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Handbook for 8th FICCI Safety Systems Excellence Awards for Industry 2019 1

Handbook forth

8 FICCI SafetySystems ExcellenceAwards for Industry

September 2019


• TheAwards 5

• TheAwardProcess 6

• LastEdition’sAwardees 7

• JuryProfile 9

• Auditors/AssessorsfortheAwards 15

• EligibilityCriteriaforAssessor/Auditorfor 16 EmpanelmenttoFICCISafetySystemsAwards

• Awardeesfor2019andtheirBestPractices 18

Contents


The Awards

FICCISafetySystemsExcellenceAwardshavecompletedtheireighthyearofjourneywithanexpandedscope.Enhancing thescopefrom“ManufacturingAwards”to“Awards for Industry”, theAwardsnowcoversectorslikeConstruction,Manufacturing,Oil&Gas,MiningandPower.

The Awards, institutionalized for excellence in workplace safety systems in industry, focus onthe robustness of systems and not just the performance. Good safety systems lead to systematicimprovementinorganizationperformance.TheAwardisaninitiativeofFICCIManufacturingCommittee& FICCI Taskforce on Manufacturing Excellence that works with an agenda of improving Industrycompetitivenessthatwouldenablethedomesticindustrytostanduptonewandemergingchallengesoftheglobalmarket.

Materialising this ambition requires enabling policy environment and also the need to follow globalbestpracticesintheprocessesatfirmlevel.Firmsandcompaniesthatdisplayhighperformancesafetysystemsandstandthrougharigorousthree-tierevaluationprocessarefelicitatedwiththeseawards.TheAwardsprovideabenchmarkfortheindustryasthebestpracticesofawardeesaresharedwithotherapplicantsandalsowiththewiderindustry.Hopefully,thiswouldmotivateandactasacatalysttoencouragetheindustrytoadoptrobustsafetysystems.

TheAwardsaregiveninthreecategorieswhichareasfollows:

• Largesizeorganization(organizationhavingeitherturnoverorinvestmentexcludingworkingcapitalofmorethanRs500crore)

• Mediumsizeorganization(organizationhavingeitherturnoverorinvestmentexcludingworkingcapitalbetweenRs100croretoRs500crore.IfanyoneoftheparametercrossesthelimitofRs500crorethentheorganizationgoesintolargesizeorganization)

• Smallsizeorganization(organizationhavingturnover&investmentexcludingworkingcapitalbothlessthanRs100crore)

PictureoflastfeweditionsoftheAwards:

Parameters Awards 2012

Awards 2013

Awards 2014

Awards 2015

Awards 2016

Awards 2018

Awards 2019

Totalapplicationsreceived 115 107 103 79 85 99 116

Totalapplicationsinlargecategory

74 61 49 70 77 85 108

Totalapplicationsinmediumcategory

37 37 37 6 7 9 5

Totalapplicationsinsmallcategory

4 9 17 3 1 5 3


The Award Process

TheAward processwas started in May 2019. FICCI Safety Systems ExcellenceAwards Process has 3qualifyingstages:

• DocumentAssessmentofallapplicantunits

• On-siteAuditforshortlistedunitsbasedonDocumentAssessment

• JuryMeetingtofinalizetheAwardees

Detailsofthisprocessareasfollows:

• Designandfinalisationofapplicationfortheawardswiththesupportofindustry

• Circulationofapplicationamongsttheindustry

• ApplicationformsreceivedbyFICCI

• Empanelmentofauditors/assessorsfortheevaluationfromtheindustrybasedonprescribedeligibilitycriteriaformedbytheSafetyWorkingGroupunderFICCIManufacturingCommitteeandFICCITaskforceonManufacturingExcellence

• Finalizationof checklists for applicationevaluation andon-site audit by FICCITaskforceonManufacturingExcellence

• Applications evaluated by the assessors and marks allotted along with feedback for eachapplication

• PresentationofdocumentevaluationresultstotheFICCIWorkingGrouponSafety

• On-siteauditforshortlistedunitsbyFICCIWorkingGrouponSafety

• Presentationofon-siteauditresultstoFICCIWorkingGrouponSafety

• PresentationoffurthershortlistedunitstotheHon’bleJuryoftheAwards

• SelectionofAwardeesbyHon’bleJury

• AnnouncementofAwardsintheConference

• Feedbacktotheapplicants.


FICCI SAFETY SYSTEMS EXCELLENCE AWARDS 2018

Manufacturing

• Large Scale Category

Platinum Prize Winner:MarutiSuzukiIndiaLimited,Gurugram,Haryana

Gold Prize Winner:UPLLimited,Unit-II,Ankleshwar,Gujarat

Silver Prize Winner:ITCLtd,IndiaTobaccoDivision,Ranjangaon,Maharashtra

Silver Prize Winner: DalmiaCement(B)Ltd.,Kadapa,AndhraPradesh

• Medium Scale Category

Platinum Prize Winner:ElinAppliancesPrivateLtd.,Baddi,HimachalPradesh

Gold Prize Winner: Mahle Anand Filter Systems India Pvt. Ltd., Khandsa, Gurugram, Haryana

• Small Scale Category

Platinum Prize Winner:ATCLtd.,Hosur,TamilNadu

Gold Prize Winner:M/sTEDeutschIndiaPowerConnectorsPvtLtd,Bangalore,Karnataka

Construction

• Winner in Large Scale Category

Platinum Prize Winner:L&TMMH–RSPHSMProject,Rourkela,Odisha

Gold Prize Winner:L&T(MMH),CDQ#10&11Project,Jamshedpur,Jharkhand

Mining Sector

• Winners in Large Scale Category

Platinum Prize Winner: Bhagyam Oil & Gas Mine, Vedanta Limited, Cairn Oil & Gas, Rajasthan

Gold Prize Winner:LanjibernaMines,OCL,DalmiaGroup,Odisha

Power Sector

• Winners in Large Scale Category

Platinum Prize Winner:SembcorpEnergyIndiaLtd.,AndhraPradesh

Gold Prize Winner:JSWEnergyLtd,Toranagallu,Vijayanagar,Karnataka

Last Edition’s Awardees


JURY PROFILE


Mrs Surina Rajan Former Director General BureauofIndianStandards

Agoldmedallist,distinctionholderandtopperinAllIndiaexaminationsforIndianEconomicsServiceandIndianAdministrativeService,sheisadevelopmentprofessionalandretiredintherankofSecretarytoGovernment of Indiawith proven track record for successful sectoral transformation. Passionateaboutexcellenceinperformanceanddelivery;aimingatnearzerodefects.

She was the CEO of the National Standards Body (NSB) of India till August 31/19. HarmonizedStandardizationwork in nearly every industry& services’ segmentwith direct technical staff (650)and10,000technicalexpertsfromindustry/academia/regulators.Ensuredcompliancethroughmultipleconformityassessmentschemesin50,000industrialunitsacross51countries.

Overthreedecadesof

• Leadershiprolesatmicroandmacrolevel

• Operationssupport&complianceadministrationinindustry;

• Policy development and programme implementation including six years in UN system(InternationalLabourOrganization).Impactedlearninglevelsofover5millionchildrenthroughpioneeringworkinaround15000schools.CreatedbasemodelsforlongdurationprofessionalteachereducationcoursesandskilltraininginmainstreameducationalinstitutionsofIndia.

Successfulpersonnelmanagementoforganizationswithemployee strength ranging from less thanahundredtomorethanalakh.Workedinquasi–judicialcapacityinvariousassignments.


Mr. Shyam BangChairmanNationalAccreditationBoardforCertificationBodies(NABCB)&Chairman,FICCIManufacturingExcellenceTaskforce

Mr. Shyam Bang is a post graduate chemical engineer and has been associated with chemical andpharmaceuticalindustriesinIndiaandabroadforoverfourdecades.Heisrecognizedforhiscontributioninthefieldofmanufacturingandsupplychainmanagement.

