).

· For greasing and oiling (ex. gears of looms).

· For carrying out repairs and alterations of minor nature (ex. General).

b. Maximum longer size opening in fixed guard relationship permissible guard
opening to distance of guards from the (sheer) points should be in accordance
with the accepted standards.

c. General code of practice for machine guards.

d. General code of practice for machine guarding is at present provided in our
country. This code specified the basic requirements with regard to machinery,
guards and also safe design of machines. It is expeclient to note that
machinery which can not be guarded, sealed in accordance with legal
requirement while remaining commercially practicable or mechanically useful
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should be no longer be used. Should also be burns in mind that absence from
injury from operating a machine is no proof that the machine is safe for
operation?.

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Chapter 7:
Major Accidents in Textile Industry

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ACCIDENTS IN SPINNING PREPARATORY
AND SPINNING PROCESS

An examination of the major causes of accidents by central labour institute
revealed that in terms of unsafe physical conditions are an unsafe act in 60.5% of the
accidents are caused. Again unsafe physical conditions including systems of work were
found to be the cause in as large as 60.5% of these accidents. This indicates the
considerable scope for improvement of the mechanical or physical conditions as a sure
method of prevention of accidents in which unsafe conditions were the major cause. The
major cause by the following two types of unsafe conditions:

i) Defective condition in agency --> 55.6% Hazardous
arrangement, procedures.
ii) Method, inherent hazard in the job, etc. --> 29.2%

This highlight that it is necessary to give weightage in accidents prevention
programmes to introduce and sustains adequate systems to have-

(i) Proper maintenance of machinery equipment and tools.

(ii) The method of work properly studies, to detect the hazards involved and to
introduce appropriate measure to control the risk of accidents in various
operation.

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MAJOR CAUSES OF ACCIDENTS AN CONTROL MEASURES

1. Opening and Blow-Room Machinery – The transmission machinery
accidents due to not guarding and due to lack of sufficient care on the
part of the employees were found responsible. Mounting of the belts
by responsible trained persons instead of leaving it to mazdoor will go
a long way in mitigating such accidents. The tendency of the part of a
jobber or a fitter to entrust the work of mounting of belts to the
mazdoor if controlled by regulatory means can help immensely. The
requirement of interlocked guard for beater cover and cylinder doors
and diagonal grids bard for dust chamber opening giving access to the
grid bars are covered under the statutory requirements in schedule I of
Rule 57. It is found that the feed rollers could be also covered by
extending the beater covers by which many accidents on scotches and
openers can be mitigated. so the inspection of the existing guards and
modifying and ensuring adequate maintenance is one area which
requires management’s attention.. It is also observed that in some
cases the workers meet with accidents because the beater’s had not
come to rest and in some other cases the operations were carried on
without taking the primary step of switching off the machines. The
management have a statutory responsibility and it is essential that the
supervisors remain alert to this problem. It is also seen that due to lack
of suitable means of access to locations and height wears certain jobs
are to be performed, workers falling.

2. CARDING MACHINES- The transmission machinery of the cards require
adequate guarding to world off accidents. Here also amounting or dismounting
belts or ropes is one area sheer accidents do take place. The employees are to be
clearly told that cleaning operations of transmission machinery without switching
of the power should not be resorted. The absence of adequate guards an
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transmission machinery parts constitutes and illegal act and adequate attention has
to be taken. cylinder’s licker in and doffer together are responsible of good
number of accidents. The accidents can prove very serious when the hands come
in contact with wire clotting of the cylinder. Provision of guards for licker-in rolls
of the cards from the front and from the sides similarly for doffer cylinders and
also for the under casing part cylinder is an important requirement to mitigate
accidents.

3. ROVING GRAMES – Bobbins fall while placing them on or removing them
from the creel too. They are responsible for a good number of accidents. A miss-
match between the m/c and the employees on work is a matter which requires
tidies and corrections. Many cases were reported where creel top was too high for
the employees to reach it easily it was also reported that there is no suitable means
of access to reach creel top. So resorting of unsafe means of placing and taking
out bobbins on and from creel top results in accidents. It is recommended to
provide suitable foot boards and hand holds on the frames. At least the
managements can ensure that not more than one row of bobbins be stacked on the
creel top. The accidents due to workers is coming in contact with moving flyers
while employees were attending to different operations is not ruled out, as
operations such as cleaning fluff in close proximity is invariably attempted
without stopping the machines.

