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