Working Safely with Machines
WSHC Hand Safety Forum 20th November 2014
Indirakumar Gunasekaran.,WSHO,ECO,FSM
Senior Executive
Tata Steel: A Top 15 Steel Company GloballyNatSteel is part of the Tata Steel Group
Tata Steel Europe
Asia Pacific
NatSteel across
Asia Pacific
Tata Steel ThailandTata Steel ThailandTata Steel India
Tata Steel Group
Production Capacity:
28 million MTPA
Annual Turnover:
US$26.23 billion (FY12)
Our Integrated Steelmaking Operations
Producing green steel from recycling metal waste
1. Radiation detection and
sorting of metal scrap
2. Steel production using world’s most energy efficient Electric Arc Furnace
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4. World’s largest Cut & Bend Centre producing 400k tonnes
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3. Rolling mill benchmarked against global standards
Centre producing 400k tonnes per year
5. Mesh Centre utilises state-of-the-art technology to manufacture high quality products
6. Caging Centre produces precages and bored piles according to customer needs
2003 – Certified OHSAS 18001:1999
• Converted to OHSAS18001:2007 in
2009
2006 – Certified ISO 14001:2004
2008 – Engaged DuPont as an external
consultant to embark on a rigorous
programme towards achieving our Safety
goals
• Reducing LTIF to Zero by 2018
2009 – bizSAFE Partner
Our Safety Journey Core Elements Of NatSteel’s
Safety Excellence Framework
Safety Management System
OHSAS 18001:2007
People Behavioural Controls
STOP Programme
Process Safety Management
Operational Discipline2009 – bizSAFE Partner
• NatSteel made it mandatory for all
business partners to achieve at least
bizSAFE Level 3
2012 – Certified ISO 50001
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NSH Safety Statistics
FY’08 FY’09 FY’10 FY’11 FY’12 FY’13 FY’14FY’15
(Target)
10.23 5.88 1.22 1.33 0.65 0.75 0.60 0.4
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Action Items for Preventing Hand Injuries
� Develop and implement Safe Loading Guide and Hand and Finger Safety rules.
� Automation to eliminate/Engineering control to reduce the exposure of man to machines.
� Training and retraining employees on safe machine operation and material handling
procedures.
� Build competency by attending mandatory trainings.
� Conducting daily TBM and regular Comm sessions to share Incidents lesson learnt and best
practices.
� To conduct Hand Safety seminar.
� Improved visible signages and lighting.� Improved visible signages and lighting.
� Maintain high 5S standard.
� Creating awareness on Operating Discipline.
� Regular factory inspections and risk containment audits.
� To increase STOP and Job cycle Check.
� Exploring appropriate Personal Protective Equipments.
� Sharing of best practices,internally,MOM,WSHC and Industry.
� Safety communications through posters,banners,bulletin and pop up message in intranet.
Safety Excellence Management System
• Full implementation on 1 April 2011
• Safety Observation and Audits (SOA)
• Incident Investigation (II)
• Process Safety Management (PSM)
• Contractor Safety Management (CSM)
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• Job Cycle Check (JCC)
• Risk Containment (RC)
• Consequence Management (CM)
• Task Risk Analysis / Safe Operating Procedure (TRA/SOP)
Risk Control Measures
e.g. use of fixed machine guards and
presence detection devices
e.g. by replacing with a safer machine
or manufacturing process
e.g. use of automation to reduce
man-machine interaction
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e.g. use of safe work procedures
and lock-out tag-out
e.g. use of safety goggles, safety
gloves and safety footwear
Conventional Methods of Loading/Unloading the rebar bundle
Spreader beam without auto release hook attachment
Substitution to Prevent Hand Injuries
Loading/Unloading of rebar bundles using auto release hook system
Reducing
rigging
process by 50%
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Removing of Chain Sling Manually Removing of Chain Sling using remote control
Reducing
hand injury
Use of Extended Hook
Substitution to Prevent Hand Injuries
Conventional Methods of Loading the Bored Pile Cage
Loading of Bored pile cages using quick release system(National WSHC Innovation Award winning project)
Reducing rigging
process by
50%
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Working Principle of the SystemRemoving of Chain Sling Manually
50%
Reducing hand injury
Engineering Controls to Prevent Hand Injuries
N-Splice Threading Machine Clamp Safety Guard
Butt Welding Machine Transparent Safety Guard
Visual metal Protection
Pinch point
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Butt Welding Machine Transparent Safety Guard
Transparent ProtectionHot surface
EVG coil machine, movable short segment guide
EVG Coil machine with adjustable protective guard
Movable Cover
Moving parts
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Sharp objects
Integrated Cut and Bend Production Line with Light curtains, visual/audible alarms and
Safety rope switches
Safety rope switches
Safety rope switches
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Light curtain
Mesh Auto bender machine fixed with Light Curtains, Interlocks and Visual/Audible
alarms
Light curtains
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Interlocks
Alarm
Golden Rules For Hand & Fingers Safety
Administrative controls to Prevent Hand Injuries
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Safety Communications
Safety Messages On Intranet Table Stickers at
CanteenBulletins Safety Survey
Canteen
Posters Safety Day 2014 Safety Banners
COO safety dialogue session with supervisors, Safety Pledge by Supervisors
Hand Safety SeminarHand Safety Seminar
Speaker - PPE Supplier Speaker - WSHC
Thank you for your kind attention
Trust, Hand injuries can be prevented