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APEX SAFETY COMMITTEE21-05-2012

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ASSESSMENT OF TRF SAFETY ON DUPONT PHILOSHPHY BY TATA STEEL

Scale : 5- World Class, 4- Excellence, 3-Skills, 2- Awareness, 1- Fundamental, 0-Basic Instinct

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SAFETY EXCELLENCE JOURNEY: METHODOLOGY

Formation of Safety Organization SHE Policy & Principle Safety Objectives & Targets

Methodology

Beginning

Quick Start

Short Term

Long Term

Feedback Incorporation

Technology

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Safety Pause before starting of Business Meeting

Implementation of No Smoking Zone Holding Hand Rails Use of Car Seat Belt Use of Crash Helmet for two wheelers

riders Inclusion of Safety in individual KRA’s

Methodology

Beginning

Quick Start

Short Term

Long Term


Technology

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Training All officers All workers All contractors and their employees

Launch Safety Observation Process for Works Officers

Contractors Site Severity Audit at Project Site 100% usage of PPE Developing guidelines for SOPs Developing process for implementing rules

and procedures Mapping of KPIs and review mechanism Release of Safety Management System

Manual

Methodology

Beginning

Quick Start

Short Term

Long Term


Technology

6


Training Employees on Safety Standards Officers on Incidence Reporting and

Analysis All concern employees on SOPs Impart training on Skill Gap identified in

Safety Organizing Special Campaigns for

identifying and recording NEAR MISSES Developing SOPs for all activities Implement Six Step Contract Management

at Project Site

Methodology

Beginning

Quick Start

Short Term

Long Term


Technology

7


Safer Work Environment Establish Positive Isolation System Train Workers on Safety

observation Process Train Contractors’ Supervisors on

Site Severity Audit

Include Benchmark Safety Goal (LTIFR 0.4 by 2012) in Annual Business Plan

Analysis of data and adjust feedback for Safe and Healthy work environment

Methodology

Beginning

Quick Start

Short Term

Long Term

Safe Work Environment &


Technology

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SAFETY@ TECHNOLOGY

Methodology

Beginning

Quick Start

Short Term

Long Term


Technology

Minimizing Potential Hazards through technology Development of Universal Insitu Machine Design / Modifying manufacturing

process Machining by Insitu machine at

fabrication location

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SAFETY POLICY & PRICIPLES

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SAFETY POLICY & PRICIPLES

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INTEGRATED SAFETY ORGANISATION

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Apex Safety CommitteeApex Safety CommitteeChaired by MDChaired by MD

Apex Safety Sub Committee for Rules & Procedures

for BMHE(N K SINGH)


for BMHS(H S PRASAD)


for P & Y(T BANDOPADHAYA)

Area Implementation CommitteeFor BMHE

(DIWAKAR JHA)

Area Implementation CommitteeFor BMHS

(RANJIT SANYAL)

Area Implementation Committee For P & Y

(GAUTAM DUTTA)

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SUPPORTIVE SAFETY PERSONNEL

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• Induction of experienced Safety Consultant

• 2 Safety Officers at TRF Works

• 29 Safety Stewards on Shop floor in three shifts

• 1 Safety Officer per site

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DEMONSTRATED MANAGEMENT COMMITTMENT

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• Safety Visit by Senior Executive on Shop Floor with line officers

• Site Safety Visit on regular interval

• Teleconferencing with site officers for safety issues

• Meeting with shopfloor supervisors on safety issues

• Entry of contractor employees after issue of Safety Induction Card

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Safety as a line organisation responsiblity

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• Safety observations for finding out the Safe / Unsafe Act and Condition

• Reporting near miss, incidences, Dangerous occurrence, Accidents

• Conducting PIR (Preliminary Investigation Report)

• Maintaining house keeping in their respective area of work

• Imparting training to concerned employees on SOP to relevant area of work

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EFFECTIVE COMMUNICATION

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• Mass meetings on regular interval

• Mass meetings in residential colony, Schools

• Special monthly Campaign on different topics like –

• Safe Loading & unloading of materials

• How to protect fingers from injury

• How to operate Mobile Cranes safely

• Safe Driving

• Display boards, Convergence, Joint Council, Weekly Safety meetings, Safety Audits etc.

• Confession / Communication through injured person in different forum

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CHALLENGING GOALS & PLANS

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• Zero Loss Time Accidents

• Hazard Identification & Risk Analysis of all activities and develop OCP/SOP

for mitigating Risks

• Recording and Root Cause Analysis for all incidences

• Monitoring of Occupational Health and Environment as per standard

• Development of model site for Safety Excellence

• Monitoring and Maintaining of relevant Statutory Requirements

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Safety Training & Development

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BMHE/BMHG OFFICERS – OBSERVATION PROCESSBMHS/P&YE OFFICERS – SIX STEP CONTRACT MANAGEMENT PROCESSWORKERS (TRF+CONTRACTORS) – SAFETY AWARENESS, PROCESS SAFETY & SOP TRAINING

270340

750 750

196 166

750

650

Officerson

Observation Process

Officerson

Six Step Contract Management

Workmenon

General Safety

Workmenon

Relevant SOP's

Num

ber

SAFETY TRAINING

TRAINING IDENTIFIED TRAINING IMPARTED

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Safety Observation & Reevaluation

