JOURNEY OF EXCELLENCE IN OCCUPATIONAL SAFETY & …...PME and Health Check-up ... Separate...
Transcript of JOURNEY OF EXCELLENCE IN OCCUPATIONAL SAFETY & …...PME and Health Check-up ... Separate...
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JOURNEY OF EXCELLENCE IN
OCCUPATIONAL SAFETY & HEALTH ……….
A CURTAIN RAISER
ALUMINA REFINERY,
NALCO,DAMANJODI
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MINESMINES REFINERYREFINERY
SOLAR POWERSOLAR POWER
SMELTERSMELTER
CAPTIVE POWER
PLANT
CAPTIVE POWER
PLANT
PORTFACILITIESPORTFACILITIESWIND POWER
PLANT
WIND POWER
PLANT
SOLAR POWERSOLAR POWER
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PRODUCTS
� ALUMINA:
� Alumina Hydrate
� Calcined Alumina
� Specialty Hydrates
� Specialty Aluminas� Specialty Aluminas
� ALUMINIUM:
� Ingot/ Sow/ T-ingot
� Wire Rod
� Billet
� Flat Rolled Products
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BEST SAFETY PRACTICES
Alumina Refinery, Damanjodi
ISO 9001:2015, ISO 14001:2015, OHSAS 18001:2007, EnMS 50001:2011 & SA 8000 Certified company
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21 Lakh TPA(Normative capacity)
REGULAR EMPLOYEES :1675
CONTRACTOR WORKERS: 2200
TOTAL : 3875
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�“Safety is not a gadget but a state of mind”.
�“Safety is cheap and effective insurance policy.”
�“Safety does not come with luck. It has to be“Safety does not come with luck. It has to be
prepared.”
�“Every day is Safety day. Safety has no holiday.”
�“Safety is not a slogan. It’s a way of life.”
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�It is the condition of being Safe or free from any
danger or being protected from any danger.
� In actual, nothing is free from danger as long as our � In actual, nothing is free from danger as long as our
life exists, but we can almost make something safer.
�This is not only important in our professional lives but
also it is equally important in our personal lives.
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�In today’s global scenario, Health, Safety & Environment (HSE) is
considered to be an integral part of the productivity.
�For Sustenance of any organization, apart from theFor Sustenance of any organization, apart from the
productivity, organisation has to focus on HSE aspects and
continually improve upon these standards so as to compete
globally in the long run.
�Culture of Health, Safety & Environment in any organization
should start from the top leadership."It takes leadership to improve Safety." - Jackie Steward.
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�Culture of HSE is to be driven from top, which peculates into middle
and bottom level & ultimately to workers level at workplaces.
�We must think “HSE” for our interested parties like all our
Stakeholders.Stakeholders.
�Our planning and thought process ought to be channelized in such a
way that our interested parties shall not be affected in any way due to
any activity, any operation or process carried out in our industry.
�Basically, the paradigm needs to be shifted in all the levels, as regards
to “HSE” standards with adopting bench marking strategies for
sustenance of organization.
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�Alumina Refinery,NALCO is pursuing the journey for Business
Excellence.
�Alumina Refinery has been assessed by a group of certified�Alumina Refinery has been assessed by a group of certified
assessors from CII in the month of October 2018.
�Unit has been recommended by the jury for Gold Plus level
under the CII-EXIM BANK Award for Business Excellence- 2018.
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European Foundation for Quality Management (EFQM) Excellence Model
PEOPLEPEOPLE PEOPLE RESULTSPEOPLE RESULTS
EnablersEnablers ResultsResults
LEADERSHIPLEADERSHIPPROCESS,
PRODUCTS &
SERVICES
PROCESS,
PRODUCTS &
SERVICES
STRATEGYSTRATEGY
PARTNERSHIP
& RESOURCES
PARTNERSHIP
& RESOURCES
CUSTOMER
RESULTS
CUSTOMER
RESULTS
SOCIETY RESULTSSOCIETY RESULTS
BUSINESS
RESULTS
BUSINESS
RESULTS
Learning, Creativity and Innovation
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EFQM Excellence Model
PEOPLEPEOPLE
ENABLERSENABLERSLEADERSHIPLEADERSHIPPROCESSES,
PRODUCTS &
SERVICES
PROCESSES,
PRODUCTS &
SERVICES
STRATEGYSTRATEGY
PARTNERSHIP
& RESOURCES
PARTNERSHIP
& RESOURCES
ENABLERSENABLERS
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EFQM Excellence Model
LEADERSHIPLEADERSHIP EnablerEnablerLEADERSHIPLEADERSHIP EnablerEnabler
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�Crash helmet have become compulsory for all the two wheeler
riders before entry to Plant premises.
