OCCUPATIONAL SAFETY AND RISK ASSESSMENT OF HUMAN BEINGS IN MANUFACTURING INDUSTRY

OCCUPATIONAL SAFETY AND RISK ASSESSMENT

OF HUMAN BEINGS IN MANUFACTURING

INDUSTRY

A Project Report Submitted For the partial fulfillment of the requirement for the

Award of the degree of

Bachelor of Engineering

In

Mechanical Engineering

RASHTRASANT TUKADOJI MAHARAJ NAGPUR UNIVERSITY,

NAGPUR

Submitted by

1) Mohd. Wasi 2) Sarang Raut

3) Kunal Dubey 4) Niladri Chakraborty

5) Ashwin Manwatkar

Under the guidance of

Prof. P. R. Gajbhiye

DEPARTMENT OF MECHANICAL ENGINEERING

K. D. K. COLLEGE OF ENGINEERING, NAGPUR

2014-15

K. D. K. COLLEGE OF ENGINEERING, NAGPUR DEPARTMENT OF MECHANICAL ENGINEERING

RASHTRASANT TUKADOJI MAHARAJ NAGPUR

UNIVERSITY, NAGPUR

CERTIFICATE

This is certify that, the Project entitled “OCCUPATIONAL SAFETY AND RISK

ASSESSMENT OF HUMAN BEINGS IN MANUFACTURING INDUSTRY ”

is a bonafide work done under my guidance and is submitted for the partial

fulfillment of requirement for the award of Degree of Bachelor of Engineering in

Mechanical Engineering.

1) Mohd. Wasi 2) Sarang Raut

3) Kunal Dubey 4) Ashvin Manwatkar

5) Niladri Charaborty

Prof. P. R. Gajbhiye

Guide

Dr. C. C. Handa Dr. D. P. Singh

Head Principal

ACKNOWLEDGEMENT

With profound feeling of immense gratitude and affection, we would like to thank

our Guide Prof. P. R. Gajbhiye, Department of Mechanical Engineering for his

continuous support, motivation, enthusiasm and guidance. His encouragement,

supervision with constructive criticism and confidence enabled us to this project.

We gratifying to Dr. C. C. Handa, Professor & Head and Dr. S. K.

Choudhary, Professor & Academic Incharge, Department of Mechanical

Engineering for motivating to put our best efforts in this project work.

We express our admirations for Prof. A. M. Badar, Vice Principal and

Dr. D. P. Singh, Principal, K. D. K. College of Engineering, Nagpur for their

constant motivation and providing necessary infrastructure.

Finally, a special thank to project co-incharge and all the faculty members

and non-teaching member of the department for their cooperation for the project

work.

Projectee

1) Mohd. Wasi

2)Ashvin Manwatkar

3) Kunal Dubey

4) Niladri Chakraborty

5) Sarang Raut

K. D. K. COLLEGE OF ENGINEERING, NAGPUR DEPARTMENT OF MECHANICAL ENGINEERING

RASHTRASANT TUKADOJI MAHARAJ NAGPUR

UNIVERSITY, NAGPUR

DECLARATION

The project titled “OCCUPATIONAL SAFETY AND RISK

ASSESSMENT OF HUMAN BEINGS IN

MANUFACTURING INDUSTRIES.” is our own work carried

out under the guidance of Prof. P. R. Gajbhiye, Department of

Mechanical Engineering at K. D. K. College of Engineering, Nagpur. As

far as my knowledge, this work in the same form or any other form is not

submitted by me or anyone else for award of any degree.

Projectee 1) Mohd. Wasi 2) Kunal Dubey 3) Sarang Raut 4) Ashvin Manwatkar 5) Niladri Chakraborty

ABSTRACT

Every year a large number of employees get injured due to accidents. Therefore,

there is a definite need to implement necessary safety measures in the industrial

organizations. The safety requirements vary according to the hazard problems. Well-

organized safety management is a necessity in any successful industrial

establishment. So, safety in industries is the need of hour. Globalization and

economic reforms warrants Indian industries to adopt better safety management to

stay competitive in international markets. It is observed that industrial accidents,

associated financial losses, and compensation claims eat away considerable portion

of the profit earn by organization. These also damage the reputation of organization

and lower moral of the employees. Safety has been recognized as an integral part of

the normal operating procedures and a definite responsibility of all supervisory

personnel along with the employees. Absence of proper safety measures would

invariably lead to avoidable accidents resulting into injuries to persons, damage to

equipment and machinery, financial losses both the employers and employees. The

human angle for providing safety to the industrial workers is no less important, in

fact the present industrial environment is one of the major reasons for the

management to undertake effective safety programs in their organizations, concerns,

and factories. Industrial safety involves not only elimination of agents of injury, but

also a reliable control to harm to employees. “The main driving force behind the

industrial safety movement is the fact accidents are expensive, substantial savings

can be made by preventing them.”

LIST OF FIGURES

Sr.

No. Figure No. Title of Figure Page No.

1 01 Result on the basis of response to Question No. 1 17





















LIST OF TABLES

Sr.

No. Table No. Title of Table Page No.

1 01 Response of workers on Question No. 1 17





















CONTENTS

Chapter

No. Particulars Page No.

Abstract

List of Figures

List of Tables

I

ii

iii

1

Introduction

1.1 Risk Assessment

1.2 Occupational Safety

1.3 Objective

1-2

1

1

2

2 Review of Literature 3-6

3

Research Methodology

3.1 Primary Sources

3.2 Secondary Sources

7-9

7

9

4 Company Profile 10-11

5 Questionnaires 12-16

6 Analysis of Questionnaire Part A 17-41

7 Analysis of Questionnaire Part B 42-62

8

Result, Conclusion and Future Scope

8.1 Result of Study

8.2 Limitation of Study

8.3 Conclusion

8.4 Future Scope

63-71

63

69

69

70

References 72

CHAPTER – 1

INTRODUCTION

Chapter 1

Introduction

1.1 Risk Assessment

Risk assessment is the determination of quantitative or qualitative value of

risk related to a concrete situation and a recognized threat.

Risk assessment is the process of quantifying the probability of a harmful

effect to individuals or populations from certain human activities. In most countries

the use of specific chemicals or the operations of specific facilities (e.g. power

plants, manufacturing plants) is not allowed unless it can be shown that they do not

increase the risk of death or illness above a specific threshold. For example, the

American Food and Drug Administration (FDA) regulate food safety through risk

assessment.

Risk assessment should:

Identify the hazards

Identify all affected by the hazard and how

Evaluate the risk

Identify and prioritize appropriate control measures

1.2 Occupational Safety

The field of occupational safety has become a topic of increasing

importance over the last 30 years. Occupational safety is generally defined as the

science of the anticipation, recognition, evaluation and control of hazards arising in

or from the workplace that could impair the health and well-being of workers, taking

into account the possible impact on the surrounding communities and the general

environment. This domain is necessarily vast, encompassing a large number of

disciplines and numerous workplace and environmental hazards. A wide range of

structures, skills, knowledge and analytical capacities are needed to coordinate and

implement all of the “building blocks” that make up national occupational safety

systems so that protection is extended to both workers and the environment.

The scope of occupational safety has evolved gradually and continuously in

response to social, political, technological and economic changes. In recent years,

globalization of the world’s economies and its repercussions have been perceived as

the greatest force for change in the world of work, and consequently in the scope of

occupational safety and health, in both positive and negative ways. Liberalization of

world trade, rapid technological progress, significant developments in transport and

communication, shifting patterns of employment, changes in work organization

practices, the different employment patterns of men and women, and the size,

structure and life cycles of enterprises and of new technologies can all generate new

types and patterns of hazards, exposures and risks. Demographic changes and

population movements, and the consequent pressures on the global environment, can

also affect safety and health in the world of work.

1.3 Objective

The Objective of the project is to decrease the number of accidents occurring

in the industry. Provide knowledge about the risk associated to the various processes.

Industrial financial losses minimization is the basic objective by providing

the preventive measure to the industrial processes so that accident can be avoided

and the financial losses minimized.

Safe work procedure reviewing and updating to make the work healthy and

safe to workers so that the environment of working is pleasant and safe at the same

time.