4. RING FRAMES – it was observed during the study that about 50% of the
accidents were due to damaged metallic shield of bobbins judicious selections and
adoption of the control measures by way of frequents inspection and rejection of
bobbins with plastic ones and used of knee brakes are some of the safe approaches
which can prevent accidents. While going out piecing work it is necessary to stop
the metallic bobbin and to lift them up since the age old practice of the workers is
to achieve both the elements of these operations in one action. By stopping the
bobbin at the shield and lifting them simultaneously many accidents are caused. If
a new worker could be trained and allowed to form a habit of carrying out these

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two elements of operations rather safely by stopping the bobbin from the top and
lifting it from the bottom many of the accidents would be controlled. It is also
observed that there is no care taken to identify the bobbin which has caused the
accident. It is a good proactive and an essential one top to remove those bobbing
causing the accidents and examining them and thereby can be ensured that the
same bobbin is not responsible for more than one accident. A good number of
accidents on ring frames are found caused due to fall of rollers or being hit against
or caught between various parts of the frames while attending to different types of
operations. The mechanism holding the rollers should be studied and the
mechanical defects should be rectified to prevent such accidents. A proper layout
the machine will also go a long way in mitigating such accidents. In ring frames
also the fall of bobbins from creel top has caused a good no. of accidents and the
same control measures suggested above for roving frames could b adopted. The
ring traveller hitting the eye and hitting the other parts of the body is another
cause of accidents. It also occurs while removing the traveller. Use of good
quality traveller, feeding them properly and introducing an effective system of
periodical replacement after determining the periodicity would minimize the
chances of travellers flying it is never found that the persons replacing travellers
wear goggles. How for it is practical is a matter for study?

5. MATERIAL HANDLING – 50% of these accidents are invariably occurred
while handling the cans and skips. The accidents due to protruding portions of
damaged cans and skips, bring out clearly the need for introduction of an effective
system of inspection and maintenance of these containers. I would like to emphasize
here that care be taken in handing of materials, particularly heavy things like bales,
machinery parts and loaded cans and skips.

6. WORKING CONDITIONS – objects such as nails, hoop iron, metal pieces, ring
travellers, glass, pieces, bobbins, cans, and skips, machinery and machinery parts,

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lying about on the floor and damaged on slippery7 conditions of the floor area
found to be the caused of accidents, the working space around machinery and
fixtures in and around textile machineries generally being already limited, it is
very important that safe movement of men and materials are not hampered by bad
house keeping, since workers normally work bore footed or with unsuitable type
of floor wear, the need for maintaining a high level of house keeping is all the
more relevant. The emphasis on controlling physical conditions and method of
work are essential means for achieving freedom from accidents. The hazards in
the job are required to be removed and behaviour of persons although difficult to
achieve requires some control. By and for the best method is to control the
physical conditions. It is an obvious truth that in the absence of safe procedures of
work for the various tasks to ensure that the employees confirm to them through
training and education and motivation accidents continue to occur to employees.
Although existing textile mills are not planned adequately, still substantial
accident reductions is possible if there is a will on the part of the management and
supervisors and workers.

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SOME OF THE RECOMMENDED SAFE PRACTICES

1. Belt and pulley primary drives to all machine shall be efficiently guarded except.

a. Those that are in such position to be equally safe as if so guarded.

b. Flat belts less than 50 mm (2”) wide are.

2. Gearing shall be completely encased except –

a. That which is in such a position as to be equally safe as if so encased.

b. Gearing on machinery constructed before 1st july 1984 that is efficiently
guarded.
c. Projection on accessible revolving parts shall sunk or efficiently guarded for
the two cylinder sizing machines. Efficient guarding shall be provided to
prevent access to the trap between the cylinders unless the distance between
the periphery of the smaller and larger cylinders i.e. greater than 150 mm. the
traps between the rollers of the hand stock shall be efficiently guarded. Such
guarding shall be either permanently fixed in position or be so interlocked that
the power supply to the machine is interrupted whenever the guard is opened
and the machine can not be set in motion until the guard is closed.

c. Across the beaming and of the machine readily accessible position there shall
be a device which when operated ensures that the power supply to the
machine is interrupted.