• Heismemberoftheboardofsomecompanies.

• HeisChairmanofNationalAccreditationBoardforCertificationBodies.

• HeisChairmanofFICCITaskForceonManufacturingExcellence.

• HeispastpresidentofIndianInstituteofChemicalEngineers.

• MemberofGoverningCouncilofNationalSafetyCouncil,MinistryofLabourandEmployment.


Dr Avneesh SinghDirector General DirectorateGeneralFactoryAdviceServiceandLabourInstitutes

Dr. Avneesh Singh is the Director General, Directorate General Factory Advice Service and LabourInstitutes(DGFASLI)underMinistryofLabourandEmployment,Govt.ofIndia.TheDGFASLIservesasthetechnicalarminformulatingpoliciesonOccupationalSafetyandHealthatthenationallevel.

Aftercompletingpost-graduation,Dr.SinghcarriedoutresearchworkatIndianInstituteofTechnology(IIT), Delhi, on ‘MentalHealth of IndustrialWorkers’ andwas awardedPh.D. in the year 1989. HehasalsocompletedgraduationcourseonOccupationalSafetyandHealthat ILOCtr.of InternationalTraining,UniversityofTurin,Italy.

Hehasdevelopedanumberoftrainingmodulesandtrainingmanuals.InadditiontothishehasdirectedanumberofOSHfilmsproducedbyDGFASLIorganisation.Hisprofessionalexperience(over28years)includesResearch,Training,andDevelopmentintheareaofBehaviouralAspectsofOSH.

Dr. Singh has carried out many prestigious national research studies in the field of OccupationalSafety and Health. Some of the notable research projects include ‘National study on IdentificationandPreventionof Silicosis in India’; ‘NationalProjecton SafeDriving inMajorPortsof India’; and,‘DevelopmentofNationalOSHProfile’.Dr.Singhhasalsobeenassignedtasksofnationalimportancesuch as ‘Development and Implementation of National Policy on Safety, Health and Environment atWorkplace’.

Dr. Singh has been instrumental in globalising the OSHActivities. Under his able guidance the firstInternationalVisionZeroConferenceonOSHwasorganisedatNewDelhiinMarch,2017andthesecondinternationalconferenceisbeingheldatMumbaiinFebruary,2019.

Inadditiontomembershipofotherprofessionalandscientificbodies,Dr.SinghheldtheofficeofthePresidentoftheIndianScienceCongressAssociation(ISCA),duringtheyear2010.


Mr. V SridharGroup Vice President & DirectorHondaMotorcycle&ScooterIndia(HMSI)

AMechanicalEngineeringGraduatefromBITSPilaniandMaster’sinBusinessAdministration,MrSridharhasatotalof33yearsworkexperienceinAutomobile&2-wheelerProductionandOperationsarea.

HestartedhisworkcareerasagraduateEngineerTraineeinMarutiUdyogLtdin1985.Hehadarichmixofproductionplanning,project&shopfloorexperiencefor15yearsinMarutiSuzukiIndiaLtd.

HehadworkedinareasofProductionPlanning&Control,EngineAssembly&VehicleAssembly.In1999,heledtheteamwhichsetupandoperatedtheVehicleAssemblylineinMaruti’s3rdplantinGurgaon.

HejoinedHondaMotorcycle&ScooterIndia(HMSI)inyear2000andhasbeenassociatedwithHMSIfor18yearssinceitsinceptionasHeadofManufacturing.

In HMSI, he has been completely involved and responsible from plant setup to operations of all 4factories,Quality,ProductionPlanning&Control,NewModels&expansionprojects.HehasbeenintheBoardofDirectorsofHMSIsince2013.

Withhisvastexperience inManufacturing&Management,MrSridharhasbeenamemberofseveralcommittees.NotableamongthemareSocietyofIndianAutomobileManufacturers(SIAM),Confederationof Indian Industry (CII), FICCIManufacturingCommittee and FICCIQuality& SafetyWork group andSocietyofAutomobileEngineers.


Mr. Satendra SinghHead- Strategy and Business Development, Supply Network and Engineering, Global Operations NokiaSolutionsandNetworksPrivateLimited.

Mr. Singh has a global role as head of strategy, quality and business development for global supplynetworkandengineeringatNokia.HeisamemberofglobalSupplyNetworkandEngineeringleadershipteam.

Inhiscurrentrole,Mr.Singhisresponsibleforglobalsupplynetworkstrategy,globalsupplynetworkarchitecture and capacitymanagement, performancemanagement, projectmanagement and globalsupply network quality. Nokia supply network consists of 30+ manufacturing sites and multipledistributionhubsglobally.PriortothisroleSatendraledmanufacturingoperationsforNokiaNetworksinIndia.

Mr.Singhhas28yearsofexperience ingeneralmanagement,operations, supplychainmanagementandqualitymanagement.Hespecializesinsettingupnewoperations,buildingupefficientteamsanddeliveringvaluetobusiness.Mr.Singhhasextremelyrichgeneralmanagementexperienceasbusinessheadinmultinationalcorporations.

Mr. Singh has started 2 world class technology manufacturing operations and has led introductionofnewtechnologyproducts into India.Hehasbeen instrumental inbuilding India’s largest telecominfrastructuremanufacturingfacilityforNokiaNetworksinChennai.NokiaNetworksChennaihasgrownveryrapidlytobecomeasignificantpartofNokia’sglobalsupplychainandhasreceivedseveralnationalawards.

Heisco-chairofFICCImanufacturingexcellencetaskforceandismemberofnationalcouncilsonsmartmanufacturing,Electronicsandconsumerdurables.Mr.Singh iselectronicsengineerwithmasters inmanagementandhascompletedadvancedmanagementfromIIM,Bangalore.


1. MrAjayPannu,GeneralManager-EHS,ThermoFisherScientificIndiaPvtLtd

2. MrArunBansal,Manager-Safety,DelhiMetroRailCorporation

3. DrAvdheshMathur,CEO,A4GlobalConsultants

4. MrAnkanMitra,HeadRegulatoryAffairs,Mining&SteelTataSteelLimited

5. MrSKSrivastava,ChiefHealth&SafetyOfficer,CairnOil&Gas,VedantaLimited

6. DrAnantTandale,SeniorManager-HSE,CairnOil&Gas,VedantaLimited

7. MrSatishKumarKaushik,Manager-SafetyDepartment,MarutiSuzukiIndiaLimited

8. MrSaurabhDixit,SeniorManager–EHS,JubilantLifeSciencesLimited

9. MrJCSekar,Co-founder&CEO,AcuiZenTechnologiesSingaporePte.Ltd

10. MrDevendraGill,GeneralManager-Safety,DelhiMetroRailCorporation

11. MrRajnishKumarSingh,Manager–Safety,HondaMotorcycle&ScooterIndiaPvtLtd

12. MrPardeepParhar,Manager-EnvironmentHealthandSafety,SignifyInnovationsIndiaLimited

13. MrKrishnanL,SeniorConsultant,HSE&FireProtection

14. MrMangeshMohanBrahme,GeneralManager,ThaneBelapurIndustries

15. DrPramodPandey,GlobalHealth&SafetyEngineeringLeader,CorporateHealth&Safety,RoyalPhilips

16. Mr Prashant Khurana,AGM – Safety & Environment, Honda Motorcycle & Scooter India PrivateLimited

17. MrGyanendraKumarPandey,CorporateHSEHead,LancoTanjorePowerCompanyLimited

18. MrM.P.Jain,ManagementConsultant,NubergEngineeringLimited

19. MrRajaniSonowal,GeneralManager,EngineersIndiaLimited

20. MrBhavaukVerma,GeneralManager,EngineersIndiaLimited

21. MrRanjanBanerjee,CorporateConsultant&IndustryConnect,RBSolutions

Auditors/Assessors for the Awards


Eligibility Criteria for Assessor/Auditor for Empanelment to FICCI Safety Systems Awards

QUALIFICATION AND EXPERIENCE OF ASSESSORS – Manufacturing & Power Generation

1. Qualification

• Bachelor’sdegreeinEngineeringOr

• Master’s degree in other science subjectswith Post graduate diploma (1 year or above) inIndustrialSafetyfromaUniversity/recognizedInstitute

2. Experience

• Minimum 10 years’ of experience in a manufacturing/power generation industry in theoperation/maintenance/safety department with aminimum 5 years’ experience in Health,SafetyandEnvironmentdepartment.

