safety at jaykaypuram - qcfi hyderabadqcfihyderabad.com/cementconclave2018/wp-content/uploads/...4...
TRANSCRIPT
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Safety at Jaykaypuram
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OH&S Vision
To be a recognized leading company promoting healthy and
safe workplace for achieving goal of “Zero Harm”
OH&S Mission
To develop and implement user friendly and effective OH&S
Management System that fits to the organization and drive
Risk Prevention Culture
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SN CONTENT
1 Safety Policy, Roadmap, Compliance & Public disclosure
2 Safety performance in the Cement manufacturing, CPP,mines & project site within the plant boundary
3 Safety performance in Logistics (inbound & outbound)
4 Safety Best practices in manufacturing & infrastructurecreated
5 Safety Best practices in mines & infrastructure created
6 Safety best practices in Logistics (inbound & outbound) &infrastructure created
7 Replicability of the idea implemented within the sector /outside the sector
8 Recognition and Awards
Presentation content
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OH&S Policy and Golden Rules
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HIRA
TBT
BBS Observation
GAP
Lack ofknowledge
Lack ofResource
At-RiskBehavior
Training &
Development
Resource allocation
1. Activate by activator2. Motivate by consequence
Feed forward for
Continual
improvement
CFT OF SECTION HEAD
ENGINEER
ISO 45001:2018 Clause 6.1.4 & 8.1.2
Safety Management - Roadmap
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Identification of Unsafe Act & Condition
Plant Safety Visit / Audit
Safety visit Mobile app
Plant Safety Inspection
Plant utilitiesInspection
Safety consultation
1. Consultation with worker at shop floor
2. SC Meeting3. CFT Meeting4. DSO Meeting5. HOD Meeting
SAP Plant SafetyInspection module
Utilities InspectionMobile app
Safety visit Mobile app
Safety Management - Roadmap
ISO 45001:2018 Clause 6.1.4 & 8.1.2
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Emergency prevention and protection
Fire Safety Inspection /
Audit
Safety visit Mobile app
&Utilities
InspectionMobile app
Detection &Alarm system
Maintaining Emergency handlingEquipment in healthy
condition
On site emergency
plan & Mock drill
Safety visit Mobile app RFID
tagging &
SAP
integration
Safety Management - Roadmap
ISO 45001:2018 Clause 6.1.4 & 8.1.2
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Safety Management - Roadmap
ISO 45001:2018 Clause 6.1.4 & 8.1.2
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Safety Standards
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1. Safety manual
2. Fire safety manual
3. Road Safety Booklet
4. First Aid Booklet
5. Golden rules
6. Visitors and business partner safety rules
7. Legal Compliance Manager
8. Contractor Safety Management System
9. Driving Safety Management System
ISO 45001:2018 Clause 6.1.4 & 8.1.2
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Safety Standards
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10.Lock Out Tag Out System
11.Incidence Investigation System
12.Standard for Machine Guarding
13.Code of practice for electrical safety
14.Onsite Emergency Plan
15.CPR Chart
16.Departmental System Procedure Manual
17.Common System Procedure Manual
18.COP & SOP
ISO 45001:2018 Clause 6.1.4 & 8.1.2
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Safety Standards
11ISO 45001:2018 Clause 6.1.4 & 8.1.2
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Golden Rules
12ISO 45001:2018 Clause 6.1.4 & 8.1.2
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SAFETY ANNUAL PLAN
13ISO 45001:2018 Clause 6.1.4 & 8.1.2
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SAFETY ANNUAL PLAN
14ISO 45001:2018 Clause 6.1.4 & 8.1.2
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Safety Department KRA
Key Result Area Daily Activity Log
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Safety department KRA; Monitoring & Reporting
Daily Report Auto Mail Digital Log Book
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Determination of legal requirements and other
requirements
17ISO 45001:2018 Clause 6.1.3
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Public Disclosure
Sustainability report Page 38 -40
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Public Disclosure
Sustainability report Page 38 -40
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Public Disclosure
Sustainability report Page 38 -40
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PERFORMANCE
SN ACTIVITY OUTCOME FY-16 FY -17 FY -18
1 Safety Audit UC eliminated 1180 1257 848
2 Fire Audit UC eliminated 105 90 40
3 Safety committee
meeting
Safety suggestions
implemented
126 238 173
4 Safety training