4. Each new or second hand cylinders, and any cylinder to which repairs which may

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effect its safety have been carried out, shall be hydraulically tested before use to
at least one and half times its working pressure.

a. Each cylinder shall be clearly marked with its safe working pressure.

b. A machine shall be fitted with –

• Suitable reducing valve or other sensible means to prevent that safe working
pressure being exceeded.
• A suitable safety valve of type which cannot be tempered with, and which is
large enough to limit the pressure in cylinders to not more than 10% above the
safe working pressure, even in the case of reducing valve failure.
• The safety valve and pressure gauge shall be fitted between the cylinders and
the reducing valve and all the fitting shall be maintained in efficient working
order.
• The cylinder shall be thoroughly examined by a approved come person at least
once in every period of two years and the vessels and fittings externally once
in during a period of six month.
• No person shall clean or lubricate any machinery if in the process of cleaning
or lubricating the worker would be exposed to risk injury from any moving
part of any machinery .The access to work places shall be –

a. Kept in good repair and free from loose article and accumulation of dirt or
size, sand or other suitable material shall be provided, used to prevent floors
becoming skippering.

b. Every effort shall be made to promote good house keeping.

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c. Ladders shall not be used unless it has a level and firm footing and is secured
near its upper resting place or another persons is poisoned at the base to
prevent its displacement.

d. Ladders and step ladders shall be examined by responsible person and in three
months. Any defects observed shall be immediately ratified. Suitable
provision shall be mode for the storage of ladders and step ladders.

f. Person working shall wear close fitting appeared and be made free of rings and
bracelets. The employees involved in transportation of material and plat be
advised to wear safely foot wearer.

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TYPES OF GUARDS

1. FIXED GUARDS – This is the best and primary method of attaining
secure fencing and should be proffered unless it is impractical under the
obtaining circumstances. They should be so provided that the danger point
would become inaccessible except when the guard is totally removed. Not
only should it be in accessible in the normal operation of the machine, but
it should be impossible for the operator or any other person how so ever be
may try to reach the danger point it is usual to provide fixed guards for
fencing transmission machinery but even on working machinery at the
point of operation, it is possible to provide fixed guards, with suitable
openings to allow the work to pass through, on power presses, a variety of
fixed guards such as the ordinary, direct feed, sliding feed etc can be fitted
and yet the work could not be hered. In conjunction with automatic or
semi-automatic feeding devices, fixed guards become all the more useful.

2. INTERLOCK FIXED GUARDS – This guard should be used on
machines as the first alternative. If a fixed guard can not be used. At the
point of operation on such machines as power presses, it is possible to
provide a gate opening which can be placed in front of the danger zone,
the remaining portions at the front and the 2 sides completely being
protected by fixed guards. The gate should be so interlocked with the press
control mechanism (Latch and key) that when it is open, it would not be
possible for the worker to dress the operating lever of the power press.
This would ensure that before the punch or machine is set in motion, the
worker has to removes his hand from the danger zone. Such interlocked
fixed guards are mainly used on power presses, textile machinery, dough
mixers, centrifugal machinery etc. the interlocking system may be either
mechanical or electrical or a combination of both. Hydraulic or pneumatic
systems used to operate certain types of machinery including power
presses may be employed for interlocking guards as well. In such cases,

however, the guards have to be carefully designed to ensure safety.

3. AUTOMATIC GUARDS – This type of guard should only be used
where neither fixed nor are interlocking guards possible and practicable to
safeguard a particular danger area. Automatic guards should operate to
remove any party of person exposed to danger to a position of safety.
These guards should function independently of the operator. These guards
are those where operators hands are automatically swift away before the
danger zone classes in such as between the die and punch of a power press
or to feed paper in a plate printing machine however, such sweep away
guards have a limited use particularly an account of the time lag involved.