• Identificationofhazards,unsafeconditions,unsafeacts

• Experience to cover implementation/knowledge of safety systems, safety inspections,investigationofincidents/accidents,rootcauseanalysis,correctiveandpreventiveactions

• On-siteemergencyplansandorganisingmockdrills

• GoodKnowledgeofFactoriesActandrelevantRules

Thequalificationandexperiencementionedaboveareessentialrequirements.

3. Preferable

• SafetyAuditexperience

• OSHAS18001LeadAuditor

QUALIFICATION AND EXPERIENCE OF ASSESSORS - Mining

1. Qualification

• Bachelor’sdegreeinMiningOr

• Master’s degree in Geology or allied subjects dealing with identification, assessment andmanagementofriskandhazardsinminingindustry

2. Experience

• Minimum 10 years’ of experience in Mining industry in the operation/maintenance/safetydepartment

• Identificationofhazards,unsafeconditions,unsafeactsrelatedtominingindustry


• Knowledge and implementation of safety systems, safety inspections, investigation ofincidents/accidents,rootcauseanalysis,identificationandimplementationofcorrectiveandpreventiveactionsinminingindustry


• GoodKnowledgeofrelevantActsandRulesapplicabletominingindustry.

3. Preferable



QUALIFICATION AND EXPERIENCE OF ASSESSORS – Construction

1. Qualification

• Bachelor’sdegreeinCivilEngineering/Mechanical/ElectricalEngineeringOr

• Master’sdegreeinSciencewithdiplomainConstructionManagement

2. Experience

• Minimum10years’ofsiteexperienceinaConstructionindustry

• Identificationofhazards,unsafeconditions,unsafeactsinconstructionindustry

• Knowledge and implementation of safety systems, safety inspections, investigation ofincidents/accidents, root cause analysis, corrective and preventive actions in constructionindustry


• GoodKnowledgeofrelevantActandRulesapplicableforconstructionindustry

3. Preferable




Awardees for 8th Edition and their Best Practices

Platinum (First) Award

Name of the Organization:ChemplastSanmarLimited,Plant-IIICausticSodaDivision

Location:MetturDam-636403,Tamilnadu

Key Features of the Safety Systems

• Duringthepowerblockoutsituation,chlorinefromtheprocess linesneedstobeabsorbedbythescrubbingsystem.Inordertoensurethecontinuousavailabilityofelectricalpowertothechlorineabsorbersystem,ChemplastSanmarhasmade6 levelsofpowerredundancies,including250KVAUPS.

• Mechanical“LOTO”ismandatoryforthepumpsattachedtohazardouschemicals,whentheprocesslinesaretakenformaintenancework.

• Crossplantauditors,whoarenothavinganydirect responsibilityon theareaaudited, arebeingdeployedfortheinternalauditingaspects.

• Allhigh-riskactivitiesarebeingexecutedonlyaftercarryingouttheJobSafetyAnalysis(JSA)byacompetentteam&implementationofactionssuggested.

• Smokedetectorswereinstalledallovertheplant,wherethemanmovementisveryminimum/isolatedlocations&thealarmsarelinkedtotheDCSofcontrolrooms.

• Periodicalinspectionoftransboundarychemicalpipelines&sustainingitsintegrity.

• Adherence on the points emerged from the Journey Risk ManagementAnalysis for variouschemicalstransportroutestoreducetherisksrelatedtodistributionofhazardousproductsminimum.

• Monitoring&ControlofhazardousgoodstransportationthroughGPSbyadedicatedteam.

• Dedicated emergency kits at strategic locations for mitigating transport emergencies bydedicatedwelltrainedteams.

• PlantSafetyInspectionbyadesignatedteamonceinamonthtoidentifytheunsafeactsandconditionstoweedoutfromtheplant&improvethesafetyculture.

• Automatic Earthrite system for unloading of methanol from the truck to bulk storage toeliminatetheriskoffireduetostaticelectricity.

• Detectionofenergizedcablesbyadedicatedequipmentbeforecarryingouttheexcavationwork.

MANUFACTURING SECTOR

Awardees in Large Scale Category (Hazardous)


Gold (Second) Award

Name of the Organization:HeidelbergCementIndiaLimited

Location:NarsingarhDamoh,M.P.

Organisation Overview:HeidelbergCementIndiaLtd.atNarsingarhisaclinkerisationunithavingminesatadistanceof22km.Limestonefrommines is transportedthroughOLBC(OverlandBeltConveyor)whichisthelongestOLBCinAsiaregion.Theannualcapacityoftheplantis3.1MTAandaWHRpowerplantof15MW.


1. Certification:

UnitiscertifiedwithISO-45001:2018ISO-14001:2015,ISO-9001:2015,ISO-50001:2011

2. Safety Committees:

FollowingSafetycommitteesareexistingintheunit

• PlantSafetyCommittee

• PitSafetyCommittee

• ApexSafetyCommittee

3. Review System:

• Safetystatisticsarereviewedondailybasisinproductionmeeting.

• ThePlantSafetyCommitteeheadedbyUnitheadreviewsthesafetyperformanceonmonthlybasis.Ahead of this, the Technical Director reviews the safety performance on every visit(oncein2months).

• 30%ofMBO(yearlyperformance)isbasedonSafetyperformanceoftheyearofindividual&department.

• ManagingDirectorreviewssafetyperformancequarterlyinMRM.

• BoardofDirectors’reviewSafetyperformanceeverysixmonths.

• Chairmanreviewssafetyperformanceannually.

4. Emergency Handling and Response:

• OHCwithqualifieddoctors,nursesandcompounders

• 03Nos.ofambulances

• 02Nos.offiretenders

• Tieupwithdistrictandstatemedicalhospitals

• Well-defined‘OnsiteDisasterManagementPlan’foremergencyhandlingwhichalso involveslocaladministration.Basedontheemergencyoftheplantmockdrillisbeingconductedonceintwomonthsforemergencypreparedness.


5. Training and Awareness:

• TNI

• Fullyequipped safety training centerswithmodelsand simulators forproviding trainingonworkplacehazardsandsignificanceofsafetycontrols.

• For job specific training toengineersand trainees, theyhaveawell-equipped separate labwithsimulators.

• Daily safety gatemeeting is conducted to enhance awareness in all aspects of safety andsharingmessageofunsafeact/condition,accidentalertandcorrectivemeasures.

• Monthlythemebookisbeingpublished&isdistributedtoallemployees&contractorworkmenfortheirawareness.MonthlyconductionofQ&Asessionisorganizedonthesafetytheme.

• Safetytrainingtofamilymembers,nearbyvillagersandschoolchildren.

• Safetytrainingtotransportersandotherstackholders.

• Bestuseofwaste.

• Suggestionschemeforsafetyandotherideasforimprovements.

6. Health Initiative:

• Pre-employmentmedicaltest

• Medicaltestforthepersonsdeployedtoworkatheightandconfinedspace.

• Annualmedicalcheckupforallcontractandownemployeesandtrendanalysis.

• EYE&ENTtestforDriversandOperators

• Hygienicmonitoring

• PortabilitytestofDrinkingwaterfacility

• ImplementedWASH

• Healthcampaigns,designatedfoodshelter,blooddonationcamps,yogacamps,RunforSafetyprogrammesareorganised.