CHAPTER – 2

REVIEW OF

LITERATURE

Chapter 2

Review of Literature

Col S Rajeev [1] in his paper titled “Studies on industrial safety in current

perspective (a few selected industries)” concluded that the story of India for the last

five decades after independence can be summarized with an unceasing invocation of

one word “If” the shorthand for a saga of missed opportunities. It is not that India

lacks achievements, a vibrant democracy, a large reservoir of skilled manpower, a

self-confident middle class at the cutting edge of new technology and above all, a

huge and growing domestic marker. It is just that these achievements are not

commensurate with India’s acknowledged potential. The country faces an

unacceptable performance potential gap in the industrial development. Safety

management is a systematic process that can help industrial establishments to reduce

industrial accidents and pave way for an accident free working environment. There is

a requirement that the regulation requires the employer to prevent exposure to

substances hazardous to health or if this is not reasonably practicable that exposure

must be controlled. The current global debate on industrial safety centres on the

pollution and environmental hazards, both natural and artificial. Some thoughts are

also being given to terrorist strikes Importance of industrial safety has increased

because of the large scale industrialization in which the workmen/worker is

subjected to mechanical, electrical, chemical and biological hazards along with

deadly radiation which are endangering human life all throughout. Accidents are

readily recognized when machinery or instruments are damaged, material is spoilt or

someone is injured. It is not necessary that all accidents should result in personal

injury. Accidents without personal injury outnumber those, which have resulted in an

injury. Mostly industrial safety is conceived in term of economic efficiency with

laws on worker safety legally interpreted through a concise economic thought.

Vinodkumar M. N. [2] in his paper titled “Study of influence of safety

engineering and management practices in selected industries in Kerala.” In the

twentieth century, as technology grew by leaps and bounds, associated hazard also

grew with it. This resulted in collective efforts and thinking in the direction of

controlling work related hazards and accidents. Thus, safety management developed

and became an important part of industrial management. While considerable

research has been reported on the topic of safety management in industries from

various parts of the world, there is scarcity of literature from India. It is logical to

think that a clear understanding of the critical safety management practices and their

relationships with accident rates and management system certifications would help in

the development and implementation of safety management systems. This study

identifies the critical safety management practices in major accident hazard

Chemical/process industry from the perspective of employees and the findings

empirically Support the necessity for obtaining safety specific management system

certifications. Safety awareness that is spreading to all walks of life and all types of

organizations has made `Safety Management' a potential area of research. While

considerable research has been done on the topics of safety management and safety

culture/climate in developed countries, such work is not to be seen reported in India.

Captains of industries are still faced with the challenge of understanding the key

issues in the safety management so as to provide health and safe work environment

to their employees. This underscores the need to study the various factors that

influence industrial safety management, especially in manufacturing industries such

as yarn manufacturing and oil extraction.

A. Azad [3] in his paper titled “The effect of training in manufacturing

industries.” Technical training of employees has become one of the major activities

of modern industries in India. Rapid growth in technology and competition has given

continuous learning a strategic importance. Training forms the backbone for the

implementation of Total Quality Management. Employee education results in giving

an organization competitive advantage. In a rapidly changing society, employee

training and development helps in maintaining a valuable and knowledgeable

workforce. Every organization needs to have well-trained and experienced people to

perform their duties. As the job becomes more complex, the importance of employee

development also increases. The influencing factors of the business improvement are

quality improvement, improvement in technical expertise and improved

performance. The major factors leading to the cultural improvement are quality

improvement, skill improvement, improved performance, work process

improvement, and self and time management. The major factors leading to the

continuous improvement are skill improvement, improved performance, work

process improvement, improvement in technical expertise, and self and time

management. The study suggests that improvement in technical expertise, quality

improvement, improved performance and work process improvement play a

significant role in influencing many organizational benefits. Training is a

requirement for higher qualifications as the present qualifications are becoming

outdated. Hence an attempt is made in this research, to make a comprehensive study

of the major effects of technical training that results in the benefits for the

organization, the improvements achieved by the employee and work practices.

Amit R. Patil [4] in his paper titled “Analysis of unsafe Human behaviour

related accidents in the mechanical engineering industry and benchmarking its

solution.” Occupational safety is an important concern for all working individuals.

Worldwide, economically active individuals constitute 60-70% of the adult male

population, 30-60% of adult female population, and 23% of the population of

children and adolescent who are 5 to 17 years old. Over the course of the 20th

century, substantial reductions were seen in the number of occupational deaths and

injuries, at least in industrialized nations. Nonetheless, despite this progress, safety

concerns in the workplace are still paramount. An examination of the available data

shows that work related injuries and death occur at an alarming and unacceptably

high rate throughout the industrialized and developing nations. The estimates of

yearly occupational injuries ranged from 4.85 million in the Former Socialist

Economies of Europe to 24.42 million in China, with an overall estimate of 100.69

million for the world. Approximately 100,000 of these occupational injuries

worldwide were fatal. There are a lot of models available for implementing

behaviour based safety in the market today which were developed in western

countries and used by them. There is very little research done on this subject in

India.

H Abdul Zubar, K Viagavel, V Deepak Raja and Arun Mohan [5] in their

paper titled “Occupational Health and safety management in Manufacturing

Industries.” The study aims at analysis the occupational health and safety of

Manufacturing industry in south India by gathering information on health

management, safety management, motivation, leadership and training, welfare

facilities, accidents statistics, policy, organization and administration, hazards

controls and risk analysis, monitoring, statistics and reporting. Data were collected

by using questionnaire which was developed on health and safety management

system. The data collected are analysed by using graphical method. Overall status

shows the performance on health and safety management systems needs

improvement in order to ensure better working condition for the workers.

CHAPTER – 3

REASERCH

METHODOLOGY

Chapter 3

Research Methodology

3.1 Introduction

Research in common parlance refers to search of knowledge. One can also

define research as scientific and systematic search for pertinent information on a

specific topic. In fact, research is an art of investigation. This research work is

analytical research, wherein facts or information already available are analysed to

make critical evaluation in the industrial safety.

3.2 Research Methods

The first part of research work presented in this project is the preparation of

questionnaire for risk assessment of the processes, safe work procedures, safety

trainings, and awareness about the safety issues, safety management and safety

incidents. Sample method is used for surveying the five industries of Nagpur region

for the collection of data. Quantitative and qualitative analysis of the data has been

done as prescribed in the next chapter of Findings.

3.3 Primary Sources

3.3.1 Sample Method

Survey of Questionnaire which is consist of 37 questions related to the risk

assessment and occupational safety of human beings in manufacturing industries.

Questionnaire formed with the help of various thesis and research work done on the

safety issues.

3.3.1.1 Questionnaire Groups

Following are the groups on which the question taken in consideration in

questionnaire.

Risk Assessment: Questions in the Questionnaire is present about the

risk assessment of human beings in the manufacturing industries. We

know by report that before each major accident a series of minor

accidents of same nature takes place. So, for avoiding the major

accidents after any minor accident happenings risk assessment must

be done. New equipment installation can cause sometimes the

accident so before installing it industry must have acknowledged the

effect of that equipment on other equipment running across. Here,

risk assessment helps a lot.

Safe Work Procedure: Question Numbers. 2, 6, 7, 9, 10, 15, and 22

based on safe work procedure. Safe work procedures are step to step

procedure to be followed to do a process in industry. It must

thoroughly teach to the persons to make safe working habits. Studies

shows that most of time cause of accident is due to improper writing

of safe work procedure. Because, it is negligently written and with the

same attitude followed by the workers. To cope up with the time and

to manage competition in present era the firm must have to review

and update their safe work procedures.

Safety Training: Question Numbers. 1, 2, 23, 27, 28, and 29 are

based on Safety trainings. Technical programme must be provided to

increase the number and competence of personnel engaged in the

field of occupational safety, health and environment at workplace.

Training provides the information about the identification of hazard

and how to deal with it.

Awareness about Safety Issues: Question numbers. 4, 5, 12, 16, 25,

26 and 30 are based on the awareness about the safety issues. Safety

issues must be dealt in serious manner because it increases the

productivity and decreases the financial losses. Worker must know

about the Concerns Related to Safety of Machines Operating and the

Processes running in Industry.

Safety Management: Question numbers. 3, 5, 9, 12, 14, 16, 17, 24,

30, 31 and 35 are based on safety management. Communication

between manager or supervisor and workers or labours is the key of

successful running of industry. Supervisor must be prepared for the

emergency situation to avoid the fatal accidents. More safety issues

are reported if the safety management team working helpfully.

Safety Incidents: Question numbers. 5, 14, 15, 16, 18, 19, 20, 21, 22

and 30 are based on safety incidents. A series of minor accidents

takes place before a major accident. So, avoid major accident by

reporting the safety incidents that take place in industry while

working. Safety management team involvement increases the

efficiency of working and increases the safety incidents reports.

