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1.1INTRODUCTION

Due to rapid industrialization, industrial workers are exposed to several types of hazardsand

accidents. Every year lakhs of workers are injured due to mechanical, chemical,

el ec tr ic al a n d r a d i a t i o n h a z a r d s a n d i t l e a d s t o p a r t i a l o r t o t a l

d is ab l em ent . S o in re ce n t yea rs , g re at er a tten tion i s g iven to health and

safe ty d ue to pressu re f rom government , tr ade unions , labour laws and awarenessof employers.The e ffic ienc y of workers depen ds to a grea t ext ends on the

envi ronment in which thework. Work environment consists of all the factors, which act

and react on the body and mind of an employee. The primar y aim is to create an

env iro nment, which ens ures the greatest ease of work and removes all causes of

worries.Occupational health and safety is a discipline with a broad scope involving many

specializedfields. In its broadest sense, it should aim at:

a)

T h e p r o m o t i o n a n d m a i n t e n a n c e o f t h e h i g h e s t d e g r e e o f p h y s i c a l ,

m e n t a l a n d s o c i a l well-being of workers in all occupations.

b)

T h e p r e v e n t i o n a m o n g w o r k e r s o f a d v e r s e e f f e c t s o n h e a l t h c a u s e d b ytheir workingconditions.

c)

The protection of workers in their employment from risks resulting from factors adverseto

health.

d)

T h e p l a c i n g a n d m a i n t e n a n c e o f w o r k e r s i n a n o c c u p a t i o n a l

e n v i r o n m e n t a d a p t e d t o physical and mental needs.

e)

The adaptation of work to humans.S u c c e s s f u l o c c u p a t i o n a l h e a l t h a n d

s a f e t y p r a c t i c e r e q u i r e s t h e c o l l a b o r a t i o n a n d participation of

both empl oyers and workers in health and safety programmes, and involves

t h e c o n s i d e r a t i o n o f i s s u e s r e l a t i n g t o o c c u p a t i o n a l m e d i c i n e ,

i n d u s t r i a l h yg i e n e , t o x i c o l o g y, education, engineering safety, ergonomics,

psychology, etc.

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Occupational health issues are often given less attention than occupational

safety issu es because the former are generally more difficult to confront. However, when

health is addressed,so is safe ty, becau se a h ealt hy wo rkplace is by defini tion also

a safe workplace. The converse,though, may not be true - a so-called safe workplace is

not necessarily also a healthy workplace.T h e i m p o r t a n t p o i n t i s t h a t i s s u e s

o f b o t h h e a l t h a n d s a f e t y m u s t b e a d d r e s s e d i ne v e r y workplace.Work plays a central role in people's lives, since most workers spend at

least eight hoursa da y in the workplac e, whe ther it i s on a plantation, in an of fice ,

factor y, etc. Therefore, work e n v i r o n m e n t s s h o u l d b e s a f e a n d

h e a l t h y . U n f o r t u n a t e l y s o m e e m p l o y e r s a s s u m e

l i t t l e responsibility for the protection of workers' health and safety. In fact,

so me employers do no teven know that they have the moral and often legal responsibility

to protect workers.

Health of the workers:

Health is a state of complete physical, mental and social wellbeing and not

merely theabsence of diseases. Its a pos itive and dynamic concept which

means someth ing more t han the absence of illness.

Statutory provisions:

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According to factories Act, 1948, the statutory provisions regarding the health

of theworkers are stated in the sections 11 to 20. They are

Cleanliness (sec 11):Every factory shall be kept clean by daily sweeping or washing the floors and workroomsand

by us ing disinfectant s wh ere every necessary. Walls, doors and windows sha ll

be repa intedor varnished at least once in every 5 years.

Disposal of wastes and effluents (sec 12):

T h e w a s t e m a t e r i a l s p r o d u c e d f r o m t h e m a n u f a c t u r i n g p r o c e s s m u s t

b e e f f e c t i v e l y disposed of wastes.