7. Enforcement of Safety:

• PTWs,toolboxtalk

• Riskassessment&SOPs

• Cardinalrules

• CardinalrulesImplementationcommittee

8. Contractor Safety Management System:

• Contractorsaredividedintofourclasses

• Contractorselection–pre-qualification

• Nominationofdesignatedcontactperson

• AssessmentofPre-commencementphase

• Rewardandpunishmentsystem

• Postassessmentsystem



Name of the Organization:MarutiSuzukiIndiaLimited

Location:1HUDA,Sector-18,IndustrialEstate,PalamGurgaonRoad,Gurgaon(Haryana)

Key Features of the Safety Systems:

MarutiSuzukihasaveryeffectiveOH&Smanagementsystem.Achievementofmorethan163millionaccidentfreemanhoursisaresultofthetopmanagementcommitments,effortsandinvolvementofall.

ThemajorsafetyinitiativestakenbyMSILlastyeartoimprovesafetycultureareexplainedbelow:

1. Zero Sai Campaign (Safety Circles Initiative):

Maruti Suzuki has launched excellent scheme of Safety Circles across the company with anobjective to spread safetyawareness, reduce risks andmotivate includingoneandall through“ZeroSaiCampaign”.

Thisisa9-stepprocess,startingfromgroupformation,datacollection,andselectionoftopicforrisklevelreduction,riskanalysis,definingcountermeasures,implementingthemandstandardizingallacrosstheplants.

The scheme has received great response and a total of 252 circles have been registered.TheschemewaslaunchedinpresenceofManagingDirectorofMarutiSuzukiinpresenceofDirectorGeneral,FactoryAdvisoryServiceandLabourInstitutes(DGFASLI)Govt.ofIndia.

Post-launchofthisscheme,campaigningandtrainingsontheschemewasconductedallacrossthecompanywiththeinvolvementofseniorleadersofManagementandUnionrepresentatives.OncetheriskreductionstepwasachievedthecompetitionsofshortlistedteamswereconductedandFelicitationwasconductedforthewinners.TheWinningteamalsopresentedtheriskreductionprocessandbenefitsuponreductionofrisksatSMCJapan.

In this way through continuous handholding and motivation Maruti Suzuki has derived greatbenefitsinreducingtherisksandmakingtheworkplacesafersothattheemployees/workersfeelsafewhileworkingatMarutiSuzukiandwithhighenthusiasmgivetheir100%attheirwork.

2. Fire Risk Assessment of Vendors Plants:

MarutiSuzukihasdevelopedacomprehensivechecklistwithlotofresearchandstartedtheFireRiskAssessmentofVendorPlantsinDecember2016.SincethenMarutiSuzukiisconductingregularauditsanddefiningtheresultsofVendorPlantsinOK/NGCategory.NumerousimprovementsaremadebyVendorsintermsoffiredetectionandalarmsystems,fireprotectionsystems,FireSafetyprocedures,electricalfiresafety.

WiththehelpofFireRiskAssessment,MarutiSuzukihasdemonstratedthesenseofresponsibilitybynotjustkeepingtheirplantssafebutalsosettingimprovingthefiresafetypreparednessandestablishing a safety culture for vendorPlants also.This initiativehashelpedVendorPlants inamannerthatNoMajorFirehashappenedin last2yearsattheirplantsandtheiremployees/workershavebecomemorewaretowardsFireSafety.

Awardees in Large Scale Category (Non- Hazardous)


3. Theme Based Safety Campaigns:

• InviewoffocusedimprovementsincertainareasThemebasedsafetycampaignsareconductedatMarutiSuzuki.

• Every quarter 3 themes are released by Sr. Vice President Safety across the company.Departments/Shopsselectthethemesandworkonthethemesforimprovementsintheirworkareas.

• TheimprovementsareverifiedbySafetydivisionfromtimetotimeandpresentedatvariousforums,reviewmeetingsforappreciationandhorizontalimplementation.

• Morethan3801improvementsaredoneinthroughThemeBasedCampaigninFY’18-19.

4. Safety Committee System

5. Road Safety Initiatives:

AtMarutiSuzukinumberofroadsafetyinitiativesistakenoutofwhichoneuniqueinitiativeisexplainedbelow:

LEDDisplayBoardforRoadSafetyAwareness:LEDdisplayboardimplementationhasturnedouttobeoneofthemanyroadsafetyinitiativestakenatMSIL.8suchboardsareinstalledatvariouslocationsoftheplant.Thisinitiativehashelpedincreatingapositiveimpactindrivingbehaviorofdriversandcreatingasenseofresponsibledrivinginsideaswellasoutsideplants.


6. KY (Kiken-Yochi) is a ‘japanese word’ meaning ‘Hazard Prediction’ iswell accepted activityacrossMSIL.

7. Sujhav Sangrehika/Suggestion Scheme:

‘SujhavSangrehika’-TheSuggestionSchemeofMSIL ‘is an importantandoutstandingplatformfor MSIL employees to give their valuable feedbacks/Suggestion/constructive thoughts for thebettermentofSafetyandprospergrowthoftheorganization.Itisanonlineportalinwhichthereisanonlinesuggestionformwhereinemployeesfillintheirsuggestionforimprovement.

8. Safety Ambassadors Scheme (200+ safety ambassadors);

9. Safety training through simulators

MSILhasestablishedafullyequippedsafetylabwithsimulatorsforprovidingrealtimesimulationtrainingofworkplacehazardsandsignificanceofsafetycontrols.

Real time models are installed and of understanding of all the above hazards and theirconsequences.

ThesimulatorsalsoconsistofEngineeringcontroldevicesforcontrolofthesehazardswhichareexplainedtothetrainees.

10. Third Party Internal Safety Audits

MSILhasappointedahighlyexperienced,CIF certified,DGFASLI and IRCAcertifiedauditors forsafety.

Everymonthminimum4auditsareconducted;thisrigorousproactiveapproachhelpstheidentifyinherentprocessrisksandtotakesuitableengineeringcountermeasures.

Gold (Second) Award

Name of the Organization:L&TShipbuilding(LTSB)

Location:TiruvallureDistrict,TamilNadu


• L&TShipbuilding(LTSB)hasoneofthebestOccupationalHealthandSafetyManagementSysteminIndia,whichwasauditedbyBritishSafetyCouncilinApril2019andaccorded“5Star”rating.TheyhaveestablishedEHSManagementSystembasedonPDCA,whichbroughtdownthe injuryrate drastically, but does not completely preclude injuries.As demonstrated in BradleyCurve,theyarelivingexampletoprovethetheoryandareinthemiddleofmigratingfromindependenttointerdependent.

• In addition to conventional EHS Apex Committee and Contractors EHS committee, LTSB hasformed Vessel Safety Co-ordination Committee (VSCC) for each new build project/ship underrefit.VSCCcomprisesProjectManager,SafetyOfficer,engineersfromeachtradeandsupervisorylevel representative from each contractor, engaged in the project/ship under refit.Meeting isbeingconvenedeverydaytoco-ordinateallactivitiesfornext24hourswiththeparticipationandconsultationofallengineers,ship’screw&contractorsupervisors.ThereAre17PermitstoWorkwhicharestrictly followed.Theprojectmanagerensures thatcontractorsare fully involved incarryingoutHIRAforanynon-routineactivityandpreparingtheworkmethodstatement.


• Involve (Hands-onpersons) toEvolve (SafetyCulture)andthus,allworkersandsupervisorsarebeing encouraged to report any sub-standard act/condition they come across and empoweredtostopthework.Healthandsafetyconcernshavebeenreportedregularlyandactiontrackingregister beingmaintained to ensure root causes are addressed and corrective action taken topreventrecurrence.Allthose,whomadeRSC(ReportingSafetyConcern),arebeingrewardedintheNationalSafetyWeekfunction.