(Man Hour)
Increase in safety
awareness
13139 14465 14062
5 Fire service week Fire Safety Awareness 470 733 1216
6 Road Safety Week Traffic safety awareness 1176 1894 1881
7 National Safety
Month
Awareness and review 1631 1513 1329
8 Near Miss UA / UC eliminated 592 748 653
9 BBS observation UA / UC eliminated 230 74 24
Leading indicator
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PERFORMANCE
Lagging indicator
Year Number of Reportable Accident
2016 0
2017 0
2018 1
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SAFETY KRA ASSIGNMENT BY
HOD
HIRA BY Section Head & APPROVAL
BY HOD
Safety Best Practices(Behaviour Based Safety Management Module in SAP)
On the Job Safety observation by Shift
Engineer
Near Miss Reporting and
implementation of action plan
Pre Job safety briefing of HIRA by Shift
Engineer (TBT)
Continual Improvement plan w.r.t.
BBS analysis report
Implemented in July 2014 – till date 2126 recommendations implemented
ISO 45001:2018 Clause 6.1.4 & 8.1.2
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Implemented in Aug 2016 – till date 938 recommendations implemented
Safety Best Practices(Safety Visit Mobile App)
LOGIN
POSTING OF OBSERVATION /
RECOMMENDATION
JOB ASSIGNMENT
TO SECTION HEAD
BY HOD
ACTION PLAN &
TARGET DATE
ENTRY BY SHIMPLEMENTATION &
MONITORING
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Sep 2016 – all 1265 equipments mapped floor wise – till date 1011 UC rectified
SAFETY INSPECTION MODULE DEVELOPED IN SAP FOR 100% INSPECTION ON 13 INSPECTION CRIETERIA WITH ACTION PLAN AND COMPLETION MONITORING SYSTEM
INSPECTION AREA SELECTION FLOOR SELECTION
EQUIPMENT SELECTION
INSPECTION STATUS ENTRY
IMPLEMENTATION &
MONITORING
Safety Best Practices(Safety Inspection Module in SAP)
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Implemented in Sep 2016 – 1241 equipment mapped & till date 189 UC rectified
Safety Best Practices(Utilities Safety Inspection Mobile App)
Open the App and login using ESS id and password
Click on Utilities Safety Inspection
Enter planner group SAF / MIN and select the Utility Equipment
Carryout inspection w.r.t. checkpoints and enter status,
measurement value & observation remark
Auto MailAction plan & Target date entry
Auto Mail
Execution & Completion date
entry
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POTENTIAL EMERGENCY & EMERGENCY RESPONSE
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Fire Safety Best Practices(RFID Tagging & online real time data update)
REAL TIME ON LINE DATA
UPDATE ON RFID TAG
AND IN SAP SYSTEM FOR
ALL FIRE DETECTION AND
ALARM SYSTEM, FIRE
EXTINGUISHERS & FIRE
HYDRANT SYSTEM
Implemented in April 2015; increased the work efficiency by 200 % & higher accuracy
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Mines Safety– Best Practice(Dust control)
VACCUME SWEEPING
Water Mist system at crusher dump hopper
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Mines Safety– Best Practice(Engineering control in dumper)
Front PROXIMITY
SENSOR
Auto Fire suppression
system
RearPROXIMITY
SENSOR
FrontBlind spot
camera
Rear ViewCamera
Down hill speed control & Hill hold system
Advanced Emergency
braking system
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Mines Safety– Best Practice(Silicosis prevention)
Screening of films on Respiratory protection
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Mines Safety– Best Practice(Silicosis prevention)
Awareness session on Silicosis to employees
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Mines Safety– Best Practice(Silicosis prevention)
Awareness session on Silicosis in nearby village
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10.10.5.4/elearningLOG IN Topic selection
Competency development – Best Practice(LEARNING PORTAL)
Learning Implementation
Plan
Study & e-note
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10.10.5.4/kioskLOG IN
LANGUAGE SELECTION TOPIC
SELECTION
FILM SCREENINGONLINE TESTCERTIFICATE GENERATION
Competency development – Best Practice(LEARNING PORTAL & KIOSK)
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Competency development – Best Practice(Customized Safety Animation Films)
Visitor Safety Induction Video Driving Safety animation Video
Mines Safety animation Video
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Tool box talk (Pre-job safety briefing)
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Pre monsoon safety – Mass awareness
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Behavior based safety observation
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On the job safety observation by HOD
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Safe execution of High Risk Job
Execution of job with Kevlar suit