4. TRIP GUARDS – Trip guars should be so arranged that an approach
by a person beyond a safe limit causes the guards to more and the
machinery to stop and / or reverse its motion before any part of the person
can reach the dangerous part. It is possible to protect some danger zones as
in rubber mixing mills, by providing such a tripping device. Trips between
rolls on rubber ear lender machine can also be so guarded. Another
example is to stop a conveyer system by this trip guard. The effective
performance of a trip guard is greatly dependent upon the stopping
characteristic of the machine, which must be controlled within defined
limits. An efficient braking system electromagnetic system is normally a
necessity. Trip guards which normally are of a mechanic nature also
include electro sensitive devices such as those complying with
photoelectric principles. Along as the ray is obstructed by the workers
hand, dangerous machine parts can not start moving the design of trip
guards of mechanical type should be such that the machinery can not again
be set in motion, unless and until the guard has been reset.

5. POSITION GUARDS – in respect of the some of the less
dangerous machines, it may be sufficient to merely provide railing

round the machines. However, such railings are going out of use for
various reasons. When such railing guards are provided, it should be
ensured that the railing in placed not more than 15” away nor less than
9” away from the moving parts to be fenced. If the distance is more
than 15”, it is possible for a worker to cross over the railing and be
close to the moving part to carry out any work this must be avoided.
The above figures are for general guidance only where as the correct
distances are determined by the tables discussed here after under this
paragraph.

GENERAL REQUIREMENTS OF STANDARD GUARD

Guards should be designed, constructed and used that –
1. Provide positive protection.

2. Prevent access to the danger zone during operations.

3. Cause the operator no discomfort or inconvenience.

4. Not interfere with efficient operation of the machine.

5. Be suitable for the job and the machine.

6. Not weaken the structure of the machine.

7. Preferably constitutes a built in features.

8. Provide for machine oiling, inspection, adjustment & repairs.

9. Be constructed strongly enough to resist normal wear & shock.

10. Operate automatically or with minimum effort.

11. With stand long use with minimum maintenance.

12. Not constitute a hazard by themselves such as splinter, pinch points,
shearing points, sharp corners, rough edges, or other sources, of
injuries and.

13. Protect against unforeseen operational contingencies, not merely

against normally expected hazards.

ACCIDENT IN FINISHING AND CERTAIN OTHER
DEPARTMENT

1. GENERAL – In nearly 54% of the accidents in the above mentioned
departments, the predominant cause for these Incidents was unsafe
physical or mechanical conditions. The principle unsafe conditions
responsible for accidents were hazardous work methods and arrangements,
defective conditions of “agencies” arising out of poor maintenance,
unguarded dangerous parts of machinery and failure to provide personal
protective equipments. The predominant unsafe actions responsible for
accidents were in the nature of unsafely performing the given tasks either
b/c of lack of knowledge on the safe methods of doing a job or because of
failure to follow the well known safe practices. Next in importance was
the practice of using equipment unsafely or using unsafe equipment. In
terms of major “agencies” contributing the accidents, “machinery”.
“materials handled” and “transport equipments” an account of 63% of the
total. The specific remedial measures for control of different types of
accidents are enumerated against each agency as follows. The methods for
control of the different accidents involving unsafe actions of persons being
common namely, safety education, training, motivation & supervision,
these are not necessary to be repeated under each agency.

2. TEXTILE PROCESSING MACHINERY –

a. The in running nips between rollers in all machinery, unless the nips are inaccessible,
should be securely guarded with nip guards.

b. In driers and similar machines where there is risk of access from the sides to nips
referred to in titan (a) and also driving gears, side guards should be provided to
prevent such access.

c. Other dangerous machinery parts such as betls, pulleys. Shafts, gears and flappers
should be guarded.

d. Removing crease from the cloth on rollers should never be done when machines are in
motion.

e. Operations like greasing or oiling which are required to be carried out in the close
proximity of dangerous parts of the machine should not be attempted with the
machine running.

f. Threading of tapes or fixing of lapping on cylinders should not be carried out while
the rollers are in motion, the Motions which marry be necessary should be provided
either manually or by provision of inching arrangement.
g. Such as face shields ro goggles, hand gloves, aprons and gum boots.

c. Wherever persons have to reach and work parts of machines situated at heights,
suitable means of access in the form of catwalks and platforms should be provided.
Where these are not provided due to infrequency of the Operations or any other
reason, alternate arrangement such as scaffolding should be provided and the
operations carried out confirming to standard safe practices.
d. Dismantling and fitting of heavy parts of machinery should be done with care. To the
extent possible, mechanical handling devices should be used or the purpose.