�A separate material gate was constructed for entry of heavy
vehicles like material handling trucks.
LEADERSHIP (Initiatives)
vehicles like material handling trucks.
�A separate parking area was built up inside the Plant premises
for parking of the material truck.
�A separate parking area was built up outside the Plant premises
for parking of material truck.
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�Retro-reflective Signage with SS steel post were displayed
through out Alumina Refinery at the side of the roads for
visibility in night.
�Road Safety studs were installed on the side of the roads for
easy visibility during night and demarcation.easy visibility during night and demarcation.
�Restriction of vehicles of Apprentice trainees and vocational
trainees inside the Plant.
�Widening of roads at various locations.
�Road Safety monitoring and campaigning is carried out regularly
by our Safety team.
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�Procurement of Radar Speed Guns.
�Restriction of vehicles of workers inside the Plant.
�Installation of CCTV at vulnerable locations of the roads and
monitoring.
�Hazard and Risk Analysis of the Roads inside Alumina Refinery.
�Modification activities on the roads at some vulnerable
locations.
�Awareness & Campaign on Road Safety.
�Mobile conveying systems for ensuring safety to the workmen
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Implementation of On-line Contract Management
SystemOn-line contract labour management system was implemented in
Alumina Refinery. Safety check is one of the process for contractor
workers. This is an on line control mechanism where Gate Pass is issued
to the contractor workers only after Safety check and induction trainingto the contractor workers only after Safety check and induction training
to contractor workers.
Setting up Tool Box Talk cultureCreating and propagating a culture of Tool Box Talk.
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TOOL BOX TALKTOOL BOX TALK
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SAFETY COMMITTEE MEETING (EVERY MONTH) SAFETY COMMITTEE MEETING (EVERY MONTH)
AVERAGE 60 NOS.
SAFETY RELATED
PROBLEMS ARE
RESLOVED EVERY
MANAGEMENT REPRESENTATIVES : 10 NOS.
WORKERS REPRESENTATIVES : 10 NOS.
SAFETY COMMITTEE PLANT INSPECTION : 15TH OF EVERY MONTH
SAFETY COMMITTEE MEETING : 25TH OF EVERY MONTH
MANAGEMENT REPRESENTATIVES : 10 NOS.
WORKERS REPRESENTATIVES : 10 NOS.
