SAFETY MANAGEMENT
Jindal Power Limited, Tamnar, Safety Dept.
Contents
Safety Ideology
Accidents, causes, factors, cost of accident.
Accident prevention.
Accident Investigation, reporting and records
Need For Safety…..
Accidents where happening in industries which lead
to Damage to property, Injuries and Loss of Life.
H.W Heinrich Father of Safety, analyzed the
accidents happening in industry arrived at following
conclusions.
1. Cost of Accident is huge and can be compared to
an iceberg. 20% cost of accidents are visible but
80% cost of accidents are unseen.
2. All accidents are caused. Hence accidents are
100% preventable.
3. Unsafe Acts are the cause of 80% Accidents and
Unsafe Conditions are the cause of 20%
Accidents.
What is Safety?
Safety can be put in simple words as Freedom
from Risk or Danger i.e. Hazard.
Hazard is anything which has the potential to
cause harm or property damage.
Risk is the probability that the hazard will result
in accident or incident.
Accident is an incident which is a series of
unplanned, unexpected events resulting in
personal injury or harm.
What is Safety?
Near Miss is an incident similar to “Just escaped
from injury” or has the potential to cause injury
which has resulted in property damage.
Heinrich Triangle
Fatal – 01 No.
Minor Injury –
29Nos.
Near Miss –
300Nos.
Types of Accidents.
First Aid Case (FAC): A First Aid Injury (FAI) is an injury that requires a single first
aid treatment and potentially a follow up visit for subsequent observation.
Such treatment and observation can be considered first aid even when
administered by a registered medical professional. First aid injury
treatments may include:
• Application of antiseptics during a first visit to medical personnel
• Treatment of minor (first degree) burns
• Application of bandages (including elastic bandages) during a first
visit to medical personnel; Irrigation of eye injuries and removal of non-
embedded objects
• Removal of foreign bodies from a wound using tweezers or other
simple first aid technique
• Use of non-prescription medication (schedule 2 or 3 medications),
and administration of a single dose of prescription medication on a first
visit to medical personnel for minor injury or discomfort
• Soaking, application of hot-cold compresses, and use of elastic
bandage on sprains immediately after injury (initial treatment only)
• Application of ointments for abrasions to prevent drying or cracking.
Types of Accidents.
• One time administration of oxygen, for example
after exposure to toxic atmosphere
• Physical examination, if no condition is identified or
medical treatment is not administered
• The conduct of diagnostic procedures such as x-
rays and blood tests with a negative diagnosis
• One time dose of prescription medication, for
example Tetanus Injection or Pharmaceutical and
• Observations of injury during visits to a registered
medical professional, including hospitalisation for
less than 48 hours.
Types of Accidents.
Medical Treatment Case (MTC) : A Medical Treatment Injury (MTI) is as an injury that
requires treatment given by a registered medical professional.
Types of treatment includes:
• Use of prescription medication (schedule 4 or 8 ‘prescription only’
medication), except a single dose administered on a first aid basis (see above)
• Therapeutic (physiotherapy or chiropractic) treatment, more than once
• Stitches, sutures (including butterfly adhesive dressing in lieu of sutures)
• Removal of dead tissue or skin (surgical debridement)
• Treatment of infection
• Application of antiseptic during a second or subsequent visit to medical
personnel
• Removal of foreign objects embedded in an eye
• Removal of foreign objects embedded in a wound (not small splinters)
• Removal of embedded objects from an eye
• Treatment of deep tissue (second or third degree) burns
• Use of hot or cold soaking therapy or heat therapy during the second or
subsequent visit to medical personnel
• Positive x-ray diagnosis of injury; and
• Admission to hospital or equivalent medical facility for treatment
Types of Accidents.
Lost Time Injury (LTI): An injury causing disablement
extending beyond the day of shift on which the
accident occurred.
Reportable Lost Time Injury (RLTI): An injury causing
death or disablement to an extent as the injured does
not report to duty within 48hrs of the time of the
incident.
Cost of Accidents – Iceberg Theory
10% Visible Cost
- Cost of Treatment.
- Property Damage
Water Surface
90% Invisible Cost
- Production Outage.
- Employee
Iceberg
Compensation.
- Family Rehabilitation
Cost.
- Insurance premium
cost.
- Loss of Morale of
Employees.
- Loss of Share Value in
Accident Causes - Hazards
Electrical Hazards
Rotating Machinery Hazards
Slip,Tip Hazards
Chemical Hazards
Fire & Explosion Hazard
Radiation Hazard
Occupational Health Hazard
Fall from Height Hazard
Asphyxiation Hazard
Accident Causes.
Accidents are caused by Unsafe Acts and Unsafe
Conditions and 2% by act of God.
Unsafe Act (80%) – An act which violates Standard
Operating Procedures, takes uncalculated risks by
violating safe procedures, rules and regulations.