Ventilation and temperature (sec 13):

There must be provision for adequate ventilation for the circulation of fresh air.

Thetemperature must be kept at a comfortable level. Hot parts of machines

must be separated andinsulated. The State Government may make rules for the

keepin g of thermometers in spec if ied places and the adoption of methods which willkeep the temperature low.

Removal of Dust and fumes (sec 14):

If the manufacturing process used gives off injurious or offensive dust and steps must

betake n so that they are not inhaled or accumulated. The exhaust fumes of

in te rnal combus tionengines must be conducted outside the factory.

Artificial humidification (sec 15):

The water used for this purpose must be pure. The State Government can frame

rulesregarding the process of humidification etc. The water used for

humidification shall be takenfrom a public supply or other source of drinking

water and must be e ffectivel y purified before use.

Overcrowding (sec 16):

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T h e r e m u s t b e n o o v e r c r o w d i n g i n a f a c t o r y . I n

f a c t o r i e s e x i s t i n g b e f o r e t h e c o m m e n c e m e n t o f t h e A c t t h e r e

mus t be a t le as t 9 .9 cub ic met ers o f spa ce pe r w ork er . Fo r factories built

afterwards, there must be at least 4.2 cubic meters of space. The chief inspector of factories

can also prescribe the maximum number of workers who can work in each work room.Lighting (sec 17):

Factories must be well lighted. Effective measures must be adopted to prevent

glare or formation of shadows which might cause eye strain.

Drinking water (sec 18):

Arrangements must be made to provide a sufficient supply of wholesome drinking water.All

supply points of such water must be marked drinking water. No such points shall be

withi n 20 ft. (or 7.5 meter s) of any l atrine, washing pl ace etc. Factories employing

more than 250 workers must cool the water during the hot weather.

Toilet facilities (sec 19):

E v e r y f a c t o r y m u s t p r o v i d e s u f f i c i e n t n u m b e r o f l a t r i n e s a n d u r i n a l s .

T h e r e m u s t b e separate provisions for male and female workers.L a t r i n e s a n du r i n a l s m u s t b e k e p t i n a c l e a n a n d s a n i t a r y c o n d i t i o n . I n

f a c t o r i e s employing more than 250 workers, they shall be of prescribed sanitary types.

Spittoons (sec 20):

A sufficient number of spittoons must be provided at convenient places, in a

clean andhygienic condition. The State Government may take rules regarding

their number, location andmaintenance.

Safety of the workers:

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Safety is a measures or techniques implemented to reduce the risk of injury,

loss andd a n g e r t o p e r s o n s , p r o p e r t y o r t h e e n v i r o n m e n t i n a n y

f a c i l i t y o r p l a c e i n v o l v i n g t h e manufacturing, producing and processing of

goods or merchandise.

Statutory provisions:

According to factories Act, 1948, the statutory provisions regarding the safety

of theworkers are stated in the sections 21 to 41. They are

Fencing of machinery (Sec 21):

In every factory, every dangerous part of any machinery, every moving part of

a primemover and every flywheel connected to prime mover the head-race andta il -r ace of ev er y water wheel and water turbine, and every part of an electric generator,

motor or rotary converter, every p a r t o f t r a n s m i s s i o n m a c h i n e r y , m u s t

b e s e c u r e l y f e n c e d b y s a f e g u a r d s o f s u b s t a n t i a l construction.

Work on or near machinery in motion (Sec 22):

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It is necessary to examine any part of the machinery while it is motion. The examinationand

lubrication of the machinery, while in motion, should be carried out only by a

specially-trained adult worker wearing tight-fitting clothing.Employment of young persons on Dangerous machines (Sec 23):

A young person should not be allowed to work at dangerous machines unless,

has be en sufficiently instructed and received sufficient training.