SAFETY COMMITTEE PLANT INSPECTION : 15TH OF EVERY MONTH
SAFETY COMMITTEE MEETING : 25TH OF EVERY MONTH
RESLOVED EVERY
YEAR
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CONTROL MEASURE BEFORE ISSUE OF GATEPASS TO CONTRACTOR WORKERSCONTROL MEASURE BEFORE ISSUE OF GATEPASS TO CONTRACTOR WORKERS
SAFETY
CLEARANCE
THROUGH ON-LINE
CLMS
(CONTRACT
LABOUR
SAFETY
CLEARANCE
THROUGH ON-LINE
CLMS
(CONTRACT
LABOUR LABOUR
MANAGEMENT
SYSTEM)
LABOUR
MANAGEMENT
SYSTEM)
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SEPARATE TRUCK PARKING AREA
NEW MATERIAL GATE AND SEPARATE TRUCK PARKING AREA (FOR ROAD SAFETY)
ROAD SAFETY MEASURES INSIDE PLANTROAD SAFETY MEASURES INSIDE PLANT
NEW MATERIAL GATE
SEPARATE TRUCK PARKING AREAINSIDE THE PLANT
TRUCK PARKING AREA
OUTSIDE PLANT
NEW MATERIAL GATE
MATERIAL GATE
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ROAD SAFETY MEAURESROAD SAFETY MEAURES
Widening of Roads Near Bio-metric punching stationstation
Tree Patches Sign Posts
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INSTALLATION OF RETRO REFLECTIVE SIGNAGES WITH STAINLESS STEEL POST ( FOR ROAD SAFETY)INSTALLATION OF RETRO REFLECTIVE SIGNAGES WITH STAINLESS STEEL POST ( FOR ROAD SAFETY)
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ROAD SAFETY MEASURES TAKENROAD SAFETY MEASURES TAKEN
CONVEX
MIRRORS
ROAD SAFETY STUDS
MARKING WITH PAINT FOR
PARKING OF BUSES
MIRRORS
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ROAD SAFETY MONITORING BY SAFETY TEAMROAD SAFETY MONITORING BY SAFETY TEAM
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Mobile Conveying System
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EFQM Excellence Model
STRATEGYSTRATEGY EnablerEnablerSTRATEGYSTRATEGY EnablerEnabler
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�Since “5S” is the key to the safety, a holistic
5”S” implementation carried out in Alumina
Implementation of 5 “S”
5”S” implementation carried out in Alumina
Refinery including township.
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Implementation of “HIRA” in Alumina Refinery
Department wise “HIRA” team is formed in Alumina
Refinery. There is total 18 teams. Each team consists of 4
to 6 members. It is reviewed and updated every year. Alsoto 6 members. It is reviewed and updated every year. Also
depending upon the incidents, change in man/machines,
this is updated regularly.
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Engineering Control Measure
�Chlorine was replaced by Sodium Hypo-chlorite in WT Plant, as Hypo-
chlorite is in powder form and it is not hazardous.
�Structural painting is being carried out in a phased manner.
�Monkey ladders were replaced by Staircases for safe movement of the�Monkey ladders were replaced by Staircases for safe movement of the
workmen to top of any hoist platform.
�Spiral staircases adjacent to some caustic tanks were replaced by making
staircases away from the tank wall for safe movement of workmen for
O&M activities.
�Replacement of Reciprocating Compressors by Screw
Compressors/Centrifugal compressors to reduce noise pollution
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Magazines/Bulletins
“Suraksha kabach” is an Annual Magazine (related to
Safety, Health and Environment) which is published everySafety, Health and Environment) which is published every
year and widely circulated in Odisha.
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5 “S” IMPLEMENTATION5 “S” IMPLEMENTATION
MECHANICAL REPAIR SHOP CENTRAL DISTRIBUTION SYSTEM BAUXITE HANDLING AREASPP
ALUMINA
REFINERY
WAS
DIVIDED IN
TO 72
ZONES.
ALUMINA
REFINERY
WAS
DIVIDED IN
TO 72
ZONES.
MECHANICAL REPAIR SHOP
MECHANICAL REPAIR SHOPCENTRAL STORE
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OUTSIDE STAIRCASE WITH PLATFORM MADE FOR APPROACHING TO CAUSTIC LIQUOR TANK
OUTSIDE STAIRCASE WITH PLATFORM MADE FOR APPROACHING TO CAUSTIC LIQUOR TANK
MONKEY LADDER WAS REPLACED BY STAIR CASE FOR APPROACHING HOIST PLATFORM
MONKEY LADDER WAS REPLACED BY STAIR CASE FOR APPROACHING HOIST PLATFORM
NEW STAIRCASE WITH PLATFORMNEW STAIRCASE WITH PLATFORM OLD SPIRAL STAIRCASE
ADJACENT TO TANK
OLD SPIRAL STAIRCASE
ADJACENT TO TANK
NEW STAIRCASE REPLACING
THE MONKEY LADDER
NEW STAIRCASE REPLACING
THE MONKEY LADDER
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FIRE FIGHTING SYSTEM ( Manned by CISF Fire Wing) Total nos. Hydrant points: 421 nos.
Total nos. Fire extinguishers deployed: 2283 nos.