Remaining: Remaining a few question are important from subject

point of view but cannot be categorized above and that will discuss in

later chapter of findings.

3.3.2 Sample Size:

Sample size is total of 530 personnel’s in which 458 are the worker which are

on temporary or on permanent basis and remaining (72) are the supervisors of the

Five industries in which these survey are carried out satisfactorily.

3.4 Secondary Sources

Industrial safety, health and environment management system by R K

Jain and Sunil S.Rao

http://shodhganga.inflibnet.ac.in/bitstream/10603/27979/8/08chapter

%203.html

http://www.nioh.org/collaborations.html

http://www.callcentrehelper.com/top-tips-for-induction-programm-

518.html

http://www.hse.gov.uk

http://www.osha.gov

http://shodhganga.inflibnet.ac.in/bitstream/10603/27979/8/08chapter%203.html

http://shodhganga.inflibnet.ac.in/bitstream/10603/27979/8/08chapter%203.html

http://www.nioh.org/collaborations.html

http://www.callcentrehelper.com/top-tips-for-induction-programm-518.html

http://www.callcentrehelper.com/top-tips-for-induction-programm-518.html

http://www.hse.gov.uk/

http://www.osha.gov/

CHAPTER – 4

COMPANY PROFILE

(BRIEF PROFILE)

Chapter 4

Company Profile

4.1 Bajaj Steel Industries limited

Bajaj steel industries limited manufacturer, exporter and supplier of cotton

processing equipment, fully automatic ginning plant, cotton bale wire ties, double

roller ginning machine spare parts, electrical panel, gear blanks, head spigot, steel

rollers, turbine housing, winder cam, wind mill shafts, manifold blocks, hydraulic

power back assembly, hot air humidification system, cotton pressing machine etc.

The largest and modern “cotton ginning and pressing machinery

manufacturer in India” located in Nagpur, Maharashtra. The company was

established in the year 1961 under the headship of Mr. M. K. Sharma (President)

4.2 Abhijeet Power Plant

Abhijeet power limited is a power project development company in Mihan

SEZ Nagpur. The power project is coal fired power project located near Khairi

Khurd village in Nagpur district, Maharashtra with 4 sub- critical coal fired

generating unit of 61.5 MW and 16 backup DG sets aggregating 25.6 MW capacity.

aggregating installed capacity of 271.6 MW.

4.3 Shalimar Nutrients Nagpur

Shalimar nutrients private limited Is food project at Nagpur in Maharashtra,

project involves setting up project for crude oil from oil seeds by solvent extraction

process. The Company was incorporated in 21 Dec. 2010.

4.4 Br. Sheshrao wankhede setkari sahakari soot girani Limited

Br. Sheshrao wankhede setkari sahakari soot girani Limited. In Mohagaon

butibori , Nagpur ,Maharashtra. The company manufacturer of pure cotton yarn,

white cotton yarn, comber noil, combed cotton yarn, organic cotton yarn, carded

cotton yarn.

4.5 Windals precision Private Limited

Windals precision Pvt. Ltd. MIDC industrial areea in Nagpur, Maharashtra.

The company manufacturer of Front axle assembly, front axle support, front axle,3-

piece, front axle sleeve, exporter of tractor parts and assembly

the company was established in 3 Sep 1997.

CHAPTER – 5

QUESTIONNAIRE

Chapter 5

Questionnaire

5.1 Questionnaire

Following table shows the questionnaire of the study which is going out on

the risk assessment and occupational safety of human beings in manufacturing

industry.