Striking gear and devices for cutting off power (Sec 24):

In every factory, suitable striking gear or other efficient mechanical appliance

has to be provided, maintained and used to move driving belts.

Self-acting machines (Sec 25):

No travelling part of a self-acting machine in any factory and no material carried

thereonshall be allowed to run on its outward or inward traverse within a distance of 18

inches from anyfixed structure which is not a part of the machine, if a person is liable to pass

over the space over which it runs.Casing of new machinery (Sec 26):

A l l m a c h i n e r y d r i v e n b y p o w e r , e v e r y s e t - s c r e w , b o l t o r k e y o r a n y

re vo lv i ng sh af t, spindle, wheel or pinion, spur, worm and other toothed or

fr ic tion-gearing has to be properlyencased or guarded in order to prevent danger to the

workmen.

Prohibition of employment of women and children near cotton openers (Sec 27):

W o m e n a n d c h i l d w o r k e r s a r e p r o h i b i t e d t o b e e m p l o y e d i n a n y p a r t

o f a f a c t o r y f o r pressing cotton in which a cotton opener is at work.

Hoists, lifts, lifting machines (Sec 28&29):

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L i f t i n g m a c h i n e s , c h a i n s , r o p e s a n d l i f t i n g t a c k l e s m u s t b e o f

g o o d m e c h a n i c a l construction, sound material and adequate strength and free from

defects. They are to be properlymaintained and thoroughly examined by a competent person

at least once in every 6 months.Revolving machinery (Sec 30):

The maximum safe working peripheral speed of every grindstone or abrasive wheel shall be

permanently affixed. Safe working peripheral spe ed of every revol ving vessel,

cage, basket,flywheel, pulley or disc has also to be ensured.

Pressure plant (Sec 31):

I n a n y f a c t o r y o p e r a t i o n i s c a r r i e d o n a t a p r e s s u r e a b o v e t h e

a t m o s p h e r i c p r e s s u r e , effective arrangements shall be taken to ensure that the safe

working pressure is not exceeded.

Floors, stairs and means of access (Sec 32):

I n e v e r y f a c t o r y a l l f l o o r s , s t e p s , s t a i r s , p a s s a g e s a n d g a n g w a y s s h a l l

b e o f s o u n d construction and properly kept and maintained.Pits, sumps, openings in floors (Sec 33):

Every fixed vessel, sump, tank, pit or opening in the ground or in a floor, which may be

asource of danger shall be either securely covered or securely fenced.

Excessive weights (Sec 34):

No person is to be employed in any factory to lift, carry or move any load so heavy as

islikely to cause him injury.

Protection of eyes (Sec 35):

The state government may require the provision of effective screens or suitable goggles

if t h e r i s k o f i n j u r y t o t h e e y e s i s c a u s e d f r o m p a r t i c l e s

o r f r a g m e n t s t h r o w n o f f i n t h e manufacturing process or from exposure

to excessive light.

Precautions against dangerous fumes (Sec 36):

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In any factory, no person shall be allowed to enter any chamber, tank, vat, pipe,

flue or other confined space in which dangerous fumes are likely to be present

to an extent involv ingrisks to persons.

Explosive or inflammable dust, gas (Sec 37):

All practicable measures have to be taken to prevent explosion by, effective enclosureof plant and machinery, removal or prevention of the accumulation of dust, gas etc and

exclusion or effective enclosure of all possible sources of ignition.

Precaution in case of fire (Sec 38):

Every factory has to be provided with adequate means of escape in case of fire. Effectivea n d

c l e a r l y a u d i b l e m e a n s o f g i v i n g w a r n i n g i n t h e c a s e o f f i r e h a v e t o b e

p r o v i d e d . A f r e e passage-way giving access to each means of escape in case of fire has

to be maintained.