• PointofWorksafetyassessmenthasbeeninitiatedforhotwork,paintingandliftingactivities.Toguidethesupervisorsonthepointofworksafetyassessment,thecheckstobemadepriortothecommencementofwork,istabulatedinthepocketcard.

• Management initiated “Process Confirmation” by engaging the team through conversation forreinforcingexpectedbehavioursofthecontractor’sworkforceispracticed.Theemphasisoftheorganisationison“BehaviourBasedSafety”throughcounsellingandreinforcingsafetyculture.

• All workforce including contractors undergo EHS basic Induction training and pre-employmentmedical screening before obtaining gate pass. Trade based EHS training is conducted beforecommencingthework.

• Contractors’tools&tacklesarebeinginspectedatgateitselftoensuretheconditionoftoolsandvalid inspectioncertificates for liftinggearsandpressurevessels.Uponbringing into theyard,thegascuttingtorch&hosesarepressuretestedfortnightlyandelectricalappliancesincludingextensionboxesareinspected&taggedonceinamonth.

• Evaluation & Continual Improvement: Top management considers OHS as an integral part ofyardoperationsandthuseverytopmanagementmeetingstartswithreviewofOHSperformanceincludingBoardofDirector’sMeeting.CEOreviewsSafetyonmonthlybasis.

• ManagementofChange(MOC)committeehasbeenrevampedandallthechanges(man/machine/method/material)arebeingensuredbytheMOCcommitteethatHIRA&OHSimpactareassessedthoroughlyusingguidingchecklist.



Name of the Organization:ArystaLifeScienceIndiaLimited

Location:Panchmaha,Gujarat


Arystafollowtheprincipalof“SafetybyDesign”and“SafetyFirst”tosustainsafeworkenvironment.

• Compliances:Toensure100%health&safetycomplianceisintegralpartofHSEpolicy.Complianceauditisbeingdrivenbytopmanagement.Theyhaveset&achievedHSEobjectiveswhichis50%lowerthanlegalcompliancecriteria.

• Resource Allocation:TheyensurebestpracticesacrossthecompanylikePPECompliances,workpermitsystem,Fallprotectiondevices.Allplantequipment’sdo’s&don’tsandworkinstructionsare displayed in pictorial and local language. Safety data sheet (SDS) provided at respectivelocation.

• Equipment Design: They followmanagement of change practice before addition,modificationandchangeinequipmentorprocessorplantwithdetailhealth&safetyriskassessmentandtheiroutcomeactionplan.

Ensureallequipmentaredesignedsafewithemergencystopprovisions.

• Infrastructure:Entirefactoryisprotectedbyfirehydrant,sprinklersystem,foamfloodingsystem,automaticfirealarmandactuatingsystem,variousfirstaidfirefightingequipmentwithemergencyresponsecontrolroom.Theyhaveachievedasbestosfreesiteintheyear2018.

• Performance Measurement:Theyhaveestablishedmeaningfulmetrics tomonitor their healthand safety performance anduse thesemetrics to set goals for safety.They have given 30% ofweightagetosafetyinemployeeannualappraisal.

• Training & Development:Theyfollow100%safetyinductiontoallcontractorworkmen,employees,visitors.TrainingispartofeveryemployeeKPIbasedontrainingneedidentification.Everyshiftstartswithsafetytalk.Contractorsandsuppliersarepartofannualtrainingplan.

• Health & OHC: Site is equipped with full-fledged OHC, shift wise medical attendant andambulance.Ensureallemployeeincludingcontractlabourhavetheirpre-medicalcheck-updone,periodichealthchecks,weeklycounsellingwithregularoccupationdoctorareconducted.

• Annual Review: Annual review the company’s HSE performance and updating of the policy,procedureandsystemasneeded.

Awardees in Medium Scale Category


Gold (Second) Award

Name of the Organization:JBMangharamFoodsPrivateLimited

Location:Gwalior,MadhyaPradesh


• Atrecruitmentstage:

(1) Occupationalhealthcheck-upalongwithstatutorycompliancesinplantpremises

(2) Biometricauthenticationfollowedbyrequiredvaccination

(3) MandatorycommunicationofEHSpolicybyHRManagerandfollowedbyendorsement

(4) Inductionaboutplantandsafetysystemsthroughanimatedmoduleoffourhours(ThismoduleisdevelopedwithhelpofPurpleframe)followedbyplantround

• Onthejobtraining:

(1) TrainingofSOPs,OCPsthroughadequatevisuals.

(2) RoundtheclocksafetycommunicationthroughvideosaboutEHSinrestroomandcanteen

(3) MustwalkthroughfromBehaviourbasedsafetytunnel

(4) Machinesafetyriskassessmentdoneforeachmachineandallsignificantriskpointsaremarkedclearlyonmachineitself

• Othershopfloorbestpracticesandoperatingsystem:

(1) Unsafeact/Unsafecondition/unsafebehaviourreportingstation

(2) PermittoworkandLOTOsystem

(3) MotivationalschemesthroughR&RprogramandThankyoucards

(4) Participation of employees’ children in safety programs through painting and postercompetition

(5) 360degreeguardingofalltherotatingpartsinmachines

(6) LearningaboutusagesofPPEsthroughmannequin

(7) ParticipationinNationaleventslikesafetyweek,IndustrialsafetydayandEnvironmentday

(8) EquippedwithFirehydrantandCCTVsystem

(9) UsageofIndustrialelectricalsocketsinsidefactoryareaandflame-prooflightsinallstores

(10)Monthlycampaignsondifferentthemeseverymonthi.e.Handsafety,Push-Pull,heatstroke,etc.

(11)SafetyCommitteemeetingandMRMdoneonscheduletime.

(12)SafetyKaizenarepromotedandrewardedinmonthlytownhall.

(13)HIRAandMSRA isbeingreviewedandupgradedforeveryprocess/machinechangethroughManagementofchangeprocess.



Name of the Organization:ATCLimited

Location:Hosur,TamilNadu

Organisation Overview:

• Factorywasestablishedin1974

• FirstcompanytostartoperationsinSIPCOTHosurbelt

• Totallandarea11.3acres,Builtuparea1.97acres

• Greencoverage62%,Roadandotheropenarea19.5%

• Manpower–187employees,140ESPs,34Managers&OAs

• LicensedCapacity–9500MillionCigarettes/Annum

• Nillosstimeaccidentsforthepast9.5years

• SeveralawardsforEHSexcellencefromCII,FICCI,NSCIandTNGovernment

• Zerowastewaterdischargeunit

• BenchmarkinEnergyConservation,WaterConservation,WasteMinimization

• 100%RoofRainwaterHarvesting

• Offsitewindpower–1.5MWcapacity

• 95%ofenergyusedisfromRenewableEnergySource(Wind)

• ExcesspowergeneratedissoldtoTNEB


1. ManagementLeadership:

• Top management demonstrates its commitment to continuous improvement in safety andhealth, communicates that commitment to workers, and sets program expectations andresponsibilities.

• Managersatalllevelsmakesafetyandhealthacoreorganizationalvalue,establishsafetyandhealthgoalsandobjectives,provideadequateresourcesandsupportfortheprogram,andsetagoodexample.

2. WorkerParticipation:

• Workersandtheirrepresentativesareinvolvedinallaspectsoftheprogram-includingsettinggoals,identifyingandreportinghazards,investigatingincidents,andtrackingprogress.

• All workers, including contractors and temporary workers, understand their roles andresponsibilitiesundertheprogramandwhattheyneedtodotoeffectivelycarrythemout.

• Workers are encouraged andhavemeans to communicate openlywithmanagement and toreportsafetyandhealthconcernswithoutfearofretaliation.

Awardees in Small Scale Category


3. EducationandTraining:

• All workers are trained to understand how the program works and how to carry out theresponsibilitiesassignedtothemundertheprogram.

• Employers, managers, and supervisors receive training on safety concepts and theirresponsibilityforprotectingworkers’rightsandrespondingtoworkers’reportsandconcerns.