3. METAL WORKING MACHINERY -

a. Grinding machine must be equipped with well designed tool rest which should be
adjusted properly. The wheels on these machines must be effectively guarded.

b. Persons operating metal working machinery must be provided a safety goggles. Their
use should be ensured by continuous education and supervision.

4. TRANSMISSION MACHINERY – All mechanical power transmission parts such as
belts, pulleys & shaft must be securely fenced to prevent access to them.

5. MATERIAL HANDLED

a. Safe methods of storing and transporting the many types of materials such as beams,
cloth rolls and other materials must be established and it would be ensured that these
are followed scrupulously.

b. Mechanical handling devices must be provided for handling heavy objects. If this is
not possible, additional assistance must be afford for manually heavy jobs.

6. HAND TRUCKS –

a. Wheels of hand trucks should be well with in the base. Also the design preferably
should provide some tye of cladding to prevent access of the fest to the wheels.

b. Trucks should be maintained in good conditions.

c. Handler of truck should be equipped with knuckle guards wherever considering the
type of handle and the method of operation, there is possibility of accidents due to

hand sticking against objects.

7. WORKING ENVIRONMENT –

Areas around machines and floors in general should be kept dry and non-slippery by
measures such as preventing splashes, provide proper drainage near machines and
promptly mapping up unintended spillages.

a. Work areas and passage should be kept clear to facilitate safe and efficient movement
of men and materials. All openings in the floors such as pits and trenches should be
kept covered with suitable covers which should be flush with the surface.

b. All pipe lines and valves should be inspected frequently and maintained in good
conditions.

c. Safe procedures should be laid down for dismantling and assembling of equipment
including pipe lines and this procedure should be followed strictly.

d. Before persons ascend of descend ladder, the latter should be lashed properly or held
securely.

8. CHEMICALS

Frequent inspections and maintenance of plant and equipment is essential for
preventing leaks of chemicals of other possible risks.

• Liquid chemical should not be carried in open containers like buckets and mage.
Containers of suitable designs and shape with closely fitting lids should be used to
avoid the risk of splashing.

• Whenever chemicals are being handled or containers opened. Transported or emptied,

suitable personal protective equipment such as face shields or goggles’, aprons and
gums boots hold be provided and their use ensured.

• Pipe lines should be marked by appropriate colour coding to avoid risk of accidents
du to mistaking the contents for another.

• There should be a proper system of warning persons before any operation which
without such snaring is likely to be source of danger to other is carried on.
• Concentration of chemicals in the work environment should be maintained well
within the permissible limits through adoption of appropriate control techniques.

9. HAND TOOLS –

a. Most of the accident due to hand tools being caused by unsafe actions it is essential to
educate employees on the safe practices and correct methods of performing jobs.

b. While using knives, hands and other parts of the body should be kept out of the path
of out and the likely sweep of the knife at the end of the cut.

c. Hand tools should be properly maintained. They should also be checked before use.

d. While using screw driven, the practice of keeping the job in the palm is unsafe and
should be avoided. Further, the method of work should be such that even if the tool
slips, hands of singers should not be in the direction of the tool.

10. MISCELANEOUS
• Many cylinders, rollers and vessels operate with stream under pressure. The usual
safety measures under such conditions comprising the provision of safety and relief
valves, thorough examination and pressure testing of the vessels periodically, laying
down proper procedures for entry into vessels, etc. must be scrupulously adopted.
• Electrical equipment should be periodically inspected and tested and maintained in

Chapter 8:
SAFETY MANAGEMENT
AT
COLOURTEX ltd.

SAFETY MANAGEMENT AT COLOURTEX ltd.

ACCIDENT INVESTIGATION

INTRODUCTION

Thousands of accidents occur throughout the United States every day. The failure of people,
equipment, supplies, or surroundings to behave or react as expected causes most of the
accidents. Accident investigations determine how and why these failures occur. By using the
information gained through an investigation, a similar or perhaps more disastrous accident
may be prevented. Conduct accident investigations with accident prevention in mind.
Investigations are NOT to place blame.

