1. Accident Prevention

8/3/2019 1. Accident Prevention

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TRAINING PROGRAMME ON

SAFETY MANAGEMENT

INDUSTRIAL SAFETY & FIRE PREVENTIONINDUSTRIAL SAFETY & FIRE PREVENTION

DEPT.DEPT.



H YUNDAI MOTOR INDIA will perform all its activities in line with Industrial Statutory Acts and Rules,

and will abide the same with a prime intention to:

1.Ensure Safety and Health of each member of the company and other members who may be

associated with day-to-day activities.

2.Ensure prevention of pollution and protection of the environment.

3.Ensure safe operation of the plant and equipment with operational standards and procedures.

H YUNDAI MOTOR INDIA is committed and firmly believes that :

j Safety, Health and Environment protection form an integral part of its production activities.

j All accidents are preventable.

j Managing and maintaining Safety, Health and Environment is the Line Management responsibility

and each individual member of the company is responsible and accountable for Safety, Health and

Environmental activities.

The above policy will be implemented through company strategies, action plans, corrective actions and

continuous monitoring with the participation of all members and others associated with it and duly

supported by proper Education and Training.

PRESIDENTPRESIDENTPRESIDENT



THE SIMPLEST

MEANING IS THE

PREVENTION OF

ACCIDENTS &

THE LOSSES

THEREAFTER.



What is safetyWhat is safety

No injuriesNo injuries

No accidentsNo accidents

No place for unplanned activityNo place for unplanned activity All activities well defined All activities well defined

Every one knows his job wellEvery one knows his job well

Operating excellenceOperating excellence

Every one takes pride in doing his job well.Every one takes pride in doing his job well.



UNFORESEEN & UNEXPECTED OCCURENCES THAT

INTERRUPT THE REGULAR WORK WHICH MAY OR MAY

NOT CAUSE INJURIES TO PERSONS OR DAMAGES TO

PROPERTIES.

1. REPORTABLE ACCIDENTS - MORE THAN 48 HRS.

2. NON REPORTABLE ACCIDENTS - LESS THAN 48

HRS.

ACCIDENTS DO NOT HAPPEN - THEY ARE

CAUSED



Safety ExcellenceSafety Excellence

It occurs only whenIt occurs only whensupervisors, managerssupervisors, managers

and executivesand executivesdemonstrate their valuedemonstrate their valuethrough actions and then,through actions and then,being credible, askbeing credible, ask

workers to help improveworkers to help improvethe system.the system.



ACCIDENT vs. Injury ACCIDENT vs. Injury Accident is an undesired incident which Accident is an undesired incident which

may or may not result into injury.may or may not result into injury. Injury is always a result of some Accident.Injury is always a result of some Accident.

Our focus should be on eliminatingOur focus should be on eliminating

accidents, and in particular to avoidaccidents, and in particular to avoidinjuries altogether.injuries altogether.

Eliminating accidents 100% may not beEliminating accidents 100% may not bepossible.possible.

Eliminating injuries 100% is definitelyEliminating injuries 100% is definitelyachievable.achievable.



Foundation of a lost timeFoundation of a lost time

injuryinjuryDeathsDeaths --No dataNo data

Lost work day casesLost work day cases --11 {*}{*}

Medical attention casesMedical attention cases --1010 {*}{*}First aid casesFirst aid cases --100100 {*}{*}

Near miss casesNear miss cases --10001000

Unsafe behaviors or conditionsUnsafe behaviors or conditions --10,00010,000

{*}has been proved by extensive research{*}has been proved by extensive research



Most process and personal

incidents, injuries and

accidents are caused byunsafe acts and behaviors,

& not merely by conditionsand equipment.



76% injuries are only due to unsafe acts.76% injuries are only due to unsafe acts.

20% due to unsafe acts and unsafe20% due to unsafe acts and unsafeconditions both.conditions both.

4% are due to unsafe conditions.4% are due to unsafe conditions.



Causes of injuriesCauses of injuries

Unsafe acts involvingUnsafe acts involving Body position..30%Body position..30%

Tools and equipment...28%Tools and equipment...28%

Actions of another...14% Actions of another...14%

Not using Protective Equipment..12%Not using Protective Equipment..12%

Procedures and Housekeeping.12%Procedures and Housekeeping.12%

Total from unsafe acts...96%Total from unsafe acts...96%

Total from other causes...4%Total from other causes...4%



ExamplesExamples BehaviorBehavior

Walked down stairs without usingWalked down stairs without usinghandrail;lost balance and fellhandrail;lost balance and fell

Behavior and conditionsBehavior and conditions Walked on water/oil coveredWalked on water/oil covered

slippery ground, slipped and fell,slippery ground, slipped and fell,broke ankle and hand.broke ankle and hand.