Q.1

a. We all get induction training when we start

b. Not everyone gets induction training when they start

c. We don’t get induction training when we start

Q.2

a. We all get trained in safe work procedures for our jobs

b. Some people miss out on safe work procedures training for their

jobs

c. We don’t get trained in safe work procedures for our jobs

Q.3

a. Our managers/supervisors makes sure we can do the work safely

b. Our managers/supervisors sometimes checks we can do the job

safely

c. No one checks if you can do the job safely

Q.4

a. We are always made aware of safety issues

b. Mostly someone makes us aware of safety issues

c. We are not aware of safety issues

Q.5

a. Our company has worked out all the jobs/tasks in my area that have

safety risk

b. Our company has worked out most of the jobs/tasks in my area that

have safety risks

c. Our company hasn’t worked out what jobs/tasks in my area have

safety risks

Q.6

a. Our company has safe work procedures for all task-based activities

in my area that have safety risks

b. Our company has safe work procedures for most task-based

activities in my area that have safety risks

c. Our company doesn’t have safe work procedures for any task-based

activities in my area that have safety risks

Q.7

a. Workers are always involved in reviewing safe work procedures

b. Workers are usually involved in reviewing safe work procedures

c. Workers aren’t involved in reviewing safe work procedures

Q.8

a. We always follow safe work procedures

b. We have safe work procedures but don’t/can’t always follow them

c. We don’t follow/have safe work procedures

Q.9

a. Our company reviews and updates our safe work procedures

regularly

b. Some safe work procedures are not up to date

c. Our company doesn’t update our safe work procedures

Q.10

a. We have enough time to learn our safe work procedures

b. Sometimes we get enough time to learn our safe work procedures

c. We don’t get enough time to learn our safe work procedures

Q.11

a. We always do a risk assessment when we start a new process or

when a process is changed

b. We usually do a risk assessment when we start a new process or

when a process is changed

c. We don’t do risk assessment when we start a new process or when a

process is changed

Q.12

a. Managers communicate with us and listen to us about health and

safety

b. We have a way of communicating with managers about health and

safety but it doesn’t work very well

c. We haven’t got a way of communicating with managers about

health and safety

Q.13

a. We are always involved in safety matters

b. We are sometimes involved in safety matters

c. We are not involved in safety matters

Q.14

a. Management takes notice of what we say about safety

b. Management sometimes takes notice of what we say about safety

c. Management doesn’t take notice of what we say about safety

Q.15

a. We are involved in putting together procedure

b. We are sometimes involved in putting together procedures

c. We are not involved in putting together procedures

Q.16

a. We always get feedback on what’s happening with our safety issues

within seven days

b. We usually get feedback on what’s happening with our safety issues

seven days

c. We don’t feedback about what’s happening with our safety within

seven days

Q.17

a. We know who our safety committee member is

b. We have safety committee member but we’re not sure who it is

c. We don’t have a safety committee or we don’t know who it is

Q.18

a. We have safety reporting procedures and we use them

b. We have reporting procedures, but we don’t always use them

c. We don’t have reporting procedures or we don’t use them

Q.19

a. We always report safety incidents

b. We mostly report safety incidents

c. We don’t report safety incidents

Q.20

a. We are always encouraged to report safety incidents

b. We are usually encouraged to report safety incidents

c. We are never encouraged to report safety incidents

Q.21

a. Safety incident reports always get followed up

b. Safety incident reports sometimes get followed up

c. Safety incident don’t get followed up

Q.22

a. Safe work procedures are reviewed and updated if there is an

incident report. We try to find out why an incident happened and

how to fix it

b. Safe work procedures are sometimes reviewed and updated after an

incident report. We usually try to find out why an incident happened

and how to fix it

c. No one reviews safe work procedures after an incident report to try

to find out why an incident happened and how to fix it

Q.23 a. Our safety training is reviewed or updated if there is an incident

b. Our safety training is sometimes reviewed or updated after an

incident

c. Our safety training doesn’t get reviewed or updated after an incident

Q.24

a. If we report a serious problem where someone could get hurt, they

put in a solution and fix it straight away

b. If we report a serious problem where someone could get hurt, they

take action as soon as they can

c. If we report a serious problem where someone could get hurt, they

don’t take action

Q.25

a. Managers seem to understand what we and they should do

regarding safety

b. Managers sometimes seem to understand what we and they should

do regarding safety

c. Managers don’t know what we or they should do regarding safety

Q.26

a. If I didn’t follow a safety instruction, I’d feel like I was letting the

team down

b. If I didn’t follow a safety instruction, I might get away with it with

some managers/supervisors

c. None would really care if I didn’t follow a safety instruction

Q.27

a. There is enough time put into safety

b. Time is put into safety but it’s not quite enough

c. There is hardly any time put into safety

Q.28

a. I feel that there are enough resources/money put into safety

b. I feel that resources/money are put into safety but it’s not quite

enough

c. I feel that there aren’t enough resources/money put into safety

Q.29

a. Safety is a high priority for our company

b. Safety is sometimes a high priority for our company

c. Safety is not priority of our company

Q.30

a. Management always gets involved in safety issues

b. Management sometimes gets involved in safety issues

c. Management doesn’t get involved in safety issues

Q.31 a. Managers/supervisors mean what they say and do what they say, in

safety matters

b. Managers/supervisors sometimes mean what they say and do what

they say, in safety matters

c. Managers/supervisors don’t mean what they say or do what they

say, in safety matters

Q.32

a. I feel like my health and safety matters here

b. Mostly I feel like my health and safety matters here

c. I don’t feel like my health and safety matters here

Q.33

a. I know who to ask about what to do, if I get injured at work

b. I’m not sure who to talk to about injuries at work, but I think

someone here could tell me

c. We don’t have anyone to talk to about injuries at work

Q.34

a. We all have to report all injuries straight away

b. They only want us to notify serious injuries

c. They don’t like us to report injuries

Q.35

a. Our notice board has a poster about injury management

b. I’m not sure if we have information about injury management or not

c. There is no information about injury management on display

Q.36

a. All injured workers are offered suitable duties and a return to work

plan is worked out for them

b. Most injured workers are helped to come back to work as soon as

possible

c. We don’t have suitable duties or a return to work program

Q.37

a. Our return to work program helps get injured workers to work

whenever possible

b. We have a return to work program but sometimes we don’t use it or

it doesn’t work very well

c. We don’t have a return to work program

CHAPTER – 6

ANALYSIS OF

QUESTIONNAIRE

(Part A)

A

66%

B

28%

C

6%

A B C

Total 348 151 31

0

100

200

300

400

No. of

Work

ers

Chapter 6

Analysis of Questionnaire (Part A)

Part A of analyzing of Questionnaire is consist of first 17 questions which

covered by various topics like Risk Assessment, Safe work Procedure and Safety

Following are the analysis based on question numbers sequentially.

Question No. 01

A. We all get induction training when we start

B. Not everyone gets induction training when they start

C. We don’t get induction training when we start

Induction gives your new employee an objective view of your company,

organisational culture, and work ethic, which will allow the employee to better

integrate into the workplace.

Response Q1

A 348

B 151

C 31

Grand Total 530

Table 1: Response of Question 1

Figure 1: Figure shows the response from workers on Question No. 1

Key Findings:

Most of the workers are trained by given induction training to them.

Suggestion:

Induction is the first real taste your new employees get of your

organisation, your culture, expectations and vision. So induction

training is must in manufacturing industry.

A

59%

B

34%

C

7%

A B C

Total 314 180 36

0

100

200

300

400

No.

of

Work

ers

Question No. 02

A. We all get trained in safe work procedures for our jobs

B. Some people miss out on safe work procedures training for their jobs

C. We don’t get trained in safe work procedures for our jobs

Safe work procedures are the written procedures for doing safe work in the

Industry.

Response Q2

A 314

B 180

C 36

Grand Total 530

Table 2: Response on Question No. 02

Figure 2: showing the response of workers on Question No.02

Key Findings:

Around 60% of the workers got training on the job on which he or she

is doing in the manufacturing industry.

Suggestions:

Safe work procedures for all the processes which has danger must be

written as quick as possible

A

44% B

54%

C

2%

A B C

Total 233 285 12

0

50

100

150

200

250

300

No.

of

Work

er

Question No. 03

A. Our managers/supervisors makes sure we can do the work safely

B. Our managers/supervisors sometimes checks we can do the job safely

C. No one checks if you can do the job safely

Managers must believe that employees know their jobs best and should be the

key decision makers relating to the safety and health of their jobs.

Response Q3

A 233

B 285

C 12

Grand Total 530

Table 3: Shows the response on Question 3

Figure 3: Shows the results of response on Question No. 03

Key Findings:

Only sometime any supervisor or manager checks the safety about

the job.

Suggestions:

Managers should involve in safety of the workers because without

them there are no Production.

A

56%

B

36%

C

8%

A B C

Total 296 189 45

0

50

100

150

200

250

300

350

No

. of

Wo

rker

Question No. 04

A. We are always made aware of safety issues

B. Mostly someone makes us aware of safety issues

C. We are not aware of safety issues

When a workplace is safe, workers feel more comfortable and confident

when they are in that environment. Productivity gets a boost, and profit margins

follow suit. Absenteeism also drops when employers take steps to implement an

effective safety program.

Response Q4

A 296

B 189

C 45

Grand Total 530


Figure 04: Showing response of the workers for Question No. 04

Key Findings:

Awareness about safety issues is done by Management but there is no

procedure provided to handle the safety issues.

In many industries none is done on safety issues

Suggestion:

Safe premises, machinery and materials, system of work is the need

of worker so management should make provisions to provide it to

workers.

Information, instruction, training and supervision must provide by

management to tackle the safety issues in a pleasant manner

A suitable working environment and facilities should give by

management by arranging the resources.

A

58%

B

31%

C

11%

A B C

Total 308 162 60

0

50

100

150

200

250

300

350

No

. of

Wo

rker

Question No. 05

A. Our company has worked out all the jobs/tasks in my area that have safety risk

B. Our company has worked out most of the jobs/tasks in my area that have safety risks

C. Our company hasn’t worked out what jobs/tasks in my area have safety risks

Safety risk of each and every job must have to done because it gives

information about the hazard.

Response Q5

A 308

B 162

C 60

Grand Total 530


Figure 5: Pie chart and bar chart showing the responses of Question No. 05

Key Findings:

Most of the Jobs that permanent workers are performing are worked

out safety risks of that process

“Need more attention on safety risks by company.” Suggested by

most of the workers

Suggestions:

Inspection by management to make safe work environment.

A 49%

B 36%

C 15%

A B C

Total 260 193 77

0

50

100

150

200

250

300

No

. of

Wo

rker

Question No. 06

A. Our company has safe work procedures for all task-based activities in my area

that have safety risks

B. Our company has safe work procedures for most task-based activities in my area

that have safety risks

C. Our company doesn’t have safe work procedures for any task-based activities in

my area that have safety risks

Safe work procedures are the written procedures for doing safe work in the

Industry. To be effective, safety procedures should be communicated in written and

verbal form and emphasized by showing the employee the procedure and then

having them demonstrate to assure proper understanding of the procedure.

Response Q6

A 260

B 193

C 77

Grand Total 530

Table 6: Response of worker on Question 06

Figure 06: Showing result based on response of Question 06

Key Findings:

Safe work procedure for the activities are there in written form but

implementation on that procedures is not there in the industry.

More than half dangerous process has nothing except for name Safe

work procedures.

Suggestions:

Management of industry must involve in in implementing the safe

work procedures for all the processes has dangers in presence.

A

51% B

40%

C

9%

A B C

Total 267 214 49

0

50

100

150

200

250

300

No

. of

Wo

rker

Question No. 07

A. Workers are always involved in reviewing safe work procedures

B. Workers are usually involved in reviewing safe work procedures

C. Workers aren’t involved in reviewing safe work procedures

Employees use knowledge of their environment to understand what things are

putting people in risky situation.

Response Q7

A 267

B 214

C 49

Grand Total 530


Figure 07: Figure showing the result from response of Question No. 07

Key Findings:

Industry keeps involve there workers while they are updating their

processes in terms of safety issues

Suggestions:

Industries must review and update their safe work procedure for

making industry safe working as the first priority.

A

42%

B

27%

C

31%

A B C

Total 225 142 163

0

50

100

150

200

250

No

. of

Wo

rker

s

Question No. 08

A. We always follow safe work procedures

B. We have safe work procedures but don’t/can’t always follow them

C. We don’t follow/have safe work procedures

A positive attitude towards safety makes the most of company safety tools

and training. When you take safety seriously, you take advantage of the protections

available on the job. Safe work procedure are must be followed by worker to make

environment safe and working safely.

Response Q8

A 225

B 142

C 163

Grand Total 530

Table 08: Response of Question No. 08

Figure 08: Pie chart and Bar Chart showing the result on Question No. 08

Key Findings:

Uncertainty in answer to follow the safe work procedure because lot

of workers does not know about the safe work procedures

Carelessness is the most common cause of workplace accidents.

Suggestions:

Industry should take care about the safe work procedures

Safety conditions must always be supervising by supervisor to make

workplace safe and healthy.

Need to improve the attitude by providing trainings to workers

A

19%

B

42%

C

39%

A B C

Total 101 221 208

0

50

100

150

200

250

No.

of

Work

ers

Question No. 09

A. Our company reviews and updates our safe work procedures regularly

B. Some safe work procedures are not up to date

C. Our company doesn’t update our safe work procedures

Implementing the Safe work procedure should be an integral part of everyday

operations and so it must be relevant at all times. Therefore, it should be revised

periodically, at least annually, and whenever significant changes take place, or when

Risk Assessments are carried out and improvements are made that have an impact on

safety and health. Such changes may include changes in the way work is being

carried out, the introduction of new work activities, changes in the organisational

structure due to redundancies and to available man power etc.