FIRE FIGHTING SYSTEM ( Manned by CISF Fire Wing) Total nos. Hydrant points: 421 nos.
Total nos. Fire extinguishers deployed: 2283 nos.
Foam Tenders : 3 nos. Mini Fire Tender : 1 no. BA Set : 14 nos.Towing Tender : 1 no. Trailer Pump: 2 nos.
DCP Trailer Pump 200Kg: 2 nos.
High Expansion Foam
generators
Honda Generators
Fire Extinguishers
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Quarterly Checking
of Transformer
Mulsifier System
Quarterly Checking
of Transformer
Mulsifier System
HVWS
MOCK DRILLMOCK DRILL
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PUBLICATIONS
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EFQM Excellence Model
PEOPLEPEOPLE EnablerEnablerPEOPLEPEOPLE EnablerEnabler
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Training and Development
�Regular toolbox talk are being conducted at work places.
�Safety training to all workers including contractor workers with�Safety training to all workers including contractor workers with
demonstration of videos are being imparted.
�Behavioral Safety training to employees.
�Competitions among employees and contract workmen on
Safety aspect.
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PME and Health Check-up
�A well-equipped Occupational health Centre with all
infrastructures for occupation health check-up of workmen is
available at Nalco, Damanjodi.available at Nalco, Damanjodi.
�100% PME checks are being done for the own employees as
well as for the contractor workmen.
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Contract Workmen
being trained
Employees being
trained
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Demonstration on use of portable Fire ExtinguishersDemonstration on use of portable Fire Extinguishers
All the Areas are
covered Every year
All the Areas are
covered Every year
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COMPETITIONS DURING CELEBRATION IN 2017COMPETITIONS DURING CELEBRATION IN 2017
QUIZ COMPETITION SKIT PLAY COMPETITION
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OCCUPATIONAL HEALTH CENTRE OF ALUMINA REFINERYOCCUPATIONAL HEALTH CENTRE OF ALUMINA REFINERY
All PME tests under one roof
Separate Biochemistry & pathology Lab in OHC, for all PME
tests every day.
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PME Examination of Employees in OHC NALCOPME Examination of Employees in OHC NALCO
Biochemistry & Pathology
Test Audiometry Test
� Anthropometry
� Audiometry (Pure tone)
� Titmus Vision Screening Test
� PFT (Pulmonary Function Test)
� ECG (Electro-cardiogram)
� X-ray chest( PA View)
� Lab tests :–
Blood (Hematology, Biochemistry),
Titmus Vision Screening
Physical Examination
Pulmonary Function Test
Audiometry Test
� Blood (Hematology, Biochemistry),
� Stool and Urine,
� Sputum for AFB for Canteen workers.
ECG TEST
Anthropometry
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PME Facilities in Alumina Refinery PME Facilities in Alumina Refinery �New Practice Adopted
• PME Individual call letter to the Employees
• PME SMS to the Employees mobile
• Department wise PME list upload on NALCO Intranet,
well in advance for the subsequent month.
• Monthly PME Defaulters list of Employees to all HODs
• Scanned documentation uploading
�HMS (Integrated Hospital Management
General Examination & PME Counselling
�HMS (Integrated Hospital Management System for Digital Documentation)
• Extended format of Form 31-A
• Blood & Other test reports
• Audiometry report
• ECG report
• PFT report
• Titmus Vision Screening reports
• X-Ray report
Digital Documentation
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RECOGNITION FOR INNOVATIVE IDEAS LIKE KAIZENSRECOGNITION FOR INNOVATIVE IDEAS LIKE KAIZENS
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EFQM Excellence Model
PATERNERSHIP PATERNERSHIP EnablerEnablerPATERNERSHIP
& RESOURCES
PATERNERSHIP
& RESOURCESEnablerEnabler
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�Engaging, communicating and working with existing and
emerging key stakeholders, for the purpose of developing long-
lasting and consistent relationships.
�Involving stakeholders in risk-assessments.�Involving stakeholders in risk-assessments.
�Partnership with National Safety Council (NSC) to educate and
influence people to prevent accidental injury and death.
