Safety Pillar internal audit
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Transcript of Safety Pillar internal audit
UNITED BREWERIES LIMITED - NELAMANGALA 1
SAFETY PILLARSl.
No.Name Role Department
1 Rupesh Verma Pillar Leader HSE
2 V S Moorthy Pillar Member Process
3 M S Manjunath Pillar Member Logistic
4 A Narasimhulu Pillar Member Bottling
5 S Satti Babu Pillar Member Process
6 Mohan Pillar Member Security
UBL- Nelamangala11th June, 2015
UNITED BREWERIES LIMITED - NELAMANGALA 2
To ensure a safe working environment in all our activities by educating, engaging, empowering all our stake holders by adhering to best safety practises.
Safety Pillar Mission is to develop and implement effective Safety policies, procedures and methodologies to eliminate safety related losses by• Identifying and Eliminating all the Unsafe Working Conditions• Preventing all the Unsafe Acts and Behaviours by people involvement. • Enabling a safe environment by promoting near miss reporting.
VISION
MISSION
UNITED BREWERIES LIMITED - NELAMANGALA 3
Pillar Team Roles & Responsibilities
Member Role ResponsibilityV S Moorthy Pillar Member To inform the pillar team members for meetings and MOM
circulation.; Pillar activity audit
Satti Babu Pillar Member Board updation & Tag register review/updation.
Rupesh Leader KPI and Master plan Review Pillar Planning Risk Assessment Training of Pillar members
A Narasimhulu Pillar Member To support the different teams/running projects to further progress.; Kaizen execution.
MS Manjunath Pillar Member Warehouse Safety compliance; Training to warehouse team.
Mohan Pillar Member Traffic safety of brewery, Training to drivers, Vehicle fitness, PPE compliance
4
Pillar Route
5
Pillar master plan
Step 1 Sub step1 Sub activities step 1 Status
Identify
Safety
Priorities and
Restore
Basic Conditions
1.1 Assess all current activities performed for safety List attached
1.2 Introduce and access Safety Pyramid, formalize KPI in practiceevidence @ gemba
1.3Assess Conformance to (HeiQ) rules, standards and procedures via HeiQuest and Legal requirements. Make Gap analysis for both and action plan to close actions
Pass compliancePillar Indicators
1.4 Define visitor and Contractor Induction Program in practiceevidence @ gemba
1.5 Define review work permit system, LOTO and PPE procedure. in practiceevidence @ gemba
1.6 Perform accident, Incident, (Vertical) deployment , define Priorities, Targets & prepare improvement action plan done
1.7 Ensure Safety activities are included in 5S activities and audits. On going
1.8 Introduce safety tagging system to identify unsafe conditions OngoingKPI
1.9 Perform basic safety awareness training for all levels. on going @trg. Mandays
6
Microsoft Excel Worksheet
1.1- Assess all current activities performed for Safety.
STEP 1.2 Introduce & assess safety pyramid – Iceberg Theory,formalise KPIs
FatalLTI
MTC
First Aid
Unsafe Act
Near Miss
Unsafe condition
YTD MTD
0
0
8
8
28
19
72
0
0
4
4
11
8
33
BE SAFE BE CLEAN
In Numbers
Till May 2015
8
Safety Pillar IndicatorsCalculation Remark
MONTHLY PILLAR KPI
TREND
S.N. KPI Description Measure UnitInitial Target
14-15 15-16 Apr-15
May-15
Jun-15
1 Accident Frequency ( LTI + Permananent Disability) Nos / 100 FTE 0.015 0 = 12X (No. of LTI + No. of
Permanent Disability) / 100 FTEFTE for Safety calculations Includes - Everybody coming in plant (Permanent Employees + Warehousing + Sighters + Nurse + QA workers + WTP RO contract members + Contract process + Contract Utility, Bottle feeding, Security, canteen, Housekeeping).