Response Q9

A 101

B 221

C 208

Grand Total 530


Figure 09: Pie chart and Bar chart showing the result about Question No. 09

Key Findings:

Near about all the safe work procedures which are available in the

industry all out of date must review.

Implementation is also not there according to the safe work

procedure.

Suggestion:

Safe work procedure must review and update as quick as possible

Implementation of available safe work procedure must be done in

proper way.

Content of Safe work procedure must be such that worker can easily

understand and can do as per procedure written in it.

A

17%

B

62%

C

21%

A B C

Total 91 327 112

0

50

100

150

200

250

300

350

No. o

f W

ork

ers

Question No. 10

A. We have enough time to learn our safe work procedures

B. Sometimes we get enough time to learn our safe work procedures

C. We don’t get enough time to learn our safe work procedures

Nearly 95% of the times, safe work procedures are really hard to read and

understand. Without implementation safe work procedures doesn’t matters in

industries only some papers. But, to implement it thoroughly management must

organize such training in which it can help worker by providing demos on it.

Response Q10

A 91

B 327

C 112

Grand Total 530

Table 10: Table showing Response of Question No. 10


Key Findings:

Time given to learn the safe work procedure and occupational safety

lessons is very limited

New technology takes more time to learn for the person due to their

attitude of doing work

Suggestions:

Time to make safe working must be increase so that the workplace

safety increases and No. of accidents decreases

A

24%

B

48%

C

28%

A B C

Total 129 255 145

0

50

100

150

200

250

300

No.

of

work

er

Question No. 11

A. We always do a risk assessment when we start a new process or when a process is

changed

B. We usually do a risk assessment when we start a new process or when a process is

changed

C. We don’t do risk assessment when we start a new process or when a process is

changed

As a part of managing health and safety of your business you must control

the risk in your workplace. the risk is the chance, high or low, that somebody could

be harmed by these and other hazards, together with an indication of how serious the

harm could be to the workplace.

Response Q11

A 129

B 255

C 145

Grand Total 529

Table 11: Table shows the result of Question No. 11


Key Findings:

Only few processes in the industry have done the risk assessment.

Not always risk assessment done when the process changes or

updated or modified

Suggestions:

Risk assessment of all the processes involves danger must be done as

quick as possible to avoid the accidents

If you have fewer than five employees you don't have to write

anything down.

A

18%

B

48%

C

34%

A B C

Total 96 255 179

0

50

100

150

200

250

300

No.

of

Work

ers

Question No. 12

A. Managers communicate with us and listen to us about health and safety

B. We have a way of communicating with managers about health and safety but it

doesn’t work very well

C. We haven’t got a way of communicating with managers about health and safety

Management involvement shows by their communication and responses over

the period given to queries asked by the workers on behalf of their safety and life

issues. Make way of communication and do the work according to the channel to

make suitable adjustments in the workplace.

Response Q12

A 96

B 255

C 179

Grand Total 530

Table 12: Response of Question No. 12


Key Findings:

Communication channel between management and workers are there

but don’t work so well.

Reply on the queries related to safety is not satisfactorily given

Suggestions:

Reply to the queries of the workers regarding to the safety concerns

must be given in satisfactorily manner

Communication strength has to be strengthen so that problems can be

easily solved

A

58%

B

31%

C

11%

A B C

Total 307 162 61

0

100

200

300

400

No.

of

Work

ers

Question No. 13

A. We are always involved in safety matters

B. We are sometimes involved in safety matters

C. We are not involved in safety matters

Safety matters for the workers because it is the concern of them. Unsafe

condition directly affected to the workers and indirectly to the owners, management

and environment.

Response Q13

A 307

B 162

C 61

Grand Total 530

Table 13: Shows the result of Question No. 13

Figure 13: Figure shows the result of the Question No. 13

Key Findings:

There is a lot of positive talks is there in the industries but for

implementation literally nothing as compare to talk.

Suggestion:

Must do the work more than the talk about the safety by management

or by workers

A

18%

B

49%

C

33%

A B C

Total 94 263 173

0

50

100

150

200

250

300

No.

of

Work

ers

Question No. 14

A. Management takes notice of what we say about safety

B. Management sometimes takes notice of what we say about safety

C. Management doesn’t take notice of what we say about safety

Management involvement in safety matters is much importance due to the

decision taking authority of the management. Workers involvement shows by their

notices and saying about the safety issues to the management.

Response Q14

A 94

B 263

C 173

Grand Total 530

Table 14: Shows the response of Question No. 14

Figure 14: Figure shows the result from the survey on Question No. 14

Key Finding:

Management responses towards the safety issues reported by the

workers are very much not entertained in a great manner.

Suggestions:

Notice of Worker should take seriously.

A

38%

B

50%

C

12%

A B C

Total 202 266 62

0

50

100

150

200

250

300

No.

of

Work

ers

Question No. 15

A. We are involved in putting together procedure

B. We are sometimes involved in putting together procedures

C. We are not involved in putting together procedures

Industrial safety is a team work. Everyone must have to perform for getting

the best available result.

Response Q15

A 202

B 266

C 62

Grand Total 530

Table 15: Shows the response on Question No. 15

Figure 15: shows the result of the Question No. 15

Key Findings:

Workers are not always involved in making procedures

Suggestions:

Workers involvement in making safe work procedure solidify the

procedure and field work is also there and it is easy to understand by

the workers.

A

35%

B

52%

C

13%

A B C

Total 187 277 66

0

50

100

150

200

250

300

No. of

Work

er

Question No. 16

A. We always get feedback on what’s happening with our safety issues within seven days

B. We usually get feedback on what’s happening with our safety issues seven days

C. We don’t feedback about what’s happening with our safety within seven days

Feedback increases the interest of the worker in the safety management

system, which is very fruitful for industrial safety.

Response Q16

A 187

B 277

C 66

Grand Total 530

Table 16: Shows the response of the workers on Question No. 16

Figure 16: Shows the result on the response of Question No. 16

Key Findings:

Feedback to safety incident not always given to the workers.

Suggestions:

Feedback should be given by management to the workers for keeping

interest in safety management system.

A

66%

B

27%

C

7%

A B C

Total 350 142 38

0

100

200

300

400

No

. of

Wo

rker

s

Question No. 17

A. We know who our safety committee member is

B. We have safety committee member but we’re not sure who it is

C. We don’t have a safety committee or we don’t know who it is

Safety committee is responsible personnel present in Industry. More

importantly responsible for making industry a safe working place for workers.

Response Q17

A 350

B 142

C 38

Grand Total 530

Table 17: Table shows the response of workers on Question No. 17

Figure 17: Shows the result on the response on Question No. 17

Key Findings:

Most of the workers are known about the safety committee member.

Suggestion:

Safety committee member must be socialized with the workers so that

worker are easily report the issues.

CHAPTER – 7

ANALYSIS OF

QUESTIONNAIRE

(Part B)

A

37%

B

52%

C

11%

A B C

Total 195 274 61

0

50

100

150

200

250

300

No. of

Work

ker

s

Chapter 7

Analysis of Questionnaire (Part B)

Part A of analyzing of Questionnaire is consist of last 20 questions which

covered by various topics like Risk Assessment, Safe work Procedure, safety

training, awareness about safety issues, safety management and safety incidents.

Question No. 18

A. We have safety reporting procedures and we use them

B. We have reporting procedures, but we don’t always use them

C. We don’t have reporting procedures or we don’t use them

Safety reporting procedure makes help in making database for safety incident

and can be useful in making future progresses in many ways.

Row Labels Q18

A 195

B 274

C 61

Grand Total 530



Key Findings:

Workers are not regularly using the safety reporting procedures they

used it at extreme positions otherwise they manage by themselves.

Suggestions:

It is for worker so worker must use safety reporting procedure.

A

18%

B

49%

C

33%

A B C

Total 94 263 173

0

50

100

150

200

250

300

No.

of

Work

ers

Question No. 19

A. We always report safety incidents

B. We mostly report safety incidents

C. We don’t report safety incidents

Safety incidents are the cause of the major fatal accidents. If safety incidents

taken consideration seriously then industry can avoid major accidents of future.