• Allworkersaretrainedtorecognizeworkplacehazardsandtounderstandthecontrolmeasuresthathavebeenimplemented.

4. HazardIdentification&RiskAssessment:

• Extensivehazardidentificationandriskassessmentacrossunit

• ConsolidatedHIRAregisteranddisplayintherelevantarea

• InclusionofallincidentsinHIRARegister

5. SafeWorkProcedures:

• Safeworkproceduresforalloperationscarriedoutintheunit

• DisplayofSWPintheareaofoperation

• Trainingandplanjobobservations

6. StandardOperatingProcedures:

• SOPforalltheOperations

• DisplayofrelevantSOPatallplacesofOperation

• Trainingandplanjobobservations

7. LegalCompliance:

• Legalregistercomprisingallapplicablestatues

• GapidentificationbyExperts

• Monthlycompliancereport

8. WorkPermitSystem:

• Heightworkpermit,Hotworkpermit,confinedspaceworkpermit

• Electricalworkpermit,Excavationworkpermit

9. PlantInspections:

• QuarterlyInspectionbyFactoryManageralongwithHODandEHSManager

• Inspectionofdifferentzonesofthefactorybycrossfunctionalteams

• Observationswithphotographsandcorrectiveactionsbyresponsibleteam


10. HygieneQualityRatingSystem:

• Thisisahygieneauditsystemwherewomenemployeesareauditors

• Elaboratechecklistandguideline.Monthlyaudit.Scorecardcirculatedaftertheauditwithobservationalongwiththephotographs

• Correctiveactionstakenagainsteachobservationwithintimelimit

11. ImplementationofIncident/AccidentCaseStudies:

• CasestudiesofaccidentsandincidentsarecirculatedbyITCCorporateEHS

• Each case study would be analysed for applicability to the unit and the case studies arecommunicatedtoallemployees

• Correctiveactionistakenforallapplicablecasestudiesandimplemented

12. PerformanceMeasures,Monitoring&ReportingSystem:

• SustainabilityReporttoITCinGRIG4format

• MonthlyEHSreport

• CorporateEHSAuditstwiceinthreeyears

• DivisionalEHSauditonceinayear

• IMSAuditsonceinayear

13. Behavioural-BasedSafetyManagement:

• OrganizedBBSMtrainingthroughNSCI

• FormedCoreCommittee

• Identified17Observersinallshifts

• OrganizedObservertrainingandinvitedsuggestionstowardsmajorrisk

• Identified5MajorRiskalongwithobservers,preparedchecklistinlocallanguageandsharedthesametotheobservers

• Implementationunderprogress



Name of the Organization:L&TConstruction,Water&EffluentTreatmentIC

Location:Erode,TamilNadu


1. SafetyPracticesforStaff,Subcontractor&Workmen

• Generalmedicalscreeningforallstaff,sub-contractors&workmen.

• Skillmedicaltestforskilledworkers.

• EHSInductionforall:-New&visitingstaff

-Subcontractors

-Workmenbeforedeployingforworks.

• DailySafetyPEPtalkforallworkmen&subcontractor.

• Motivationforsafetyconsciousnessplannedfor:-Workmen-Weeklybasis

-Subcontractors–Quarterly

-Staffs-Monthly

• PeriodicEHStrainingplannedforallstaffs,sub-contractors&workmen.

• PeriodicHeathcheck-upforstaffs,sub-contractors&workmen.

• Codeofconductcommunicatedtosub-contractorsandregularevaluationisconducted.

• Sub-contractorsaremotivatedtoparticipateinMonthlyCommitteeMeetings.

2. SafetyPracticesinExecutionActivities

Electrical Works:

• ElectricalconnectionsroutedonlythroughRCCB&Earthingensuredforallconnections.

• Safety&precautionarywarningsignboardsareplacednearallelectricalequipment.

• OnlyIP-55PowerDistributionBoards(PDB’s)&Junctionboxused.

• ElectricalResistantRubberMatsplacedinfrontofallPDB’s&DieselGenerators.

• Allelectricalcablesroutedeitheroverheadorunderground.

CONSTRUCTION SECTOR

Awardees in Large Scale Category


Gold (Second) Award

Name of the Organization:SiemensIndiaSmartInfrastructure-“CreatingEnvironmentsthatCare”

Location:GreaterNoida,UttarPradesh


• Zeroharmculture is implementedbyembeddingEHSwithintheareaofmanufacturingandproject business by ensuring safetywalkthroughs, identifyingUA/UC alongwith analysis ofcriticalrisks,robustcontractormanagementandadoptingthefirsttimeright&safeapproach.

• EHS ownership is throughout the hierarchy and reviews are held at the highest level ofmanagementwithonlinedashboardforreportingKPI’s.

• Robustcontractormanagementprocesswithperformance-basedincentivesforfutureorders,sitekickoffmeetingsduringsitemobilization,contractorengagementprograms,contractorqualification process, contractor evaluation process with traffic lights RED/YELLOW/GREENcontractor.

• Award and consequence policy applicable to all employees. ZeroTolerance is keymessagebeing spread through regular communications on safety alerts, SURAKSHA (EHSmagazine).Globalevents likeWorldEnvironmentday, Safetydaybeingcelebratedatall factoriesandprojectsites.

• SITRUST (Siemens Training Center) being used to impart training/certification to ownemployeesandcontractorsonsafetyguidelinesandmethodsforsafesiteactivities.

Height Works:

• Heightpassismandatoryforworkmeni.e.onlyworkmenfitforheightworksareallowed.

• Primaryfallprotectionarrangementalongwithsecondaryprotectioni.e.safetynetensuredwithsafeworkingplatform.

• ProperHardBarricationandappropriatesignboardsplacedinallworkingareas.

• Jerzybarriersimplementedinallsitesforbarricationinbusyroads.

• Shoring,BenchingorSloppingarrangementsprovidedforworkinginsidetrenchesbasedonthesoilconditions.

• ProperTrafficmanagementplanimplementedinpipelayingareas.

• TrafficMarshalldeployedinallpipelaying,loading&unloadingareas.

Material Handling:

• Skilledworkmenwithskillpassmandatoryformaterialhandlingworks.

• Allliftingtools&tacklesisperiodicallyinspectedbyhome&annuallyinspectedby3rdparty.


• Safetyparksbuiltoneachsitetodemonstrate/displayourcommitmenttoEHSandshowcasesamplesofgoodworkpracticeandmethods.

• Operation controls in place at all sites like live line detectors, LOTO kits,Arc flash suits,ELCBtesters,LUXmeters,solarsnakerepellants,temperatureandpressuresensingflashbackarrestors,pictorialSafeworkmethodstatements.

• To address health issues, camps are organized for check-ups, behaviour-based trainingprogramsareheld,tieupsaredonewithlocalhospitalsandAirAmbulanceserviceprovidertoprovideinstantmedicalhelp.

• SIEvellance-remoteviewingapptomonitorsiteprogressandevaluatesafetycompliance.

• Everysiteisratedsafe/unsafeasperitscompliancetosafetyrequirementsusinganonlinetooltocapturedifferentelementsandpredefinedpointssystem.



Name of the Organization:RaageshwariOil&GasMine,CairnOil&Gas,VedantaLimited

Location:Dist.Barmer,Rajasthan


AsBestPracticesinSafety,followingkeyinitiativesareimplementedatRaageshwariOilandGasMine

1. Awards&Recognitions

• CelebratingHSEmilestones–11yearsand15millionmanhoursofLTIfreeoperations.

• AchievedSwordofHonourfromBritishSafetyCouncil,5ScertificationfromJUSE.

2. Visible Felt Leadership

• ScreeningofGroupCEOVideoMessage“Safetyisourfirstvalueandourtoppriority”inlocallanguagebeforeeverycontractormeeting/townhall

• Visible Felt Leadership initiatives- Safety Interactions, hazard tours, toolbox embedded inSeniorsleadership/frontlinesupervisorsKPIandtrackedonmonthlybasis.