00
2 Incident Frequency (MTC + FA): Own & Contractor Nos / 100 FTE 3.29 1.71 =12X (No. of MTC + FA) / 100 FTE 1.33 1.35
3 Near misses : Own & Contractor Nos 48 180
= No. of Nearmisses cases reported in plant including Own and Contractual person 11 8
4 Improvement in Pass compliance Value 83.55 90 = Pass score based on pass
checklist 90.10 90.78
5Risk assessment completion wrt. Plan and (No risk above 35 RPN)
% 83 doneNo >200= 0 175
= (No. of Risk assessment completed with action/ No. of Risk assessment schedule by that time )X100
act-8sub
act- 17>200=
0
act-15sub
act- 63>200=
0
6 Average time to solve Safety Tags Days
tags put wef oct-14 to mar-15 =
237tags closed- 113
%age closed-47.6%
65% closure
PM= Average No. of days required to solve safety related tags. Near miss Unsafe
Conditions and other audit Observations
TP-57TC-30%age
-52.6%
TP-44TC-17%age -38.6%
STEP 1.2 Introduce & assess safety pyramid – Iceberg Theory,formalise KPIs
Step 1.3 Assess conformance to (HeiQ) Rules, Standards & Procedures via HeiQuest & legalrequirements. Make gap analysis on both & prepare action plan to close actions (1)
POSITIVE SAFETY ASSURANCE SYSTEM ACTION PLAN
Sl No. (as per
checklist) Initiative FPR Status
10Training calendar for each workmen and executive HRP
In process; target- 30 june.
12Refresher training of cont. and engg. And certificate RKV 14 June.
21 Restaring APEX safety committee HRP DONE22 Safety committee points review RKV DONE
28 PPE compliance by contractor supervisor CRDONE (Training, audit, TBT in
place).34 List of authorized permit issuer RKV 15th June33 Permit being issued as per module CR DONE
39
Different color code badges are provided to contract workers depending on the area in which they are working
HRP Budget, next contract renewal.
93 Color coding of plants & pipes are in place CR Will start on 20th June
103
Check adequacy of the number of lighting arrestors & their location CR DONE
Step 1.4 Define visitor and contractor safety/introductionprogram
Identity Type FPR
Visitor/ contractor Induction PPT in English/ Kannada Security
Contractor Equipment Checking and registerElectrical/Mechanical Engineer
New J oineeInduction PPT in English
Induction by HSE Manager HR
Contract employees Safety Talk Shift engineer
Safety Induction Procedure
Step 1.5 Define, review Work permit system, LOTO & PPEprocedures
Work permit system
LOTO Procedure
PPE Procedure
Adobe Acrobat Document
PPE Procedure
LOTO Procedure
SWP Procedure
1.6 Safety Incident Deployment 2014-15
Pacakaging Warehouse & logistics/stores
Process /lab Admn./others Utility
157
2515 9 7
First Aid 2014-15
Pacakaging Admn./others Utility
9
2 2
MTC 2014-15
Pacakaging
1
LTI 2014-15
FA MTC LTI
213
13 1
2014-15 Incident deployment
Deployment First aid 2014-15
13
Empty
bottl
e fee
ding
Crate f
eedin
g
Bypas
s/ L-b
ent-
Line 2
Paste
urize
r
glass
culle
t disp
osal
Packe
r
Labe
ller
Test
lamp-1
(pos
t pas
teuri
zer)
Washe
r
Crating
Shift
ing of
bag
Unload
ing of
bags
Filler EB
I
Test
lamp-2
(pos
t pas
teuri
zer)
Test
lamp-2
(pas
teuri
zer in
feed)
hous
ekee
ping o
f bro
ken g
lass
Carton
form
ing
Pressu
re les
s com
biner
(line
-2)
Test
lamp-1
(pas
teuriz
er inf
eed)
BBH work
shop
Pressu
re les
s com
biner
(line
-1) -
5
10
15
20
25
30
0
20
40
60
80
100
120
27 26
18
13 11 11
8 7 7 7 5
3 3 2 2 2 1 1 1 1 1 -
17
3445
5461
6873 77 82 86 89 91 93 94 96 97 97 98 99 99 100100
Area of concern packaging-157
incidents
14
1.7-Ensure Safety activities are included in 5S activities and audits.