Row Labels Q19

A 94

B 263

C 173

Grand Total 530


Figure 19: Shows the result on the response on Question No. 19

Key Findings:

33% of the workers don’t report the safety incident and another 49%

may report or not cannot say.

Suggestions:

Workers should be motivated by the management to report the safety

incidents.

A

18%

B

48%

C

34%

A B C

Total 95 256 179

0

50

100

150

200

250

300

No.

of

Work

ers

Question No. 20

A. We are always encouraged to report safety incidents

B. We are usually encouraged to report safety incidents

C. We are never encouraged to report safety incidents

Safety incidents reports should encouraged by safety management team to

make work safe by eliminating it after reporting by workers.

Row Labels Q20

A 95

B 256

C 179

Grand Total 530

Table 20: Shows the response of the Worker on Question No. 20


Key Findings:

33% of the worker are never encouraged in the industry to report the

safety incident

Suggestions:

Encouragement from the management team should be given to the

workers so that they can report the safety incidents

A

16%

B

49%

C

35%

A B C

Total 87 258 185

0

50

100

150

200

250

300

No.

of

Work

ers

Question No. 21

A. Safety incident reports always get followed up

B. Safety incident reports sometimes get followed up

C. Safety incident don’t get followed up

Following up the safety incident reports provides the solution about the

incident and future coming faults can be rectified.

Row Labels Q21

A 87

B 258

C 185

Grand Total 530


Figure 21: Shows the results on the response on Question No. 21

Key Findings:

Nothing done on safety incident report as suggested by results

because only 16% saying that it followed up

Suggestions:

Safety incident report must be taken seriously by management and

workers both to make a safe environment

A

17%

B

50%

C

33%

A B C

Total 92 265 173

0

50

100

150

200

250

300

No. of

Work

ers

Question No. 22

A. Safe work procedures are reviewed and updated if there is an incident report. We

try to find out why an incident happened and how to fix it

B. Safe work procedures are sometimes reviewed and updated after an incident

report. We usually try to find out why an incident happened and how to fix it

C. No one reviews safe work procedures after an incident report to try to find out

why an incident happened and how to fix it.

Row Labels Q22

A 92

B 265

C 173

Grand Total 530

Table 22: Shows the response or workers on Question No. 22

Figure 22: Shows the results on responses given for Question No. 22

Key Findings:

Half of workers saying that safe work procedures are sometimes

reviewed and updated after an incident.

Suggestions:

Safe work procedures are must reviewed and updated as decided by

the safety management

A

8%

B

37% C

55%

A B C

Total 44 195 291

0

100

200

300

400

No.

of

Work

ers

Question No. 23

A. Our safety training is reviewed or updated if there is an incident

B. Our safety training is sometimes reviewed or updated after an incident

C. Our safety training doesn’t get reviewed or updated after an incident

Safety training must be reviewed and updated according to the situation

present in the industry after any incident takes place.

Row Labels Q23

A 44

B 195

C 291

Grand Total 530

Table 23: Shows the response of workers on Question 23

Figure 23: Shows the result on basis of response of Question No. 23

Key Findings:

Training doesn’t updated and reviewed after the accident as shown by

the responses

Suggestions:

Training session must be provided after incident so that situation of

panic can be avoided and productivity increments.

A

15%

B

53%

C

32%

A B C

Total 78 284 168

0

50

100

150

200

250

300

No.

of

Work

ers

Question No. 24

A. If we report a serious problem where someone could get hurt, they put in a

solution and fix it straight away

B. If we report a serious problem where someone could get hurt, they take action as

soon as they can

C. If we report a serious problem where someone could get hurt, they don’t take

action

Management response to the danger situation and in emergency provides the

better relation between the worker and employer.

Row Labels Q24

A 78

B 284

C 168

Grand Total 530

Table 24: Shows the response of worker on Question No. 24


Key Findings:

Action has taken but not primarily. Management takes time to act in

the situations.

A

12%

B

46%

C

42%

A B C

Total 62 245 223

0

50

100

150

200

250

300

No.

of

Work

ers

Question No. 25

A. Managers seem to understand what we and they should do regarding safety

B. Managers sometimes seem to understand what we and they should do regarding safety

C. Managers don’t know what we or they should do regarding safety

Managers involvement with the workers in making a safe place for work can

be achieved if both works well for it.

Row Labels Q25

A 62

B 245

C 223

Grand Total 530

Table 25: Shows the response of workers on Question 25

Figure 25: Shows the result based on the response on Question No. 25

Key Findings:

42% of the workers says that managers don’t know what to do next in

safety issues

Suggestions:

Mangers should involve in the safety issues by involving in person

with industrial worker or by reading the documentation.

A

41%

B

51%

C

8%

A B C

Total 217 273 40

0

50

100

150

200

250

300

No

. o

f W

ork

ers

Question No. 26

A. If I didn’t follow a safety instruction, I’d feel like I was letting the team down

B. If I didn’t follow a safety instruction, I might get away with it with some managers/supervisors

C. None would really care if I didn’t follow a safety instruction

If you are determined safety consciousness by yourself then it will be easier

for you to follow the safety instructions

Row Labels Q26

A 217

B 273

C 40

Grand Total 530


Figure 26: Shows the result based on the responses given on the Question 26

Key Findings:

51% of people says that if they did not follow the safety instruction,

they might get away with the help of some manager/supervisor.

Suggestions:

Managers and supervisor must not to be on side of the persons which

negotiates the safety instructions.

A

8%

B

35% C

57%

A B C

Total 42 188 300

0

100

200

300

400

No.

of

Work

ers

Question No. 27

A. There is enough time put into safety

B. Time is put into safety but it’s not quite enough

C. There is hardly any time put into safety

Safety is a full time work while doing your job you must feel safe so that you

can concentrate on your job and give hundred percentage of yourself.

Row Labels Q27

A 42

B 188

C 300

Grand Total 530



Key Findings:

There is hardly time to put in safety is said by 57% of the workers.

Suggestions:

Weekly some time may be one hour must be given for it by the

industrial authority.

A

15%

B

54%

C

31%

A B C

Total 81 284 165

0

50

100

150

200

250

300

No.

of

Work

ers

Question No. 28

A. I feel that there are enough resources/money put into safety

B. I feel that resources/money are put into safety but it’s not quite enough

C. I feel that there aren’t enough resources/money put into safety

If enough resources and money puts into safety is sufficient then the problem

can be solved.

Row Labels Q28

A 81

B 284

C 165

Grand Total 530

Table 28: Shows the response on Question No. 28

Figure 28: Shows the result on the basis of response of Question No. 28

Key Findings:

69% of the workers says the resources/money put into safety are not

quite enough and must increases

Suggestions:

Resources/money put into safety has to increase in result productivity

increases due to which industry can make profit.

A

51%

B

43%

C

6%

A B C

Total 272 228 30

0

50

100

150

200

250

300

No.

of

Work

ers

Question No. 29

A. Safety is a high priority for our company

B. Safety is sometimes a high priority for our company

C. Safety is not priority of our company

Safety must be high priority to the industries because safe work is better then

to not be in work.

Response Q29

A 272

B 228

C 30

Grand Total 530

Table 29: Shows the response of workers on Question No. 29

Figure 29: Shows the result based on the responses of Question No. 29

Key Findings:

Safety is the high priority of the company says by 51% workers

Suggestions:

Implementation of the sentence is more important than just writing it

as a tag line.

A

28%

B

57%

C

15%

A B C

Total 150 299 81

0

50

100

150

200

250

300

350

No

. of

Wo

rker

s

Question No. 30

A. Management always gets involved in safety issues

B. Management sometimes gets involved in safety issues

C. Management doesn’t get involved in safety issues

Management involvement provides a meaningful way to industrial safety as it

gives means and ways to do it in better way.

Response Q30

A 150

B 299

C 81

Grand Total 530


Figure 30: Shows the result based on the response of Question No. 30

Key Findings:

Management sometimes gets involved in the safety issues

28% says the management always involves in safety issues

Suggestions:

More involvement by management should be their.

A

28%

B

58%

C

14%

A B C

Total 146 307 77

0

100

200

300

400

No.

of

Work

ers

Question No. 31

A. Managers/supervisors mean what they say and do what they say, in safety matters

B. Managers/supervisors sometimes mean what they say and do what they say, in safety matters

C. Managers/supervisors don’t mean what they say or do what they say, in safety matters

It is not true always what management saying will do that in future because

of their own reasons.