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Execution of job with lifting plan; proper rigging and monitoring with CCTV camera 42
Safe execution of High Risk Job
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Execution of job with lifting plan; proper rigging and monitoring with CCTV camera 43
Safe execution of High Risk Job
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Safe execution of High Risk Job
Execution of job with SRP System
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Display at Main Gate
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Display at Mines Gate
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Activators for Safe Behavior
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Activators for Safe Behavior
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Activators for Safe Behavior
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Activators for Safe Behavior
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Activators for Safe Behavior
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Activators for Safe Behavior
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Activators for Safe Behavior
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Activators for Safe Behavior
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Activators for Safe Behavior
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Training for Senior Management team
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Awareness session for transporters
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Contractor Safety Management Committee Meeting
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Safety Committee Meeting
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Scaffolding training
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Safety campaign inaugural address
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Safety Campaign
1. Road Safety Week
2. National Safety Month
3. Fire service Week
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Safety promotional activity by contractor
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Emergency Response Group Meeting
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Emergency Mock drill
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Emergency Mock drill
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First Aid Training
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Suraksha Janki – Republic day
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Suraksha Janki – Republic day
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Pedestrian Path
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PPE Booth for Truck Drivers
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Traffic sign display at LPSS
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Safety Awareness test at LPSS
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Safety Awareness trg in nearby school
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Acknowledgements
1. “Safety Management System of JK Lakshmi Cement is most
innovative system” - Shri Gopalkrishna PB Sr. President
(Manufacturing) Ramco Cements Limited - QCFI National Conclave
held at HICC Hyderabad.
2. “I have not seen such an innovative system in my life” – Shri PR
Kumar; CEO BSES Yamuna Power Delhi - International Safety
Convention organized by The Institution of Engineers (India) at New
Delhi.
3. “I had visited about 5000 companies but haven’t seen such robust
system for fire and safety Management” – Shri A. V. V. Gopal Rao;
Country Head Reliance Risk Services - at the time of HAZOP study.
4. RFID tagging system for monitoring and maintaining fire fighting
equipments is innovative and unique. I have never seen such a
robust system – Dr. Vinod Kumar Jain Managing Director M/s Vexil
Business Processes Services Private Limited - IMS Re-certification
audit concluding function.
5. Appreciated by the distinguished auditors of National Safety
Council of India during statutory safety audit which is conducted bi-
annually for cement plant and annually for TPP.
Shri PR Kumar (CEO) BSES Yamuna Power
Shri Gopalkrishna PB Sr. President (Mfg)
Ramco Cements Limited
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AWARDS AND RECOGNITION
1. National Safety Award – 2011 &
2016 by DGFASLI Ministry of
Labor Government of India.
2. International Safety Award from
British Safety Council UK from
year 2013, 2014, 2015 2016 & 2017
3. National Safety Award – 2013 &
2014 from National Safety Council
of India.
4. Safety system Excellence award -
2013 from FICCI
5. Safety Innovation Award 2010,
2011, 2012, 2013, 2014, 2015, 2016
& 2017 from The Institution of
Engineers (India)
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Thank you!
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