Unsafe Condition (20%) – A situation like poor
housekeeping, open electrical fittings, violation of RCCB
which has the potential to cause injury.
Unsafe Act
Unsafe Act
Unsafe Condition
Unsafe Condition
Unsafe Condition
Risk Assessment
Risk Not Acceptable -
Severity of Accident
Area
ALARP
Likelihood of Occurrence
Risk Acceptable - Area
Risk Assessment
Non Tolerable Risk
Medium Risk -
ALARP
Tolerabl
e Risk
Hierarchy of Hazard Controls
Elimination
Substitution
Engineering
Risk Control
Administrat
ive Control
PPE
ALARP – As Low As Reasonably Practicable
HIRA - Procedure
Risk is a combination of the likelihood and consequence/s of a
hazardous event occurring. While assessing the risks, normal,
abnormal, and potential emergency conditions have been
considered.
The basic steps of process of risk assessment are explained as
A. Classification of Work Activities: T he Process owners shall
follows:
list out the routine and non-routine activities and gather
the following information for each work activity:
• Activities being carried out; their duration and
frequency.
• Location/s where the activity is carried out.
• Who normally carries out the said activity
• Others who may be affected by the activity (e.g.
visitors, contractors, public).
• Training that personnel have received about the
activity.
• Permit –to –work system for the job
• Size, shape, surface character of and weight of
materials that might be handled.
HIRA - Procedure
B. Identify hazards: The Process owners shall identify all
unacceptable hazards and resultant harmful effects. A walk
through inspection shall also be undertaken for effective
identification of hazards. The following three questions enable
hazard identification.
• Is there a source of harm?
• Who (or what) could be harmed?
• How could harm occur?
Broad categories of hazard that are considered include: Hazards identified
can be Physical (operational, mechanical, heat, noise, electrical, slip and
fall etc.) / Working at height and confined spaces Hot work, Chemical
(fumes, gases, spills / leaks of chemicals, mist etc.) / Biological (Bacteria,
Virus, fungi, Animals /insects: Snake / Dog / Reptile / Honey-Bee bites etc.
including contagious diseases and contamination of food ) / Electrical
HIRA- Procedure
C. Determine Risks:
Severity/Consequence of harm: The risk from the hazard is
determined by estimating the potential severity of harm and the
likelihood of that harm could occur.
• Part of the body likely to be affected
• Nature of harm ranging from physical discomfort to fatal/ total
permanent disability shall be considered
HIRA - Procedure
Likelihood /probability of harm: While establishing likelihood of
harm the adequacy of control measures already implemented and
complied with are considered. The following other factors are also
considered:
• Frequency and duration of exposure to the hazard.
• Failure of safety devices.
• Protection afforded by the personal protective equipment and
usage rate of personal protective equipment.
• Human behaviour (unintended errors or intentional violations of
procedures) by persons
• Past accidents
HIRA - Procedure
While assigning the rating for Risks, consider the probable
failures in the existing Risk Control measures or Effectiveness
of existing control measures.
Examples of failures of risk control measures are:
• Control mechanisms not working such as failure of alarms or sensors
or interlocks
• Maintenance not carried out as per schedule.
• Contractor not following Safety guidelines.
• Failure of Permit to work system.
• People not following the specified control procedures.
• People not wearing PPE or Damaged PPEs.
• PPEs not available / not provided.
• People not aware of control measures / untrained or new personnel
HIRA - Procedure
D. RISK ASSESSMENT: Risk level is determined by referring to the Risk
prioritization Matrix below:
Risk prioritization status (RPS) is assigned as follows:
RPS RPN Risk level
L 1-4 Low Risk,
M 5-15 Moderate Risk,
H 16-25 High Risk
RISK PRIORITIZATION MATRIX:
SEVERITY / CONSEQUENCE
Likelihood / Probability
Insignificant Minor Moderate Major Catastrophe
(1) (2) (3) (4) (5)
Slight Injury or Minor Injury/Health Major Injury/ Loss of Body parts, Fatality / Multiple
Health effect, Effect, Minor Health effect, Major Damage, Major fatality, Massive
Slight Damage, Damage, Minor Moderate Damage, Environment Effect, Damage, Massive
Slight Effect, Slight Environmental Moderate Major Reputation Environment Effect,
Impact effect, Minor environment Effect, Impact Massive Reputation
Reputation Effect Moderate Impact
Reputation Effect
Almost impossible[1]
(Neither can be perceived
L (1) L(2) L(3) L(4) M(5)
nor Occurred)
Unlikely [2]
(Not known to have L(2) L (4) M(6) M(8) M(10)
occurred )
Unusual / but Possible
[3]
(Not a Commonly L (3) M(6) M(9) M(12) M(15)
occurring event but
cannot be ruled out)
Quite Possible (Likely )
[4]
(Known to have occurred
or has Occurred in similar L(4) M(8) M(12) H(16) H(20)
Organizations, not in our
organization)
Almost Certain [5]
(Always known to have
M(5) M(10) M(15) H(20) H(25)
occurred while such
tasks are carried out)
HIRA - Procedure
Further all the risks which fall into moderate level of risk are assigned,
a Risk scale of Medium risk and assigned a risk control Plan of RCP2.