Response Q31

A 146

B 307

C 77

Grand Total 530


Figure 31: Shows the result of the response on Question No. 31

Key Findings:

Managers/supervisor only sometimes do what they say in safety

issues is answered by 58% workers

Suggestions:

Managers and supervisor must understand the situation of the industry

and do the work accordingly

A

15%

B

54%

C

31%

A B C

Total 81 284 165

0

50

100

150

200

250

300

No.

of

Work

ers

Question No. 32

A. I feel like my health and safety matters here

B. Mostly I feel like my health and safety matters here

C. I don’t feel like my health and safety matters here

One is responsibility of the industrial unit who is working in the environment

Response Q32

A 81

B 284

C 165

Grand Total 530


Figure 32: Shows the result on the basis response of Question No. 32

Key Findings:

Mostly the workers feel like their health and safety matters in the

industry said by 54% of workers

While 31% thinks that their health safety does not matter here

Suggestions:

Safety management team must do the works to make industry feel

safe and great working environment.

A

14%

B

54%

C

32%

A B C

Total 77 284 169

0

50

100

150

200

250

300

No

. of

Wo

rker

s

Question No. 33

A. I know who to ask about what to do, if I get injured at work

B. I’m not sure who to talk to about injuries at work, but I think someone here could tell me

C. We don’t have anyone to talk to about injuries at work

Injuries while working in the industry comes in if proper taken care during

the work is not taken consideration.

Response Q33

A 77

B 284

C 169

Grand Total 530

Table 33: Shows the response of the worker on Question No. 33

Figure 33: Shows the result on the basis of responses on question no. 33

Key Findings:

54% of the workers are not sure about whom to ask in case of injury

but they are sure that someone around can help them.

Suggestions:

Identify a person who has responsibility for injuries during work.

A

14%

B

55%

C

31%

A B C

Total 77 290 163

0

50

100

150

200

250

300

350

No

. of

Wo

erker

s

Question No. 34

A. We all have to report all injuries straight away

B. They only want us to notify serious injuries

C. They don’t like us to report injuries

Injuries notified to the management can help in making job specification easy

and avoidance of injuries can be easily done with the help of it.

Response Q34

A 77

B 290

C 163

Grand Total 530


Figure 34: Shows the result on the basis of response of Question No. 34

Key Findings:

Only serious injuries has to notify to the management system says

55% of the workers

Suggestion:

All the injuries should be entertained and changes to the processes foe

making good

A

58%

B

37%

C

5%

A B C

Total 309 196 25

0

50

100

150

200

250

300

350

No

. of

Wo

rker

s

Question No. 35

A. Our notice board has a poster about injury management

B. I’m not sure if we have information about injury management or not

C. There is no information about injury management on display

Posters on notice board are the easiest and best information to keep

inform the workers in an easy manner

Response Q35

A 309

B 196

C 25

Grand Total 530


Figure 35: Shows result on the basis of response on Question No. 35

Key Findings:

Notice board has the posters about the injury cure

Suggestions:

Notice board must be noticed and changed regularly with updating it

time to time

A

14%

B

55%

C

31%

A B C

Total 77 290 163

0

50

100

150

200

250

300

350

No

. of

Wo

rker

s

Question No. 36

A. All injured workers are offered suitable duties and a return to work plan is worked out for them

B. Most injured workers are helped to come back to work as soon as possible

C. We don’t have suitable duties or a return to work program

Workers are the best assets of an industry. Most valuable and skilled

worker are offered come back to work after an injury as quick as possible.

Response Q36

A 77

B 290

C 163

Grand Total 530

Table 36: Shows the response of worker on the Question No. 36

Figure 36: Shows the result on the basis of Question No. 36

Key Findings:

Most of the injured workers are helped in coming back to work in the

industry says by 55% of the workers

Suggestions:

Some of attractive plans must be develop to encourage the worker

came back to its working position.

A

29%

B

57%

C

14%

A B C

Total 156 301 73

0

50

100

150

200

250

300

350

No

. of

Wo

rker

s

Question No. 37

A. Our return to work program helps get injured workers to work whenever possible

B. We have a return to work program but sometimes we don’t use it or it doesn’t work very well

C. We don’t have a return to work program

Return to work programme is the basic need in industry to keep its

skilled man power with itself.

Response Q37

A 156

B 301

C 73

Grand Total 530

Table 37: shows the response from worker on Question No. 37

Figure 37: Shows the result on the basis of response on Question No. 37

Key Findings:

There is return to work programme available in the industries but it

doesn’t work very well said by 57% of the workers

Suggestions:

Modify the programme to provide back entry to the worker which are

injured during working.

CHAPTER – 8

RESULT, CONCLUSIONS

AND FUTURE SCOPE

Chapter 8

Result, Conclusion and Future Scope

“The main driving force behind the industrial safety movement is the fact

accidents are expensive, substantial savings can be made by preventing them.”

8.1 Result of Study

Study followed by containing the answer from all five industries on the

questionnaire prepared has the following results. Results are categorized as shown in

follows.

8.1.1 Risk Assessment

Following are the key findings of the research taken out on the Risk

Assessment

Risk assessment of new process informs about the safety regarding

the process and definition of hazards related to that process. 48% of

the workers said that the industry has followed the risk assessment

while new process added or the old process is updated.

While the 28% of the workers said that they don’t have any provision

of risk assessment in their industry may be with the new process

addition or the process has been changed.

Identification of hazard in the various processes running in the

industry is not identified yet and not written information about the

hazard is available in the industries.

Risk factor is high for the health

Precaution while emergency is available in written form but the

workers are not pre-informed about the situations

8.1.2 Safe Work Procedure

Following are the key findings in the survey on topic of safe work procedure.

Around 42% of the workers are not trained with the safe work

procedure due to absence or don’t get training from industry in which

they are working.

Almost half of the workers of the industry are saying that there

industry have the safe work procedure written for all task based

activities in their area that have safety risk. But, that are not easily

understandable to each and every one.

81% of the workers saying that safe work procedure are updated

only some times in their working life. In it, around 40% of the

workers are literally saying that there is no updating in the safe work

procedure in their working time.

62% of workers gets enough time for learning only sometime

otherwise they don’t get enough time to learn anything other than

doing work.

Even management and supervisor with the help of the worker are only

half of the time involve in putting procedure together on field for

Industrial safety

“Safe work procedures are sometimes reviewed and updated after and

incident report. They usually find out why an incident happened and

how to fix it” said by half of the worker who take part in survey.

8.1.3 Safety Training

Safety training are the technical training provided to make work safe so that

workers feel safe while working and work with increasing his efforts which increases

the productivity of the company.

34% of the workers don’t get trained when they start the working in

the industries.

“Safety training doesn’t reviewed or updated after an incident.” 55%

workers said it

Time to put in safety training is hard to get in industry. Almost 57%

of workers said that the there is hard to get time for industrial safety

training.

Resources or the money which puts in for safety are not enough said

by 54% of the workers of industries.

Safety is the high priority of the company saying by the 51% workers

but the actual scenario is quite different than this.

8.1.4 Awareness about Safety Issues

Awareness on safety is better than regretting on accident. So, following are

the various awareness related questions answered by the workers.

56% of the workers saying that they are made aware of safety issues

which are present in the industry at present is informed from

management to the workers for their safety.

82% of the worker saying is that there is a way of communication

between the worker and management on the health safety issues. But,

only 48% thinks its works usually but remaining think it is useless

equal to nothing.

Feedback on the queries asked related to safety issues is answered but

not always only on few times as suggested by 52% of the workers

Managers are not aware of what to do regarding safety is the 42%

workers responded when ask about managers responsibility in

emergency situations.

Workers feels sorry if they don’t follow the safety tips but only 42%

feel it and for other it doesn’t matter most.

Management only sometimes involved is the safety issues said by

57% workers while 15% replied there is no involvement at all in the

name of safety by the management.

Industries visited have worked out all the jobs/tasks in the area of

worker have awareness about the safety issues are done by the

management as 58% workers said.

8.1.5 Safety Management

Managers and supervisors sometimes checks workers doing the job

safely saying of 54% workers while another 44% said they always

check whether the worker doing the job safely or not. But, in actual

practice only a few times the managers and supervisors involve in it

otherwise they are happily doing their all jobs irrespective of this.

Industries doesn’t update their safe work procedure documentation

says by 40% workers in the industries while another 42% workers

said that only a few changes in a long distance takes place in the

documentation. Even documentation for safety precaution of the

various processes has not been formulated yet.

33% of the worker saying that the management doesn’t take notice of

what they say about the safety. A safety issue given to management

doesn’t take consideration by management. While 49% of the worker

replied that only sometimes the management take due considerations

to their notices on safety issues.

