Safety at Jaykaypuram

OH&S Vision

To be a recognized leading company promoting healthy and

safe workplace for achieving goal of “Zero Harm”

OH&S Mission

To develop and implement user friendly and effective OH&S

Management System that fits to the organization and drive

Risk Prevention Culture

2

SN CONTENT

1 Safety Policy, Roadmap, Compliance & Public disclosure

2 Safety performance in the Cement manufacturing, CPP,mines & project site within the plant boundary

3 Safety performance in Logistics (inbound & outbound)

4 Safety Best practices in manufacturing & infrastructurecreated

5 Safety Best practices in mines & infrastructure created

6 Safety best practices in Logistics (inbound & outbound) &infrastructure created

7 Replicability of the idea implemented within the sector /outside the sector

8 Recognition and Awards

Presentation content

3

4

OH&S Policy and Golden Rules

5

HIRA

TBT

BBS Observation

GAP

Lack ofknowledge

Lack ofResource

At-RiskBehavior

Training &

Development

Resource allocation

1. Activate by activator2. Motivate by consequence

Feed forward for

Continual

improvement

CFT OF SECTION HEAD

ENGINEER

ISO 45001:2018 Clause 6.1.4 & 8.1.2

Safety Management - Roadmap

6

Identification of Unsafe Act & Condition

Plant Safety Visit / Audit

Safety visit Mobile app

Plant Safety Inspection

Plant utilitiesInspection

Safety consultation

1. Consultation with worker at shop floor

2. SC Meeting3. CFT Meeting4. DSO Meeting5. HOD Meeting

SAP Plant SafetyInspection module

Utilities InspectionMobile app

Safety visit Mobile app

Safety Management - Roadmap

ISO 45001:2018 Clause 6.1.4 & 8.1.2

7

Emergency prevention and protection

Fire Safety Inspection /

Audit

Safety visit Mobile app

&Utilities

InspectionMobile app

Detection &Alarm system

Maintaining Emergency handlingEquipment in healthy

condition

On site emergency

plan & Mock drill

Safety visit Mobile app RFID

tagging &

SAP

integration

Safety Management - Roadmap

ISO 45001:2018 Clause 6.1.4 & 8.1.2

8

Safety Management - Roadmap

ISO 45001:2018 Clause 6.1.4 & 8.1.2

Safety Standards

9

1. Safety manual

2. Fire safety manual

3. Road Safety Booklet

4. First Aid Booklet

5. Golden rules

6. Visitors and business partner safety rules

7. Legal Compliance Manager

8. Contractor Safety Management System

9. Driving Safety Management System

ISO 45001:2018 Clause 6.1.4 & 8.1.2

Safety Standards

10

10.Lock Out Tag Out System

11.Incidence Investigation System

12.Standard for Machine Guarding

13.Code of practice for electrical safety

14.Onsite Emergency Plan

15.CPR Chart

16.Departmental System Procedure Manual

17.Common System Procedure Manual

18.COP & SOP

ISO 45001:2018 Clause 6.1.4 & 8.1.2

Safety Standards

11ISO 45001:2018 Clause 6.1.4 & 8.1.2

Golden Rules

12ISO 45001:2018 Clause 6.1.4 & 8.1.2

SAFETY ANNUAL PLAN

13ISO 45001:2018 Clause 6.1.4 & 8.1.2

SAFETY ANNUAL PLAN

14ISO 45001:2018 Clause 6.1.4 & 8.1.2

15

Safety Department KRA

Key Result Area Daily Activity Log

16

Safety department KRA; Monitoring & Reporting

Daily Report Auto Mail Digital Log Book

Determination of legal requirements and other

requirements

17ISO 45001:2018 Clause 6.1.3

18

Public Disclosure

Sustainability report Page 38 -40

19

Public Disclosure

Sustainability report Page 38 -40

20

Public Disclosure

Sustainability report Page 38 -40

21

PERFORMANCE

SN ACTIVITY OUTCOME FY-16 FY -17 FY -18

1 Safety Audit UC eliminated 1180 1257 848

2 Fire Audit UC eliminated 105 90 40

3 Safety committee

meeting

Safety suggestions

implemented

126 238 173

4 Safety training

(Man Hour)