An accident is any unplanned event that results in personal injury or in property damage.
When the personal injury requires little or no treatment, it is minor. If it results in a fatality or
in a permanent total, permanent partial, or temporary total (lost-time) disability, it is serious.
Similarly, property damage may be minor or serious. Investigate all accidents regardless of
the extent of injury or damage.

Accidents are part of a broad group of events that adversely affect the completion of a task.
These events are incidents. For simplicity, the procedures discussed in later sections refer
only to accidents. They are, however, also applicable to incidents.

This discussion introduces the reader to basic accident investigation procedures and describes
accident analysis techniques.

ACCIDENT PREVENTION

Accidents are usually complex. An accident may have 10 or more events that can be causes.
A detailed analysis of an accident will normally reveal three cause levels: basic, indirect, and
direct. At the lowest level, an accident results only when a person or object receives an
amount of energy or hazardous material that cannot be absorbed safely. This energy or
hazardous material is the DIRECT CAUSE of the accident. The direct cause is usually the
result of one or more unsafe acts or unsafe conditions, or both. Unsafe acts and conditions are
the INDIRECT CAUSES or symptoms. In turn, indirect causes are usually traceable to poor
management policies and decisions, or to personal or environmental factors. These are the
BASIC CAUSES.

In spite of their complexity, most accidents are preventable by eliminating one or more
causes. Accident investigations determine not only what happened, but also how and why.
The information gained from these investigations can prevent recurrence of similar or
perhaps more disastrous accidents. Accident investigators are interested in each event as well
as in the sequence of events that led to an accident. The accident type is also important to the
investigator. The recurrence of accidents of a particular type or those with common causes
shows areas needing special accident prevention emphasis.

INVESTIGATIVE PROCEDURES

The actual procedures used in a particular investigation depend on the nature and results of
the accident. The agency having jurisdiction over the location determines the administrative
procedures. In general, responsible officials will appoint an individual to be in charge of the
investigation. The investigator uses most of the following steps:

1. Define the scope of the investigation.

2. Select the investigators. Assign specific tasks to each (preferably in writing).

3. Present a preliminary briefing to the investigating team, including:

a. Description of the accident, with damage estimates.

b. Normal operating procedures.

c. Maps (local and general).

d. Location of the accident site.

e. List of witnesses.

f. Events that preceded the accident.

4. Visit the accident site to get updated information.

5. Inspect the accident site.

a. Secure the area. Do not disturb the scene unless a hazard exists.

b. Prepare the necessary sketches and photographs. Label each carefully and keep
accurate records.

6. Interview each victim and witness. Also interview those who were present before the
accident and those who arrived at the site shortly after the accident. Keep accurate records of
each interview. Use a tape recorder if desired and if approved.

7. Determine

a. What was not normal before the accident.

b. Where the abnormality occurred.

c. When it was first noted.

d. How it occurred.

8. Analyze the data obtained in step 7. Repeat any of the prior steps, if necessary.

9. Determine

a. Why the accident occurred.

b. A likely sequence of events and probable causes (direct, indirect, basic).

c. Alternative sequences.

10. Check each sequence against the data from step 7.

11. Determine the most likely sequence of events and the most probable causes.

12. Conduct a post-investigation briefing.

13. Prepare a summary report, including the recommended actions to prevent a recurrence.
Distribute the report according to applicable instructions.

An investigation is not complete until all data are analyzed and a final report is completed. In
practice, the investigative work, data analysis, and report preparation proceed simultaneously
over much of the time spent on the investigation.

FACT-FINDING

Gather evidence from many sources during an investigation. Get information from witnesses
and reports as well as by observation. Interview witnesses as soon as possible after an
accident. Inspect the accident site before any changes occur. Take photographs and make
sketches of the accident scene. Record all pertinent data on maps. Get copies of all reports.
Documents containing normal operating procedures, flow diagrams, maintenance charts, or
reports of difficulties or abnormalities are particularly useful. Keep complete and accurate
notes in a bound notebook. Record pre-accident conditions, the accident sequence, and post-
accident conditions. In addition, document the location of victims, witnesses, machinery,
energy sources, and hazardous materials.