Safety committee representative are unknown to the 27% of the

workers while another 66% know their representative of the safety

committee member. In a few industries there is no safety committee at

all till now.

If workers report a serious problem where someone could get hurt,

management put in a solution and fix the problem straight away says

by 15% while in the same situation management take action as soon

as they can answered by 53% but management don’t take any action

is replied by 32% workers which is very shocking but true.

Management not always involved in safety issues replied by 57% of

the workers while there is no involvement of management in safety

issues said by 15% of the workers.

In safety issues management always does not mean what they say it is

in their dual standard always as suggests by 58% workers

management do something and say something which is not equal

always.

Injury management is the biggest concern in emergencies all worker

agrees to it. But, is there any poster on the notice board of industry to

deal with it in a pleasant manner answered yes by 58% workers and

37% workers are not sure about it whether it is there or not.

8.1.6 Safety Incidents

Reporting of safety incident on time can prevent the major and fatal accident

of future because before a major accident there is a series of minor accidents takes

place as suggested by various accident studies carried out in subject of industrial

safety.

Following are the reports on the safety incident related question asked in our

survey

Involvement of workers in safety issues shown by their notices about

the safety issues but management must response in pleasant manner to

their reports and notices. But, study shows management only

sometimes take care of notice what workers say about the safety

because 49% workers said it. And another 33% says there is no

response on the notices which puts by them to the management

regarding industrial safety.

In case in any safety incidents taken place in the industry then

workers reports that incident to the management then management

must reply with suitable answer in seven days. But, only 33% of the

workers get responded within seven days, 52% may get or may not

get the answer from management while 13% don’t get any answer

regarding their issues on safety.

Management involvement in the safety issues are only sometimes is

there on field as said by 57% while there is no involvement in safety

issues by 15% workers.

Reporting of safety incidents to the management is the best

prevention from the fatal accidents. Around 49% of the workers

report the safety incidents to the management while 33% don’t report

it and manage it by themselves. 18% always reports the safety

incidents.

Encouragement to report the safety incidents is the responsibility of

the management to make work safe in industry. 17% workers say that

they always encouraged reporting the safety incidents while 48%

workers sometimes encouraged to report it but 35% never encouraged

to report the safety incidents.

Followed up on their safety incidents reports is necessary to

encourage them to report more. Only 16% safety incident reports

surely followed up by management while 49% may followed or not

but 35% worker says it won’t followed up therefore, no need to report

safety incident just manage it by ourselves only.

Is safety incident affects the safe work procedure or not? 17% says

the safety incident has positive impacts on safe work procedure

updating done when safety incidents report but 50% says nothing

changes with it while 33% says just fixation of condition is done by

management and there are on solid steps taken to make safe work

procedure well.

8.1.7 Remaining Questions

The industrial safety movement in India is of a very recent origin. So,

the industrial workers in India are more vulnerable to unethical

practices by owners and management.

Industrial safety in acceptable terms is the ability of a firm to increase

productivity without increasing industrial accident.

Maximisation of industrial safety standards and advance of accidents

are considered as the dominant goal of industrial safety norms, with

safety system striving to achieve the highest practical level of safety

norms.

Attitude towards following the safe work procedure of the worker

must be changed by making a safe culture by management after

utilization of available resources

8.2 Limitations of Study

As mentioned earlier, much work has not been done in this area in India.

Hesitation of the industrial units in participation in the Industrial safety research is

the biggest limitation of the study. Limiting the number to five resulted in the

handicap of not being able to carry out correlations and some more predictive

analysis with a high degree of reliability.

Availability of a small sample size reduced the number of organizations with

OHSA 18001 and ISRS certifications available in the samples to one each, which is

definitely a limitation when one wants to generalize the results obtained in the study.

The impact of this was contained to some extent by taking a large sample size from

each of the organizations in order to understand and determine the characteristics of

each organization.

Despite the above limitations of the study, with proper use of statistical tools

and rigour of research methodology adopted, this research has been able to make

contributions.

8.3 Conclusions

Safety training is essential at all levels, If a company cannot afford

safety, it cannot afford to be in business, Lethargy in implementing safety procedures

and using protective equipment’s increases chances of industrial accidents.

The survey of literature on Occupational safety and risk assessment

revealed that application of quality integrated safety management practices have

enable different types of industries to gain better control over accidents and injuries,

and also to improve the production and employee satisfaction and thus strengthen

their level of competitiveness. Therefore, it is evident that a clear understanding of

the critical factors in safety management would help the implementation of

management practices to improve safety of employees and enable better control over

accidents and injuries.

A good safety programme can reduce occupational injury/illness and the

operating costs, which in turn contributes towards increased productivity and

improved profits. Industrial safety has been described as the only aspect of industrial

relations where there is no advantage to either side at the expense of the other. Safety

and health have great importance in industrial development and productivity.

Therefore utmost attention needs to be given to maintain excellent safety and health

standards at the places of work of the employees and also off the work.

8.4 Future Scope

This work being one of the earliest ones in this area in the country has to stop

at a place which leaves much more to be done by future researchers. This work

effectively demonstrated the research ability and usefulness of this important area of

research. Emphasis was given to manufacturing units in this research for reasons

stated earlier. It is possible and even desirable to extend this type of work to cover

other industrial sectors where safety plays an important role.

This work reveals clearly the importance of worker involvement in safety

management, which in turn determines safety performance. It is a proven fact that

behavioural studies can be used to study people related parameters. Worker

involvement, being people based, could be studied from behavioural science angle

also.

Safety has been recognized as an integral part of the normal operating

procedures and a definite responsibility of all supervisory personnel along with the

employees. Absence of proper safety measures would invariably lead to avoidable

accidents resulting into injuries to persons, damage to equipment and machinery,

financial losses both the employers and employees. The human angle for providing

safety to the industrial workers is no less important, in fact the present industrial

environment is one of the major reasons for the management to undertake effective

safety programs in their organizations, concerns, and factories. Safety has been

recognized as an integral part of the normal operating procedures and a definite

responsibility of all supervisory personnel along with the employees. Absence of

proper safety measures would invariably lead to avoidable accidents resulting into

injuries to persons, damage to equipment and machinery, financial losses both the

employers and employees. The human angle for providing safety to the industrial

workers is no less important, in fact the present industrial environment is one of the

major reasons for the management to undertake effective safety programs in their

organizations, concerns, and factories. Industrial safety involves not only elimination

of agents of injury, but also a reliable control to harm to employees.

Safety has been recognized as an integral part of the normal operating procedures

and a definite responsibility of all supervisory personnel along with the employees.

Absence of proper safety measures would invariably lead to avoidable accidents

resulting into injuries to persons, damage to equipment and machinery, financial

losses both the employers and employees. The human angle for providing safety to

the industrial workers is no less important, in fact the present industrial environment

is one of the major reasons for the management to undertake effective safety

programs in their organizations, concerns, and factories. Industrial safety involves

not only elimination of agents of injury, but also a reliable control to harm to

employees.

References

1. Col S Rajeev “Studies on industrial safety in current perspective (a

few selected industries)” Thesis submitted to the Bundelkhand

university, Jhansi for the degree of Doctor of Philosophy. From

shodganga

2. Vinodkumar M. N. “Study of influence of safety engineering and

management practices in selected industries in Kerala.” Thesis

submitted to the faculty of engineering in school of engineering

cochin university of science and technology Kochi in June 2005 from

shodhganga

3. A. Azad “The effect of training in manufacturing industries.” Thesis

submitted to the faculty of mechanical engineering anna university

Chennai in June 2008 from shodganga

4. Amit R. Patil “Analysis of unsafe Human behaviour related accidents

in the mechanical engineering industry and benchmarking its

solution.” Thesis submitted to faculty of management symbiosis

International University Pune in January 2009 from shodhganga

5. H Abdul Zubar, K Viagavel, V Deepak Raja and Arun Mohan

“Occupational Health and safety management in Manufacturing

Industries.” Journa 32133wl of scientific & Industrial research vol 73,

June 2014, pp. 381-386

6. http://www.hse.gov.uk

7. http://www.osha.gov

8. Safety management system and documentation training programme

handbook by S V Paul.

9. Safety, Security and Risk Management by U K Singh & J M Dewan

10. Industrial Safety management by L M Deshmukh

11. Industrial health and safety management by A M Sharmas

http://www.hse.gov.uk/

http://www.osha.gov/

OCCUPATIONAL SAFETY AND RISK ASSESSMENT OF HUMAN BEINGS IN MANUFACTURING INDUSTRY

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