ConditionsConditions

Food poisoning at a seminar.Food poisoning at a seminar.



Risk perception with timeRisk perception with time Lack of risk perception / reduction in riskLack of risk perception / reduction in risk

perception is responsible for accidents resultingperception is responsible for accidents resultinginto severe injuries.into severe injuries.

Risk perception reduces with time if there areRisk perception reduces with time if there areno accidents/injuries.no accidents/injuries.

Risk perception is Safety Attitude.Risk perception is Safety Attitude.

Safety norms are followed only if the risk is

Safety norms are followed only if the risk isperceived. Education/information is important.perceived. Education/information is important.

This has to be developed and maintained in theThis has to be developed and maintained in themanagement as well as the employees.management as well as the employees.



Time

Serious

accident/incident

Rules and safeguards

devised here may be

violated, when riskperceptions decay with

passage of time



COMMON ORG ANIZATIONALCOMMON ORG ANIZATIONALPROBLEMS WHICH IMPEDE S AFETY PROBLEMS WHICH IMPEDE S AFETY

Management interpretation that safety can beManagement interpretation that safety can be

hired.hired.

Tolerance of unsafe behavior by management.Tolerance of unsafe behavior by management. Priority to business over safety.Priority to business over safety.

Enforcement of rulesEnforcement of rules (different standards)(different standards)

Responsibility/Accountability is not defined clearlyResponsibility/Accountability is not defined clearly

demonstrated prodemonstrated pro--activelyactively

Champions in safety initiatives lose interest.Champions in safety initiatives lose interest.



Behavior improvement modelBehavior improvement model Every one likes to be appreciated.Every one likes to be appreciated. No one has all the good things.No one has all the good things.

Every one has something good or bad.Every one has something good or bad.

It is very difficult to change behavior of It is very difficult to change behavior of people. It is one of the most difficult jobs.people. It is one of the most difficult jobs.

To change the behavior of people is aTo change the behavior of people is achallenge.challenge.

ThisThis cancan be achieved slowly but surely.be achieved slowly but surely.

Organized, concerted and conscious effortsOrganized, concerted and conscious effortsfrom all management personnel is required.from all management personnel is required.



Look for safe behaviorLook for safe behavior Body position, eyes on work, eyes on path,Body position, eyes on work, eyes on path,

lifting practice, holding practice,lifting practice, holding practice,

Work condition, selection of tools, use of toolsWork condition, selection of tools, use of tools

, labeling, proper tags, permits well prepared,, labeling, proper tags, permits well prepared,work area free of trip, slip hazards, signs,work area free of trip, slip hazards, signs,barricading, lighting, ventilation, fall protection,barricading, lighting, ventilation, fall protection,

PPE condition, use of eye/face protection,PPE condition, use of eye/face protection,helmet, respirators, N2 blanketing, earthing.helmet, respirators, N2 blanketing, earthing.



Understanding Accident Causes

Accidents are caused by:

± Unsafe act (88 %)

1. Working on unguarded m/c

2. Horseplay

3. Standing under a suspended load.

± Unsafe conditions (10 %)

1. Unguarded machines2. Oily floor

3. Gangway congested



Cause of Accident Cause of Accident

Unsafe ConditionsUnsafe Conditions

Unsafe ActionsUnsafe Actions

Personal CausesPersonal Causes

Proximate CausesProximate Causes

Green Triangle

For Safety



HEINRICH AN ALYSISHEINRICH AN ALYSIS

OF ACCIDENTSOF ACCIDENTS

1ACCIDENT

29NEAR ACCIDENT

300INCEDENTS



HEINRICH ACCIDENT PREVENTION

Ancestry &

Social

environment

Fault of

persons

Unsafe act

(or) unsafe

condition

Accident Injury



UNSAFE CONDITIONSUNSAFE CONDITIONS

Unguarded & inadequately guardedUnguarded & inadequately guardedmachinesmachines

Unsafe design & constructionUnsafe design & construction

Defective machines & toolsDefective machines & tools

Hazardous processHazardous process Improper IlluminationImproper Illumination

High noise levelsHigh noise levels

Hot working environmentHot working environment

Dusts, Fumes & GasesDusts, Fumes & Gases

Inadequate VentilationInadequate Ventilation

Hazardous RadiationsHazardous Radiations

Unsafe DressUnsafe Dress



UNSAFE CONDITIONSUNSAFE CONDITIONS

Unsafe storage of materialsUnsafe storage of materials

Defective Machines & ToolsDefective Machines & Tools

Unsafe floors & passageUnsafe floors & passage

Unsafe Electrical wiring & fittingsUnsafe Electrical wiring & fittings

Unsafe Lifting & Transport MachinesUnsafe Lifting & Transport Machines Unsafe Pressure VesselsUnsafe Pressure Vessels