Increase in safety

awareness

13139 14465 14062

5 Fire service week Fire Safety Awareness 470 733 1216

6 Road Safety Week Traffic safety awareness 1176 1894 1881

7 National Safety

Month

Awareness and review 1631 1513 1329

8 Near Miss UA / UC eliminated 592 748 653

9 BBS observation UA / UC eliminated 230 74 24

Leading indicator

22

PERFORMANCE

Lagging indicator

Year Number of Reportable Accident

2016 0

2017 0

2018 1

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SAFETY KRA ASSIGNMENT BY

HOD

HIRA BY Section Head & APPROVAL

BY HOD

Safety Best Practices(Behaviour Based Safety Management Module in SAP)

On the Job Safety observation by Shift

Engineer

Near Miss Reporting and

implementation of action plan

Pre Job safety briefing of HIRA by Shift

Engineer (TBT)

Continual Improvement plan w.r.t.

BBS analysis report

Implemented in July 2014 – till date 2126 recommendations implemented

ISO 45001:2018 Clause 6.1.4 & 8.1.2

24

Implemented in Aug 2016 – till date 938 recommendations implemented

Safety Best Practices(Safety Visit Mobile App)

LOGIN

POSTING OF OBSERVATION /

RECOMMENDATION

JOB ASSIGNMENT

TO SECTION HEAD

BY HOD

ACTION PLAN &

TARGET DATE

ENTRY BY SHIMPLEMENTATION &

MONITORING

25

Sep 2016 – all 1265 equipments mapped floor wise – till date 1011 UC rectified

SAFETY INSPECTION MODULE DEVELOPED IN SAP FOR 100% INSPECTION ON 13 INSPECTION CRIETERIA WITH ACTION PLAN AND COMPLETION MONITORING SYSTEM

INSPECTION AREA SELECTION FLOOR SELECTION

EQUIPMENT SELECTION

INSPECTION STATUS ENTRY

IMPLEMENTATION &

MONITORING

Safety Best Practices(Safety Inspection Module in SAP)

26

Implemented in Sep 2016 – 1241 equipment mapped & till date 189 UC rectified

Safety Best Practices(Utilities Safety Inspection Mobile App)

Open the App and login using ESS id and password

Click on Utilities Safety Inspection

Enter planner group SAF / MIN and select the Utility Equipment

Carryout inspection w.r.t. checkpoints and enter status,

measurement value & observation remark

Auto MailAction plan & Target date entry

Auto Mail

Execution & Completion date

entry

27

POTENTIAL EMERGENCY & EMERGENCY RESPONSE

28

Fire Safety Best Practices(RFID Tagging & online real time data update)

REAL TIME ON LINE DATA

UPDATE ON RFID TAG

AND IN SAP SYSTEM FOR

ALL FIRE DETECTION AND

ALARM SYSTEM, FIRE

EXTINGUISHERS & FIRE

HYDRANT SYSTEM

Implemented in April 2015; increased the work efficiency by 200 % & higher accuracy

29

Mines Safety– Best Practice(Dust control)

VACCUME SWEEPING

Water Mist system at crusher dump hopper

30

Mines Safety– Best Practice(Engineering control in dumper)

Front PROXIMITY

SENSOR

Auto Fire suppression

system

RearPROXIMITY

SENSOR

FrontBlind spot

camera

Rear ViewCamera

Down hill speed control & Hill hold system

Advanced Emergency

braking system

31

Mines Safety– Best Practice(Silicosis prevention)

Screening of films on Respiratory protection

32

Mines Safety– Best Practice(Silicosis prevention)

Awareness session on Silicosis to employees

33

Mines Safety– Best Practice(Silicosis prevention)