Power to require specifications of defective parts or tests of stability (Sec 39):

The factory inspector to serve on the manager of a factory to furnish

specifications of defective parts or he may order the manager to carry out tests

as he may sp eci fy and to inform him of the results.Safety of buildings and machinery (Sec 40):

E v e r y f a c t o r y s h o u l d a d o p t t h e m e a s u r e s t o e n s u r e t h e s a f e t y o f t h e

b u i l d i n g s a n d machinery. The factory must employ the requi red safety officers

according to th e num ber of workers working in the factory.

Power to make rules (Sec 41):

The state government has the power to make rules to supplement the provisions

re la ting to safety contained in the act.

Occupational accidents/disease:

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di rect and i n d i r e c t e f f e c t s o n t h e l i v e s o f w o r k e r s a n d t h e i r f a m i l i e s .

F o r w o r k e r s s o m e o f t h e

directcosts

of an injury or illness are:

a)

the pain and suffering of the injury or illness;

b)

the loss of income;

c)

the possible loss of a job;d)

Health-care costs.It has been estimated that the

indirect costs

of an accident or illness can be four to ten timesgreater than the direct costs, or even more.

An occupational illness or accident can have so manyi n d i r e c t c o s t s t o w o r k e r s t h a t

i t i s o f t e n d i f f i c u l t t o m e a s u r e t h e m . O n e o f t h e m o s t o b v i o u s indi re ct

costs is the human suffering caused to workers' families, which cannot be

compensatedwith money.

Identifying hazards in the workplace:

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an d af fe ct wo rk er s in different ways depending on the nature of the hazard,

the route of exposure, the dose, etc. Somewell-known occupational diseases include:

a)

Asbestosis (caused by asbestos, which is common in insulation, automobile brake

linings,etc.)

b)

Silicosis (caused by silica, which is common in mining, sandblasting, etc.)

c)Lead poisoning (caused by lead, which is common in battery plants, paint factories, etc.)

d)

Noise-indu ced hearing los s (caused by noise, which is common in many

wo rk places ,including airports, and workplaces where noisy machines, such as presses or

drills, etc.)

Importance of management commitment on health and safety:

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In order to develop a successful health and safety programme, it is essential that there

bes t r o n g m a n a g e m e n t c o m m i t m e n t a n d s t r o n g w o r k e r p a r t i c i p a t i o n i n

the effort to create andmaintain a safe and healthy workplace. An effective

managem ent addresse s al l work-relatedhazards, not only those covered by governmentstandards.A l l l e v e l s o f m a n a g e m e n t m u s t m a k e h e a l t h a n d

s a f e t y a p r i o r i t y . T h e y m u s t communicate this by going out into the

worksite to talk with workers about their concerns and toobserve work procedures and

equipment. In each workplace, the lines of responsibility from topto bottom need to be clear,

and workers should know who is responsible for different health andsafety issues.

Importance of training:

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Workers often experience work-related health problems and do not realize that the

problemsare relat ed to their work, pa rt icu lar ly when an occu pational disease , fo r

example, is in the earlystages. Besides the other more obvious benefits of

tra ining, such as ski ll s development, hazardrecognition, etc., a comprehensive training

programme in each workplace will help workers to:

a)

Reco g n ize ea r ly s ig n s / sy mp to ms o f an y p o ten t i a l o ccu p a t io n a l d i seases

b e f o re t h e y become permanent conditions.

b)

Assess their work environment.

c)

Insist that management make changes before hazardous conditions can develop.Health and safety programmes:

Effective workplace health and safety programmes can help to save the lives of

workers byreducing hazards and thei r consequences . Heal th and safe ty

p r o g ram me s a l s o ha v e p o s i t i ve effects on both worker morale and productivity,

which are important benefits. At the same time,effect ive programmes can save

employers a great deal of money. For all of the reasons given below, it is crucial

that employers, workers and unions are committed to health and safety.

a)

Workplace hazards are controlled - at the source whenever possible.

b)

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c)

Both workers and employers are informed about health and safety risks in the workplace.

d)

There is an active and effective health and s afety committee that includes both

workersand management.e)

Worker health and safety efforts are ongoing.