8097

17%920

83%4414

28%765

72%1998

0

2000

4000

6000

8000

10000

Observations Safe Act Unsafe Act Safe Condition Unsafe Condition

Num

ber

SAFETY OBSERVATION 2010-2011

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6232

31% 1268

69%2865

34%717

66%1382

0

2000

4000

6000

8000

Observations Safe Act Unsafe Act Safe Condition Unsafe Condition

Num

ber

SAFETY OBSERVATION 2011-2012

20


17

83

28

72

31

69

34

66

0

25

50

75

100

Safe Act Unsafe Act Safe Condition Unsafe Condition

PER

CEN

TAG

E

SAFETY OBSERVATION TREND - SAFE/UNSAFE ACT/CONDITION

2010-2011 2011-2012

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Injury & Incident Investigation

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• Format developed in consultation with Tata Steel, Safety Department

• Training completed to all Officers

• Root cause analysis and corrective / preventive action for all incidences

• All injury & incident analysis discussed in weekly safety meeting under the

chairmanship of VP(PB)

• Injury and incident is being communicated through mass meetings

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TRANSPORT SAFETY

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• SOP prepared and released for implementation

• Training imparted to all concerned

• Traffic control inside TRF & vehicle parking rule implemented

• All vehicles are checked at the entry level for compliance of safety requirements as per

SOP

• Ensure safe loading and unloading of materials at the point of operation

• Ensured safety compliance for ODC consignment

• Safety check before releasing of vehicle from TRF

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PROGRESSIVE MOTIVATION

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• Intersection competition for best hosuekeeping

• Assessment of contractor’s on 5 point scale

• Safety slogan competition

• Zero accident gifts to all employees

• Encouraged suggestion for improvement in safety

• Safety Training in good learning atmosphere for TRF & Contractor’s workmen

• Weekly Safety committee meeting with union members

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HIGH STANDARD OF PERFORMANCE

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SL.NO.

KEY PERFORMANCE INDICATORACTUAL ACTUAL

FY 10-11 FY 11-12

1Frequency Rate – LTIFR(Bench Mark 0.4)

0 0

2 Severity Rate 0 0

3 No. of First Aid Cases 98 78

4Severity Index (Bench Mark 1.50)

2.46 2.34

5 No. of SOP (Identified - 119) to be prepared & implemented 64 30

6 Number of Near Miss /Incidences Reported, Analyzed & CAPA taken 104 56

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Training – Overall (a+b+c) 30% 100%

(a) Officers on Observation Process & Six Step Contract Management 33% 59%

(b) Workmen on Relevant SOPs 22% 87%

(c) Contractors Employees on Relevant SOPs 100% 87%

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STANDARD OPERATING PROCEDURES

5342

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119

53

2714

94

0

25

50

75

100

125

150

ASSC-BMHE ASSC-BMHS ASSC-PYE TOTAL

SOP - STANDARD OPERATING PROCEDURE

NO. OF SOP IDENTIFIED NO. OF SOP PREPARED & IMPLEMENTED

Common SOP for Sites 66 Nos.

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ABP 2012-2013

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SL.NO.

KEY PERFORMANCE INDICATORACTUAL TARGET

FY 11-12 FY 12-13

1Frequency Rate – LTIFR(Bench Mark 0.4)

0 0

2 Severity Rate 0 0

3No. of First Aid Case Reported (BMHE+BMHS+PYE+BOP+O&M)

BMHE – 78BMHS - 101

20% Reduction over last year

4Severity Index (Bench Mark 1.50)

2.34 2.00 (Retraining to all concerned)

5 No. of SOP (Identified - 119) to be prepared & implemented 30 25

6 Number of Near Miss /Incidences Reported, Analyzed & CAPA taken

BMHE - 56BMHS- 20

CAPTURE 100%

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Training – Overall (a+b+c) 100% 100%

(a) Officers on Observation Process & Six Step Contract Management 59% All officers to be covered

(b) Workmen on Relevant SOPs 87% 100%

(c) Contractors Employees on Relevant SOPs 87% 100%

8 Number of Audit at Site In place 1 Audit/Wk/Contractor covering 80 % employees

9 Safety Audit for deployment of SOP on Shopfloor Started 2 Audit/Month

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Way forward – To implement Positive Isolation

POSITIVE ISOLATION

• Training of Positive Isolation Level-1 conducted by Tata Steel for 20 People of TRF

• Energy Source identification (Electrical, Air, O2, Water)

• Air line flow diagram with gate valve completed

• Oxygen line flow diagram with gate valve completed

• Electrical energy source identification will be completed by 20th May 2012

• All displays will be completed in May 2012

• Authorization of positive isolation given on 11th May 2012

• Procurement of Isolation locks & its arrangement will be completed by Jun 2012

• Implementation & deployment of Positive Isolation by 30th Jun 2012

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• Training to all officers on Six Step Contract Management

• Training on Accident Investigation, Contractor Audit Process

• Retraining to all officers who were previously trained on Six Step Contract Management

• Site severity audit to be more focused and target is 1 Audit/Wk/Contractor covering 80% of the employees

• Training to all contract workmen on relevant SOPs

• Preparation of balance SOP and implementation

• Site audit by senior people

• Weekly reporting to AIC for analysis of data and subsequent report to ASC

• 100 % recording of first aid cases and near miss

• Special campaign for recording near miss, mass meetings, slogan competition, suggestion, prizes etc.

• MODEL SITE DEVELOPMENT – DVC RAGHUNATHPUR

Way forward – SITE SAFETY FOCUS 2012-13

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