Working on HeightsWorking on Heights

Improper Personal ProtectiveImproper Personal ProtectiveEquipmentsEquipments

Unsafe House KeepingUnsafe House Keeping

Unsafe Waste disposalUnsafe Waste disposal



UNSAFE ACTIONSUNSAFE ACTIONS

Disregard to Safety Rules & ProceduresDisregard to Safety Rules & Procedures

Working without authorityWorking without authority Unsafe speed of actionUnsafe speed of action

Making Safety Devices inoperativeMaking Safety Devices inoperative

Sleeping in the work placeSleeping in the work place Playing & Teasing in the work placePlaying & Teasing in the work place

Quarreling with the coQuarreling with the co--workers &workers &supervisorssupervisors

Smoking in work placeSmoking in work place

Eating in work placeEating in work place

Intoxication with Alcohol or DrugsIntoxication with Alcohol or Drugs



UNSAFE ACTIONSUNSAFE ACTIONS

Disregard to Hygiene & CleanlinessDisregard to Hygiene & Cleanliness

Improper work DressImproper work Dress

Failure to use Personal ProtectiveFailure to use Personal ProtectiveEquipmentsEquipments

Using improper toolsUsing improper tools

Using tools improperlyUsing tools improperly

Joy Ride on material handling machinesJoy Ride on material handling machines

Working on roofs without SafetyWorking on roofs without Safety

EquipmentsEquipments Improper handling of materials & machinesImproper handling of materials & machines

Unsafe use of electrical equipments & toolsUnsafe use of electrical equipments & tools

Cleaning & Lubricating machines in motionCleaning & Lubricating machines in motion



PERSON AL FACTORSPERSON AL FACTORS

1. Good Physical condition1. Good Physical condition

( Good Food, Sleep & Habits )( Good Food, Sleep & Habits )

2. Good Mental condition2. Good Mental condition

( Correct thinking, avoid anger, envy,( Correct thinking, avoid anger, envy,greed & worry )greed & worry )

3. Good Social Relationship3. Good Social Relationship

( Good Friends, Social Service etc.)( Good Friends, Social Service etc.)



Cost of Accidents:

The Iceberg Effect

On average, the indirectcosts of accidentsexceed the directcosts by a 4:1 ratio



Cost of Accidents Direct Costs

± Medical Costs (including worker¶s comp)

± Indemnity Payments

Indirect costs

± Time Lost (by worker and supervisor)

± Schedule delays

± Training new employees

± Cleanup time / equipment repairs

± Legal fees



Cost of the ACCIDENTCost of the ACCIDENT

DIRECT COSTDIRECT COST INDIRECT COSTINDIRECT COST SUFFERINGSSUFFERINGS

Medical ExpenseMedical Expense Loss of productionLoss of production Physical SufferingPhysical Suffering

CompensationCompensation Damage to MachinesDamage to Machines Mental SufferingMental Suffering

Unproductive wageUnproductive wage Loss of MaterialsLoss of Materials Family SufferingFamily Suffering

-------------------------- Legal ExpenseLegal Expense ----------------------------

-------------------------- Loss of MoraleLoss of Morale ----------------------------

-------------------------- Loss of ReputationLoss of Reputation ----------------------------

20 %20 % 80 %80 %

Cannot beCannot be

CompensatedCompensated



ARM SLEE VE GLOVES SAFET Y SHOES

GOGGLES APRON C ANISTER MASK



DUST MASKHELMET

DUST MASK NITRILE GLOVES FACE SHIELD

E AR PLUG



SAFETY MANAGEMENT IN HMI

1. ACCIDENT REPORTING & INVESTIGATION

2. HOT WORK PERMIT SYSTEM

3. COLD WORK PERMIT SYSTEM

4. JOINT SAFETY INSPECTION SYSTEM5. PERIODICAL SAFETY AUDITS

6. DAILY SAFETY OBSERVATION TOURS

7. CONTRACTORS SAFETY MGMT

8. MATERIALH

ANDLING SAFETY AUDIT9. MACHINE SAFETY AUDIT

10. FIRE SAFETY MGMT



SAFETY PROMOTION ACTIVITIES

1. EDUCATION & TRAINING

2. SAFETY CAMPAIGNS

3. SAFETY DAY CELEBRATIONS

4. SAFETY COMPETETIONS

5. SAFETY PUBLICATIONS ± ARTICLES IN VANAKKAM

5. DISPLAYING SAFETY MESSAGES IN THE PLANT

6. REWARDING FOR SAFETY PERFORMANCE



BE AWARE OFBE AWARE OFTHE

SE

THE

SE

H AZARDSH AZARDS



WINNING ATTITUDE WINNING ATTITUDE FILMFILM

1. Accident Prevention

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