1.2 COMPANY PROFILE

Wheels India Limited, Padi.

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About company:

W h e e l s I n d i a i s p r o m o t e d b y t h e

TVS Group

a n d w a s s t a r t e d i n t h e e a r l y 6 0 ' s t o manufa cture automobile wheels .Today, Wheels India has grown as a leading manufacturer of s t e e l w h e e l s f o r

p a s s e n g e r c a r s , u t i l i t y v e h i c l e s , t r u c k s , b u s e s , a g r i c u l t u r a l

t r a c t o r s a n d construction equipment in India. The company supplies 2/3

rd

of the domestic market requirementand exports 18% of the turnover to North America,

Europe, Asia Pacific and South Africa.The company also has a technical-financial

collaboration with

Titan Europe

.Wheels India designs and manufactures wheels for the specific requirements of the

customer.Our activities are driven by the following objectives:

Maintain leadership in the domestic market and presence in export markets.

Ensure customer satisfaction through timely delivery of quality products and services,

atcompetitive prices.

Co n t in u o u s ly imp ro v e & in n o v a t iv e pro d u c t d es ig n , p ro cess t e ch n o lo g y

a n d wor k environment to offer better products.

Bring about involvement of all workers in achieving the above objectives.

Location:The company has strategically located plants that give it a logistical advantage and

allowsflexibility in manufacturing.

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Capabilities:Product Development

a)Design and develop wheels for a wide range of applications, backed by four

decadeso f e n r i c h i n g

e x p e r i e n c e f r o mf i e l d ,

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i n t e rn a l t r i a l s , an d E SA (E x p er imen ta l S t ress An a ly s i s ) &

FEM (Finite Element Method). b)Caters to OEM, after-market and niche

segments.c ) C o n t i n u o u s l y e n h a n c i n g t h e v a l u e o f t h e p r o d u c t ,

b a s e d o n f e e d b a c k f r o m c u s t o m e r s a n d o u t c o m e o f o u r i n -h o u s e facilitieslisted below:d) Wh ee ls te st in g la b to ev al ua te en du ra nc e

c a p a b i l i t i e s , by conducting radial fatigue test, bending fatigue test,multiaxis fatigue test

and connecting member test.e) CA E (C om pu te r Ai de d En gi ne er in g) l ab to do

s ur fa ce & s o l i d m o d e l l i n g , f i n i t e e l e m e n t a n a l y s i s , l i f e pr ed ic ti on ,

data acqu i s i t i on & expe r iment a l s t ress analysis.f )Fu l ly e qu ippe d ch emic al ,

meta l lu rg ical and physical lab .

Process Design

a)

Is in final phase of development of a new process tomanufacture tube type truck rim

from plates.

b)H a s d e v e l o p e d p r o c e s s t e c h n o l o g y t o o p t i m i z e tubeless truck rim

design with lesser material input.

c)

P r oc e ss te c hn ol o gy de ve l op me nt , u pg ra d at io n a nd o p t i m i z a t i o n t o

a c h i e v e p r o d u c t s w i t h t i g h t e r specifications to meet growing

demands of the newer generation vehicles.

d)

C o n t i n u o u s r e s e a r c h o n p r o c e s s i m p r o v e m e n t s t o minimize cost of

production.

Tool Design & Manufacture

a)

Has a qualified and experienced team specialising in tool design for forming

/rolling steel.

b)

Fully equipped in-house tool room facility with state-of-the-art machinery and

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design tools.

c)

Com pute r a ide d t ool mod ell ing & m anu fa ctu rin g s oft war e facilities, for manufacturing complicated tool profiles.

1.2.2 Table showing the Products

Wh ee l s In d ia h as th e ab i l i ty to d es ig n th e co mp le te r an g e o f s t ee l -

wh ee l s to su i t c us to m er requirements, incorporating necessary styling and

performance characteristics

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