• FullDaySafetyTrainingimpartedtoleadershipteam(includingbusinesspartners)onHazardidentificationandSafetyinteractiontechniquesforqualitysafetyinteraction

• MonthlyHSELeadershiptourbyCorporateSeniorManagement(Operationsdept.)

3. RiskManagement

• SafetyCritical tasks (Workatheight,ConfinedSpaceentryetc.)are identifiedandensuredthatcriticalcompetencies,criticalcontrolsrequiredforthejobarecompiledpriortostart.

• CriticalControls(CC)identifiedforMajorRiskEventsthruQRA,Bow-TieandhealthinessofCCmonitoredmonthly.

4. Contractor Management

• Every Contractor/business partner needs to qualify Safety evaluation as per ContractorManagementProcedure,beforeawardofcontract.

• DailyHSEtipsonrandomsafetytopics,WeeklyHSEmeetinginvolvingcontractorpersonnel.

• Monthlyrewardsschemes

BestContractorPersonnel

BestDriver

BestBBSCard

AllPersonnelreportingnearmiss

MINING SECTOR



5. Safety Initiatives

• SafetypartofAnnualPerformanceManagementSystemforeachemployeeand25%oftotalweightageforSafety.

• Personnel lockwith name/photo issued to allworkers. Individuals apply personnel lock foractivitiesinvolvingisolationpriortoJobstart.

• “PERFECTDAY”conceptatRGTforoperationalexcellencewithHSEtargetsembedded

• StrictimplementationofZeroTbehaviorsandLifeSaverRules.

• EmergencyPreparednesswithscenariospecificERPandmonthlymockdrills

6. Digitisation

• OnlineApplicationsfor

- Monthly compliancemonitoring of HSE regulation by respective HOD, legal departmentandTPC.

- Reporting,investigationofHSEIncidents.

- Trackingofrecommendationsfromincidentinvestigations,Internal/Externalaudits,Safetystudiesetc.

- BBSintervention

- GPStrackingofdeviationbyvehiclelikeoverspeeding

7. Occupation Health

• TieupwithMedicalairliftserviceprovidertocommutepatientduringemergency.

• VariousHealthpromotionevents-DietManagement,Diabetics,preventionofdrugandalcohol,Yoga/laughterYogacampsetcareorganized.

• PersonalHeathCard(pocketsize)withkeyhealthparametersissuedtoall.

8. Training & Competency

• Competencygapanalysisdoneannuallyforemployees/contractors.Trainingsimpartedbasedonassessment.

• Mandatory2man-daysofSafetytrainingperyearforallemployees/contractors.

• HSE Passports issued to employees/contractor personnel and training details updated inpassportfortracking.

• Classroomtraining,BalancetestandVertigotestmandatoryforpersonnelworkingatheight.

• InternationalMinimumIndividualSafetyTraining(IMIST).

• ExternalAdvancedFirefightingtrainingthruM/sSurakshaMarineforIncidentResponseTeam

• ThemebasedMonthlyHSECampaign.


Gold (Second) Award

Name of the Organization:DalmiaCementBharatCement

Location:Kadapa-AndhraPradesh.


The Safety best Practices Systems that were followed for the operations/Processes/MaintenanceactivitiesandforHumansafetyareasfollows:

Systems:

• Unit levelApex committee headed by Unit Head will review the performance onmonthlybasis. The vertical heads for Safety observation, Incident investigation, Contractor SafetyManagement,Standards&Procedures,RoadSafetyManagement,reviewtheperformancefortheirrespectiveverticalheadsonmonthlybasis.

• CardinalRules

Employee Motivation:

• SafetyParkDevelopedwithLiveModels.

• Introduced the concept of “Safety Star Award” to bring strong safety culture among theworkmenandalsoisthehighestappreciationawardintheunit.

• Ceremonial red carpet honouring of best safetyworker inmonthly safetymeeting for flaghoisting.

Leadership:

• Safetyreviewmeetingonmonthly,meetingischairedbytheCEO.

• TheManagingDirectoroftheorganizationreviewstheSafetyPerformance,astheoneofthemaindimensionsofthebusinessatBoardlevelonquarterlybasis.ThereviewdecisionfromCEOcascadetoCOOthroughvariouscommunicationchannels.

• SHEcouncilheadedbyCOOtoreviewtheSafetyPerformanceeverymonth.

• Safety committee meeting headed by Unit Head to review the Safety performance withworkersparticipation.

• Daily intheProductionreviewmeetingheadedbyUnitHead/TechnicalHead,a5-minuteeachdurationshallbegivenforSafetyforknowinganysafetyrelatedmatters.

• EverymonthconductingSafetyGatemeetingheadedbyUnitHead.

• SeniorManagementAuditonceinamonthwithUnitHead,withrespectiveHoD’s.

• Everyexecutiveisgivenresponsibleforsafetyandgivenhighestweightageinkeyresponsibilityarea.

• 5sbroughttremendousdevelopmentin5ssystemsacrosstheentryplantandownthemodelcompanyawardformABKAOTS.


• Kiln coating removing bymanually is risk, by using brokemachine risk severity reduced tozero.

• Flyashsamplecollectionformtruckfallfromheightisriskbyusingflyashsamplecollectionfromhopperriskseverityreducedtozero.

Controls:

• Clearancecertificateformsafetydepartmentforeveryrestartofkilntoensuresafety.

• VisualindicationofConfinedSpaceProvidedanautomatedvisualindicationatentrypointofconfined space area using a light (Green/Red)&developing interlocks in plantDCS systemconsideringisolationofallequipment’s.Thiswillensurethatnowareaissafeforcarryingoutworkatconfinedspaceinadditiontoourexistingpermitsystem.

• EquipmentInterlocksasperthesequenceofoperationseithertostart/stopoftheoperation/equipment.

• Monitoring the light vehicle speed through GPS system is a key reinforce positive drivingbehavioursamongdriversalongthevehiclecheck.

Motivational Training:

• 360-degreeapproachtocreatesafetycultureinoverallteam,family,societyandpartners.

• Created safety awareness among workers that no work is so important (or) urgent that itcannotbeperformedsafely.

• InstantGiftsandgoodcitizens.

• RoadsafetyconductedalongwithRTAdepartmentinplantandinnearby4villagestobringawarenessontrafficmanagementandsafetysystems.

• PictorialSOPdisplayedinLocalLanguageinallsections.

• Posters and wall paintings have been used as an efficient tool to make awareness amongworkersonsafety.



Name of the Organization:UdupiPowerCorporationLimited

Location:Udupi,Karnataka


• UPCLhasundertakenaSafetyProcessTransformationProjectinconsultationwithM/sDuPontinthename“Chetna”withthetagline“AapkiSuraksha,HamaaraLakshya”.Themainobjectiveoftheprojectistoinvolve/engagealllevelofemployeesintothesafetysystemtoachievethemissionzeroharm.Underthisprojectsitehasimplemented05SafetyManagementSystemStandardswhichareasfollows:

• Safety Interaction (SI): Structured pro-active two-way safety conversation with people attheirworkplacetoachievepositivechangeinpeople’sbehaviourtowardssafety.

• Incident Management (IM): Employees andAgencyemployees areencouraged to report allincidentsandincidentsareinvestigatedtofindouttherootcause.TheCorrectiveactionsarehorizontallydeployedtoavoidthereoccurrence.

• High Risk Activities (HRA): High performance standards and governance structure for safeexecutionofhigh-riskactivitiesisensuredinHRA.UPCLhasidentified12highriskactivitiesandpreparedtheFatalityandSeriousIncidentPreventionPlan(FSIPP).RiskownerandbarrierownersareidentifiedforallFSIPPandmaderesponsibletoensurethehealthinessofallthebarrierbyregularauditbytheconcernbarrierownerandKPIsaremonitored.