In some investigations, a particular physical or chemical law, principle, or property may
explain a sequence of events. Include laws in the notes taken during the investigation or in
the later analysis of data. In addition, gather data during the investigation that may lend itself
to analysis by these laws, principles, or properties. An appendix in the final report can include
an extended discussion.

INTERVIEWS

In general, experienced personnel should conduct interviews. If possible, the team assigned to
this task should include an individual with a legal background. In conducting interviews, the
team should:

1. Appoint a speaker for the group.

2. Get preliminary statements as soon as possible from all witnesses.

3. Locate the position of each witness on a master chart (including the direction of view).

4. Arrange for a convenient time and place to talk to each witness.

5. Explain the purpose of the investigation (accident prevention) and put each witness at ease.

6. Listen, let each witness speak freely, and be courteous and considerate.

7. Take notes without distracting the witness. Use a tape recorder only with consent of the
witness.

8. Use sketches and diagrams to help the witness.

9. Emphasize areas of direct observation. Label hearsay accordingly.

10. Be sincere and do not argue with the witness.

11. Record the exact words used by the witness to describe each observation. Do not "put
words into a witness' mouth."

12. Word each question carefully and be sure the witness understands.

13. Identify the qualifications of each witness (name, address, occupation, years of
experience, etc.).

14. Supply each witness with a copy of his or her statements. Signed statements are desirable.

After interviewing all witnesses, the team should analyze each witness' statement. They may
wish to re-interview one or more witnesses to confirm or clarify key points. While there may
be inconsistencies in witnesses' statements, investigators should assemble the available
testimony into a logical order. Analyze this information along with data from the accident
site.

Not all people react in the same manner to a particular stimulus. For example, a witness
within close proximity to the accident may have an entirely different story from one who saw

it at a distance. Some witnesses may also change their stories after they have discussed it with
others. The reason for the change may be additional clues.

A witness who has had a traumatic experience may not be able to recall the details of the
accident. A witness who has a vested interest in the results of the investigation may offer
biased testimony. Finally, eyesight, hearing, reaction time, and the general condition of each
witness may affect his or her powers of observation. A witness may omit entire sequences
because of a failure to observe them or because their importance was not realized.

PROBLEM SOLVING TECHNIQUES

Accidents represent problems that must be solved through investigations. Several formal
procedures solve problems of any degree of complexity. This section discusses two of the
most common procedures: Change Analysis and Job Safety Analysis.

CHANGE ANALYSIS

As its name implies, this technique emphasizes change. To solve a problem, an investigator
must look for deviations from the norm. Consider all problems to result from some
unanticipated change. Make an analysis of the change to determine its causes. Use the
following steps in this method:

1. Define the problem (What happened?).

2. Establish the norm (What should have happened?).

3. Identify, locate, and describe the change (What, where, when, to what extent).

4. Specify what was and what was not affected.

5. Identify the distinctive features of the change.

6. List the possible causes.

7. Select the most likely causes.

Job Safety Analysis

Job safety analysis (JSA) is part of many existing accident prevention programs. In general,
JSA breaks a job into basic steps, and identifies the hazards associated with each step. The
JSA also prescribes controls for each hazard. A JSA is a chart listing these steps, hazards, and
controls. Review the JSA during the investigation if a JSA has been conducted for the job
involved in an accident. Perform a JSA if one is not available. Perform a JSA as a part of the
investigation to determine the events and conditions that led to the accident.

REPORT OF INVESTIGATION

As noted earlier, an accident investigation is not complete until a report is prepared and
submitted to proper authorities. Special report forms are available in many cases. Other
instances may require a more extended report. Such reports are often very elaborate and may
include a cover page, a title page, an abstract, a table of contents, a commentary or narrative
portion, a discussion of probable causes, and a section on conclusions and recommendations.