All the risks falling under the Medium risk category require
Process Owners to prepare the SOPs/ ensure availability of
Common procedures (CP).
For all the activities Objectives & Management Programmes (OAP)
would be taken up wherever feasible.
All risks under ‘High’ are considered as unacceptable.
All “E” Emergencies are considered as High Risks.
HIRA - Procedure
All OHS hazards associated with the following categories are
considered ‘Medium’ irrespective of risk score and assigned the risk
control plan of RCP-2. Criteria for qualitative assessment are as
follows:
LC – Legislative Concern 🡪 Hazard and risks is associated with a legal
requirement (Covered by need for by Licenses, Permits, Consents and
require specific procedures provided in the law needs to be complained.
IPC–Interested Party Concern🡪The hazard/risk concern expressed by
Employees, Neighbours, local residents and the risks may impact people
outside the boundary.
BC – Business Concerns 🡪The Hazard/risk having a potential
opportunity for eliminating a risk or would result in loss of reputation.
All emergency situations and hazards where the potential
consequence is fatality, such risk will be considered as
HIRA - Procedure
1.Risk Based Control Plans (RCP):
Categor Risk
Risk
y of Details Control
Scale
Risk Plan
LR Low ● These risks are considered acceptable. No further RCP1
risk: actions are necessary other than to ensure that
(Risk present controls are maintained.
Rating ● Manage by Routine Procedures.
1-4)
MR Medium These risks are acceptable under the following RCP2
risk: conditions:
(Risk ● Documented Operational Control Procedures,
Rating common procedures and emergency management
(5-15) plan are available to address the identified and
implemented.
● People are trained and made aware of OCPs.
● Activities carried out under Supervision where
necessary.
● Identified OH&S Parameters related to the activity
are monitored at specified intervals.
HIRA - Procedure
1.Risk Based Control Plans (RCP):
Categor Risk
Risk
y of Details Control
Scale
Risk Plan
These Risks are considered unacceptable unless the following
High risk: controls are mandatorily is in place.
HR (Risk ● Documented Operational Control Procedures (OCPs) are RCP3
Rating 16- available and implemented.
25)
● Activity should be carried out by competent persons.
● People are trained and made aware of OCPs.
● Activities should be carried out under Supervision and with
Permit to work system.
● Compliance to applicable Legal requirements should be ensured
each time before starting the activity.
Note: In the absence of above Controls, the work activity should be
halted until risk controls are implemented .If it is not possible to
reduce the risk, the work should remain prohibited.
Accident Prevention – PDCA Cycle
Plan
Act Do
Chec
k
Accident Prevention – PDCA Cycle
PLAN
• OH&S Policy
• Hazard Identification, Risk Assessment
& Risk Control
• Legal & Other Requirements
• Objectives, Targets
• OH&S Management Programme
Accident Prevention – PDCA Cycle
DO – Implementation &
Operation
• Structure & Responsibilities
• Training, Awareness & Competence
• Consultation, Communication
• Documentation
• Control of Documents
• Operational Controls
• Emergency Preparedness & Response
Accident Prevention – PDCA Cycle
CHECK
• Performance Measurement & Monitoring
• Evaluation of Compliance
• Incident Investigation
• Non Conformity Check
• Corrective & Preventive Action
• Control of Records
• Audit
Accident Prevention – PDCA Cycle
ACT
• Management Review (Continual
Improvement)
• Safety Motivation – Employee Rewards/
Awards
• Safety Benchmarking – Integrated
Safety Circle
• Safety Celebration – March 04th, Safety
Month
Accident Investigation
Accident Investigation
Collect and Organize Facts
• Physical Facts– Machinery, PPE, Spot Visit.
• Human Facts– Interview
• System Facts– Rules, SOP, MOC, Training.
Accident Investigation
Ascertain the Facts - Ask
• What happened?
• When happened?
• Where happened?
• Who went wrong?
• What went wrong?
• How it happened?
Accident Investigation
Develop Chronology
• SOE Report.
• Sequence of events.
Accident Investigation
Root Cause Analysis
• Why, Why, Why Analysis
• Define the Incident
• List The Observations
• Select an Observation to Investigate
• Hypothesize possible causes
• Check the Hypothesis
Accident Investigation
Recommend Corrective &
Preventive Actions
Safety is A Team Effort