• Process Safety Management (PSM):Application ofmanagement principles and systems fortheidentification,understandingandcontrolofprocesshazardstoprotectemployees,facilityassetsandtheenvironment.

• Contractor Safety Management System (CSM): Process to establish safety standards fordefining pre-qualification criteria for contractors, contract preparation and post contractcompliance.Sixstepsarefollowedincontractor’ssafetymanagement,Contractorselection,Contract Preparation, Contract Award, Orientation and Training, Managing the work andPeriodicEvaluation.

• Plant Implementation Committees (PIC) -Inordertoimplementallthestandardseffectively,theentireplantisdividedintosiximplementationcommittee.

• Dedicated software – GENSUITE is used for reporting of Safety concerns, Incidents, Safetysuggestions and other Safety elements. All the employees are provided with training andaccesstoreportthesafetyconcerns.

• Legatrix –onlinelegal&otherrequirementsevaluationisundertaken.

• SiteisfollowingtheWearthree(Helmet,ShoesandReflectiveJacketismandatory)carryfourPPEsprocedures(EarPlug,Goggles,HandglovesandDustmaskonneedbasis)

POWER SECTOR



• Site has implemented 04 Life Saving Safety Rules. (Work with a valid work permit whenrequired,verifyisolationbeforeworkbeginsandusethespecifiedlifeprotectingequipment,protect yourself against a fall when working at height & Do not walk under a suspendedload).Alltheemployeesandtheagencyemployeesaretrainedandundertakingtaken.Posterdisplayedatprominentlocationinlocallanguage.

• SafetyKPIarelinkedtoallEmployees’PMSandabout25%oftotalweightageisreserved.

• EverymeetingstartswithaSafetypledgeandSafetycontact–Sharingof incidents/events,learningsofwhichcanpreventreoccurrence.

• Personnelengagedforworkatheightundergovertigotestandisissuedheightworkpass.

• ElectricalArcsuitiskeptinalltheLT/HTroomandbeingusedduringelectricalisolation.

• AnychangeintheexistingsystemisstrictlyfollowedthroughMOC.

• DedicatedworkatheightequipmentareavailablelikeJLG,Manar.

• Newgenerationpick&carrycraneisusedforliftingofmaterial.

• TVsarefixedatwaitinglocationinthesiteandshortsafetymoviesarescreenedoncontinuousbasistocreatethesafetyawarenessamongtheemployees.

• JobCycleCheckiscarriedoutbythetrainedJCCauditorswhileonjobtocheckweatherjobiscarriedoutaspertheSOP.Anydeviationnoticediscorrectedthenandthereandrecordsmaintained.

• PTWwithLOTOisstrictlyfollowedforallthejobsandPTWauditsareconductedtocheckforeffectiveimplementation

• Monthly Safety Activities planner is made and the compliance for the planner is strictlymonitoredthroughdailyplanning,dailymorningandeveningmeeting.

• At Entry gate Safety chanting is continuously played during shift IN/OUT hrs to createawarenessaboutsafetyprecautionstobetakenduringthework.

• Firstday3hrsmandatorySafetyInductionforallemployeesandcontractingagencyemployeesbeforedeploymentonjobandrefreshertrainingconductedonquarterlybasis.

• ToolBoxTalkbeforestartofwork&MassToolBoxTalkbySafety&Executionteamondailybasis&areawisecoveringtotalplantarea.

• Displayed Dos and Don’ts & MSDS at prominent locations in the plant in local languages.DisplayedofHSEslogansonalllightingpoles.

• SafetyMelaisconductedoneverymonthwhereagencyemployeesareperformingtheSafetyskit and Safety speech on different topics is delivered by the agency employees. Suitableawardisgiventothewinners.

• Safetyperformanceisreviewdoneatdifferentforumwhichinvolves

QuarterlyChairmanReviewmeeting,AGSSC(AdaniGroupSafetySteeringCouncil),APSSC(AdaniPowerSafety Steering Committee),Apex Meeting, ORM (Operation Review Meeting ),HSE Meeting and PIC(PlantImplementationCommittee)

• Allsafetypermitsarediscussedonedayinadvanceintheeveningmeetingtoensureproperplanningforsafeexecutionofjob.


Gold (Second) Award

Name of the Organization:CESCLimited(BudgeBudgeGenerationStation)

Location:Parganas(S),WestBengal


BudgeBudgeGeneratingStation,CESCLtd.hasembedded‘Safety’asacultureovertheyears.Whilecontinuing the journey towardsonemission- ‘Zero Incidence’, ithas takenvarious safety initiativesandpractices. To enable safety in every tier of the organization a proper hierarchical structure ismaintaineddescribedasbelow:

1. Inaddition,therearefivesafetysub-committeenamely

a) SafetyObservation

b) IncidentInvestigation

c) Rules&Procedure

d) ContractorSafetyManagement

e) CapabilityBuilding

Eachsub-committeemeetonceeverymonthtodiscussgaps.AnyissuewhichneedstopmanagementinterventionaretakenupintheAPEXcommitteemeeting

2. Everyday Morning Manager’s Meeting is started with previous day’s safety issues if any.

A) Training&awareness:Basicsafetytrainingiscompulsorilygiventoallnewentrantsbeforeissuingthemgate-pass.Jobspecificsafetytrainingsareimpartedtoconcernedemployees.

B) OnlinesoftwaremoduleonTraining.

C) 24X7safetysurveillanceteam.

D) LOTO(LockOutTagOut)system.

E) SafetyDayCelebration

F) PeriodicSafetymeetingwithContractorProprietors

Managing Director

Vice President (BBGS) General Manager

Deputy General Manager Manager

Chief Safety Officer Safety Officer

Safety Surveillance Team Deputy General Manager (Safety Cell)


Recent Innovative Safety Measures and Practices:

• AutomatedFireBallinunmannedareas

• StaticElectricityDischargePlateattheentranceofHydrogenadmissionroom

• FoammonitoratLDOdykearea

• HydrogenLeakageDetector

• CompartmentalizationofCablealleytopreventfirefromspreading

• FluorescentPaintingonStaircaseatBunkerforbettervisibility

• Unmanned level crossing alarming system:Through Beam sensor alarming systemwith onetransmitterandonereceiver

• MillBallsafeLiftingarrangement

• InstallationofHosereelstoprotectrooftopassets

• WaterSprinklingSysteminHydrogenadmissionroom

• BatteryoperatedHeadLight:Mainlyusedforconfinedspacejobsandtunneljobs


NOTES


Established in 1927, FICCI is the largest and oldest apex business organisation in India. ItshistoryiscloselyinterwovenwithIndia’sstruggleforindependence,itsindustrialization,anditsemergenceasoneofthemostrapidlygrowingglobaleconomies.

Anon-government,not-for-profitorganisation,FICCIisthevoiceofIndia’sbusinessandindustry.From influencingpolicy toencouragingdebate,engagingwithpolicymakersandcivil society,FICCI articulates the views and concerns of industry. It serves its members from the Indianprivate and public corporate sectors andmultinational companies, drawing its strength fromdiverseregionalchambersofcommerceandindustryacrossstates,reachingouttoover2,50,000companies.

FICCIprovidesaplatformfornetworkingandconsensusbuildingwithinandacrosssectorsandisthefirstportofcallforIndianindustry,policymakersandtheinternationalbusinesscommunity.

Purtika Kalra SeniorAssistantDirector-Manufacturing

T:+91-11-23487381E:[email protected]

Ankita Sharma ResearchAssociate-Manufacturing

T:+91-11-23487269E:[email protected]

Contact:

FederationHouse,1,TansenMarg,NewDelhi110001,INDIA

Handbook for - FICCIficci.in/events/24453/ISP/Safety-Systems-Handbook.pdf · 2019-10-11 ·...

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