The following outline has been found especially useful in developing the information to be
included in the formal report:

1. Background Information

a. Where and when the accident occurred

b. Who and what were involved

c. Operating personnel and other witnesses

2. Account of the Accident (What happened?)

a. Sequence of events

b. Extent of damage

c. Accident type

d. Agency or source (of energy or hazardous material)

3. Discussion (Analysis of the Accident - HOW; WHY)

a. Direct causes (energy sources; hazardous materials)

b. Indirect causes (unsafe acts and conditions)

c. Basic causes (management policies; personal or environmental factors)

4. Recommendations (to prevent a recurrence) for immediate and long-range action to
remedy:

a. Basic causes

b. Indirect causes

c. Direct causes (such as reduced quantities or protective equipment or structures)

Chapter 9:
How to Maintain Industrial Safety?

How to Maintain Industrial Safety
Industrial safety regulations are designated by the Federal Occupational Safety and Hazard
Administration (OSHA) to reduce the risks of industrial injuries and harm to employees in
whatever their workplace situation or occupation is. These industrial safety regulations
largely depend on the specific industry, based on the equipment used, job location,
procedures and operations undertaken and other potential risks attached. However, industrial
safety can be maintained through these general tips that could encompass different
occupations:

• Always be careful when handling industrial supplies. When you're in a highly
specialized, technical occupation, you'd most likely be regularly handling
equipment that would cause severe injury and harm when used improperly. Invest
some time in undergoing the proper training to get to know how to handle this
equipment, and have someone supervise your handling methods until you are one
hundred percent prepared and comfortable in operating such equipment.

• Adhere to work safety standards. Always be aware of ongoing policies,
processes and prescribed solutions, and adhere to them. Don't be tempted to do
shortcuts on your job, as your actions could have tremendous negative
reverberations not just on your part, but on many other people as well. Work
safety standards could be as simple as donning your hard hat, wearing protective
gloves and eye shields, having a fall protection kit, and having a good stock of
safety supply that is pertinent to your occupation - yes, no matter how long you've
been working or how good you are already at your job.

• Respect regulated barriers. Stick within your job locations and avoid going to
places that your job doesn't require you to go to. Some locations may require you
to take special measures, such as gearing up with safety suits to avoid toxic and
radioactive substances or infectious diseases, before you are allowed to gain entry.

• Have your equipment consistently monitored and inspected. All equipment
should be regularly checked for safety and efficiency since any damage they may
have could lead to injury or even death. If you're in the cargo transport industry,
for example, straps and chains (every single link) that attach heavy-duty loads to
trucks should be inspected for cuts, scrapes or wear and tear; you could just

imagine what could happen if these damages, no matter how small, are left
unnoticed and allowed to worsen over use. Other conditions should regularly be
inspected, such as the air composition (whether toxic fumes or vapors are being
leaked out from equipment), patterns of accidents (whether particular systems,
procedures or equipment regularly cause injuries, and how to eliminate them) and
whether the workers' tools and equipment are ergonomically correct.

• Take time to read safety posters. Safety posters put up around your workplace
are there for a reason: to help you lower your risk from injuries and harm. Safety
poster topics could include what to do in case of an emergency, how to avoid the
injuries that commonly occur within your workplace, and other announcements
that would definitely help you avoid risk and injury.

• Attend safety programs and trainings. Some employees may brush off safety
programs and trainings as a waste of their time; however, they serve to update you
on current job safety regulations that you may not know of yet. Since employees
have a tendency to get lax in safety measure adherence over time, it's also good to
subject yourself to regular wake-up calls to remind you to on how to protect your
safety in the job.

• Remember, your health and well-being are your best allies in your capacity as a wage
earner, and it pays to make sure you keep yourself safe and unharmed at all times.
Undertaking these measures can sometimes prove to be tiresome for you, but then
again one day they just might save your life.

My Learning:

• Practical knowledge of Safety management System.

• Safety management is a key part of any manufacturing unit

• Safety is a Tool of Motivation.

• It is an indicator of company’s HR policy and its image.

Bibliography:
• Colourtex ltd (Visit)

• http://en.wikipedia.org/wiki/Process_Safety_Management

• www.bis.org.in/forms/ohsms.html

• http://www.aerb.gov.in/T/sj/book/chapter10.pdf

• www.npcil.nic.in/pdf/Endowment%20lecture%20by
%20CMD-1.pdf

• Book- Risk assessment and process safety management

By Ian Sutton

Comprehensive project

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