Awareness session on Silicosis in nearby village

34

10.10.5.4/elearningLOG IN Topic selection

Competency development – Best Practice(LEARNING PORTAL)

Learning Implementation

Plan

Study & e-note

35

10.10.5.4/kioskLOG IN

LANGUAGE SELECTION TOPIC

SELECTION

FILM SCREENINGONLINE TESTCERTIFICATE GENERATION

Competency development – Best Practice(LEARNING PORTAL & KIOSK)

36

Competency development – Best Practice(Customized Safety Animation Films)

Visitor Safety Induction Video Driving Safety animation Video

Mines Safety animation Video

37

Tool box talk (Pre-job safety briefing)

38

Pre monsoon safety – Mass awareness

39

Behavior based safety observation

40

On the job safety observation by HOD

41

Safe execution of High Risk Job

Execution of job with Kevlar suit

Execution of job with lifting plan; proper rigging and monitoring with CCTV camera 42

Safe execution of High Risk Job

Execution of job with lifting plan; proper rigging and monitoring with CCTV camera 43

Safe execution of High Risk Job

44

Safe execution of High Risk Job

Execution of job with SRP System

45

Display at Main Gate

46

Display at Mines Gate

47

Activators for Safe Behavior

48

Activators for Safe Behavior

49

Activators for Safe Behavior

50

Activators for Safe Behavior

51

Activators for Safe Behavior

52

Activators for Safe Behavior

53

Activators for Safe Behavior

54

Activators for Safe Behavior

55

Activators for Safe Behavior

56

Training for Senior Management team

57

Awareness session for transporters

58

Contractor Safety Management Committee Meeting

59

Safety Committee Meeting

60

Scaffolding training

61

Safety campaign inaugural address

62

Safety Campaign

1. Road Safety Week

2. National Safety Month

3. Fire service Week

63

Safety promotional activity by contractor

64

Emergency Response Group Meeting

65

Emergency Mock drill

66

Emergency Mock drill

67

First Aid Training

68

Suraksha Janki – Republic day

69

Suraksha Janki – Republic day

70

Pedestrian Path

71

PPE Booth for Truck Drivers

72

Traffic sign display at LPSS

73

Safety Awareness test at LPSS

74

Safety Awareness trg in nearby school

75

Acknowledgements

1. “Safety Management System of JK Lakshmi Cement is most

innovative system” - Shri Gopalkrishna PB Sr. President

(Manufacturing) Ramco Cements Limited - QCFI National Conclave

held at HICC Hyderabad.

2. “I have not seen such an innovative system in my life” – Shri PR

Kumar; CEO BSES Yamuna Power Delhi - International Safety

Convention organized by The Institution of Engineers (India) at New

Delhi.

3. “I had visited about 5000 companies but haven’t seen such robust

system for fire and safety Management” – Shri A. V. V. Gopal Rao;

Country Head Reliance Risk Services - at the time of HAZOP study.

4. RFID tagging system for monitoring and maintaining fire fighting

equipments is innovative and unique. I have never seen such a

robust system – Dr. Vinod Kumar Jain Managing Director M/s Vexil

Business Processes Services Private Limited - IMS Re-certification

audit concluding function.

5. Appreciated by the distinguished auditors of National Safety

Council of India during statutory safety audit which is conducted bi-

annually for cement plant and annually for TPP.

Shri PR Kumar (CEO) BSES Yamuna Power

Shri Gopalkrishna PB Sr. President (Mfg)

Ramco Cements Limited

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AWARDS AND RECOGNITION

1. National Safety Award – 2011 &

2016 by DGFASLI Ministry of

Labor Government of India.

2. International Safety Award from

British Safety Council UK from

year 2013, 2014, 2015 2016 & 2017

3. National Safety Award – 2013 &

2014 from National Safety Council

of India.

4. Safety system Excellence award -

2013 from FICCI

5. Safety Innovation Award 2010,

2011, 2012, 2013, 2014, 2015, 2016

& 2017 from The Institution of

Engineers (India)

Thank you!

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