�Stakeholders participation in HSE-led seminars, meeting and
events.
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�Working hand in hand with the CISF for the safety of the
employees.
�Conducting Mock drills time to time at various locations.
�Displayed Safety instructions at the entry of the Plant�Displayed Safety instructions at the entry of the Plant
premises.
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�Suppliers are being informed about the Safety Policies,
Aspects & Procedures of the unit during placement of P.O. &
W.O.
�Safety awareness training are being imparted to the
transporters, contract workmen, local community.transporters, contract workmen, local community.
�Guidelines to the transporters are being issued before entry
of the heavy vehicle inside the plant premises.
�Distribution of proper PPEs to the contract workmen.
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EFQM Excellence Model
PROCESS,
PRODUCTS
PROCESS,
PRODUCTS EnablerEnablerPRODUCTS
& SERVICES
PRODUCTS
& SERVICES
EnablerEnabler
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MANAGEMENT SYSTEM CERTIFICATION
ISO 9001- Certified during the year 1994
ISO14001- Certified during the year 1996
OHSAS 18001- Certified during the year 2005
SA8000- Certified during the year 2010SA8000- Certified during the year 2010
ISO 50001- Certified during the year 2014
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VARIOUS AUDITS/ STUDY
�Alumina Refinery has foolproof firefighting system and infrastructure
manned by CISF (Fire wing). As a proactive measure, Comprehensive Fire
Audit was carried out by M/s MECON. Action Plan has been drawn out as
per the audit report.
�PESO Audit was conducted for Oil handling SYSTEM..�PESO Audit was conducted for Oil handling SYSTEM..
�As a pro- active measure, M/s CPRI ( Central Power Research Institute,
Bangalore) was engaged for testing of structural stabilities of some
concrete and steel structures of Alumina Refinery like Cooling Towers,
concrete structure of various equipments. Action is being taken in this
regard.
�RLA studies of the Boilers are being carried out as per statutory
requirement.
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�Work Permit System
�Competent Persons for testing Lifting tools and tackles,
Pressure vessels and Confined Space
�Internal Safety Audit (Once in a year)
�Reporting of Near-misses and Corrective & Preventive Actions
OHS SYSTEMS & PROCEDURES
�Reporting of Near-misses and Corrective & Preventive Actions
�Incident Investigation and Corrective & Preventive Action
�Work zone monitoring
�SOP & SMP
�Plant Safety Inspection
�Display of MSDS (Material safety data sheet)Boards
�Adoption of Safety Practices
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ADOPTION OF SAFETY PRACTICES ADOPTION OF SAFETY PRACTICES
SAFETY TAG
SAFETY TAGAREA LAYOUT DISPLAYED AT EACH SITE
SAFETY TAG
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MSDS BOARDS AT WORK PLACESMSDS BOARDS AT WORK PLACES
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PLANT SAFETY INSPECTION PLANT SAFETY INSPECTION
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WORK ZONE MONITORING INSTRUMENTSWORK ZONE MONITORING INSTRUMENTS
WORK ZONE MONITORINGWORK ZONE MONITORING
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� “PESO” AUDIT WAS CARRIED OUT IN ALUMINA REFINERY IN 2017
� COMPREHENSIVE FIRE AUDIT WAS CARRIED OUT BY M/S MECON IN 2017
PESO AUDIT
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1. Visual Examination of RCC Structure of D.M. Plant
2. RCC Structure of Cooling Tower No.4
3. RCC Structure of Wagon Tippler Pedestals with discharge
hopper
4. RCC Structure of Lime slaking Unit
5. RCC foundation of Grinding Ball Mill (No.4)
6. Visual Examination of Old Bauxite Crusher
7. Visual Examination of RCC Structure of Steam Turbine U#2
8. RCC Water Tank at Hill Top
STRUCTURAL STABILITY TESTED BY CPRI, BANGALORE STRUCTURAL STABILITY TESTED BY CPRI, BANGALORE
8. RCC Water Tank at Hill Top
9. Tunnel of Lime Conveyor at Lime slaking unit
10.Tunnels of Coal Conveyor at CHP.
11.Precipitation Tank Foundation (TK No. 149)
12.RCC Structure of Intake Well Pump House
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CELEBRATIONS
Various celebrations are observed to promote awareness
amongst the employees and contract workmen. like:
�National Safety Week,�National Safety Week,
�Chemical Disaster Prevention Day,
�Road Safety Week,
�National Pollution Prevention Day,
�Earth Day,
�World Environment Day etc.
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OBSERVANCE OF VARIOUS CELEBRATIONSOBSERVANCE OF VARIOUS CELEBRATIONS
NATIONAL SAFETY WEEKNATIONAL SAFETY WEEK ODISHA DISASTER PREPAREDNESS DAYODISHA DISASTER PREPAREDNESS DAY
ROAD SAFETY WEEKROAD SAFETY WEEK CHEMICAL DISASTER PREVENTION DAYCHEMICAL DISASTER PREVENTION DAY
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FIRE SAFETY DAY/WEEK
Mock Drill during Fire Safety Day/Week
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EFQM Excellence Model
PEOPLE RESULTSPEOPLE RESULTS
RESULTSRESULTS CUSTOMER
RESULTS
CUSTOMER
RESULTS
SOCIETY RESULTSSOCIETY RESULTS
BUSINESS
RESULTS
BUSINESS
RESULTS
RESULTSRESULTS
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Year Reportable
Incident
Non-reportable
Incident
First-Aid
Injuries
2016 0 0 432016 0 0 43
2017 0 0 37
2018 (up to
Sept)
1 0 30
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PRODUCTION ACHIVEMENTS
(FY 17-18)
REMARKS
Hydrate Production 21,05,500 MT Highest ever
Calcined Alumina
Production
21,11,000 MT Highest ever
75
SGA Production 8,800 MT Highest ever
Power 484.33 MU Highest ever
Steam Generation, 68 ata 52,57,293 Highest ever
Total Rail Despatch 20,99,461 Highest ever
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�Fly Ash Expo Award for Efficient utilization of Fly Ash by Mission
Energy Foundation, Mumbai.
�Good Green Governance Award by Shristi Foundation, New
Delhi.
AWARD & ACCOLADES
Delhi.
�Kalinga Safety Award(Silver) by Odisha State Safety Conclave for
the performance year 2016.
�Greentech Environment Award for outstanding achievement in
Environment Management by Greentech Foundation, New Delhi.
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�Pollution Control Excellence Award(PCEA-2018) under Industry
Category of Odisha State for Excellent Pollution Control Practices
by Director of Factories & Boilers, Bhubaneswar, Odisha for the
performance year 2016.
�Best State Safety Officer Award by Director of Factories &
Boilers, Bhubaneswar, Odisha for the performance year 2016.Boilers, Bhubaneswar, Odisha for the performance year 2016.
�Best State Safety Practices Award by Director of Factories &
Boilers, Bhubaneswar, Odisha for the performance year 2016.
�Kalinga Safety Award(Gold) by Odisha State Safety Conclave for
the performance year 2017.
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State Safety Award for 2016State Safety Award for 2016
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Good Green Governance Award-2016Good Green Governance Award-2016
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FLY ASH UTILISATION AWARD - 2018FLY ASH UTILISATION AWARD - 2018
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KALINGA SAFETY AWARD – 2018KALINGA SAFETY AWARD – 2018
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State Pollution Control Excellence Award-2018State Pollution Control Excellence Award-2018
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BEST SAFETY OFFICER AWARDBEST SAFETY OFFICER AWARD
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STATE POLLUTION CONTROL EXCELLENCE AWARD - 2018
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�Alumina Refinery was recently awarded
Certification of 5 “S” from M/s QCFI, Hyderabad on
successful audit by certified auditors from M/s
Certification of 5 “S”
successful audit by certified auditors from M/s
QCFI and M/s JUSE.
�Very shortly, Certificate from “JUSE” will be
received by Alumina Refinery.
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5 “S” Certificate received from M/s QCFI5 “S” Certificate received from M/s QCFI
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"Safety isn't expensive,
it's priceless." it's priceless."
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Thank YouThank You