15
1.8- Introduce safety tagging system to identify unsafe conditions.
Safety tag by tagger posted and
handed over to safety pillar
Tag register maintained by
Pillar team
Follow-up with concern HOD and
tag hand over.
Follow-up with concern HOD and
tag hand over.
Closed tag returned back to
safety pillar
Keep informed the status
to AM pillar
Safety tag collected from TCO, nearmiss,
whats app.
OPLs and trainings
Safety Tags
16
1.9- Perform basic safety awareness training for all levels.
Fall arrestor- ORR project
Fall arrestor- ORR project
Safety in pallet handling- ORR project
Fire trainingSCBA trainingDaily Tool box talk meeting at time office
17
Shift wise Tool box talk at shop floor.
1.9- Perform basic safety awareness training for all levels.
18
1.9- Perform basic safety awareness training for all levels.
Safety talk- speakers at main gate & time office
19
1.9- Perform basic safety awareness training for all levels.
20
Pillar master plan
Step2 Sub Step 2 sub activities step 2 status
Systematic Analy
se accident and
incidents
2.1 Select and train Safety Experts/ champions in all Departments
Fire-SOFA- Nurse
Dept- Champions identified
2.2 Perform accident and Incident analysis to establish root causes via 5Why
Done for all incidents
Evidence 0f CAPA2.3 Prepare and execute countermeasure plan Done
evidence example
2.4 Start horizontal expansion of actions to similar areas Ongoing evidence @ gemba
STEP 2.1 Select & train safety experts/ champions in all departments
Safety Training Committee 1 Rupesh Verma HSE
2 V S Moorthy PROCESS
3 M S Manjunath P &L
4 Madhu BBH
5 Dinesh Nayak Electrical
6 Mahesh, Saju & Lalitha OHC
8 Mohan & Vikas Security
10 Kumar, Sidhappa & Srinivas BBH
12 Umesh Warehouse
13 Saravanan PROCESS
Safety Hand book has been created by steering committee and training being delivered to all. Basic safety training is provided to all levels
22
2.2- Perform accident & incident analysis to establish root cause via % why
Case- 1. Swami was doing his usual duty of wet spent grain unloading.2. Swami is engaged in the brewery since last 20 years through Vendor.3. Swami climbed up the lorry to level the spent grain heap. While
levelling ,his gum boot got stuck in the spent grain, he lost his balance and has fallen on the hot (70 degree) heap of spent grain. His right leg and right hand got stuck into the spent grain.
4. His colleague Mr. Umesh ( who was standing nearby at ground floor), after hearing the noise of injured, rescued Swami.
5. Immediately the injured was sent to nearby JP hospital at Nelamangala by company owned Ambulance for treatment.
6. After the treatment doctor declared him out of danger with 30% burn. Later as per the advice of the Doctor, he was shifted to Victoria Hospital in Bangalore City for further treatment as JP hospital does not have burnt care specialist.
7. The injured was in the influence of liquor and was suffering with convulsions.
23
2.2- Perform accident & incident analysis to establish root cause via % why
why why
24
2.2- Perform accident & incident analysis to establish root cause via % why
25
2.2- Perform accident & incident analysis to establish root cause via % why
26
2.2- Perform accident & incident analysis to establish root cause via % why
27
2.2- Perform accident & incident analysis to establish root cause via % why
28
2.2- Perform accident & incident analysis to establish root cause via % why
SOP Spent
29
2.3- Perpare and execute counter measures.
With access platform- person need not to get exposed with hot spent.
30
2.2-Incident Analysis – LTIDate Incident Description Reason CA PA
29th Oct’14 Mrs. Sakamma was engaged for crate removal at sighter point, line-1 past-1. The loose arm sleeve came in contact with moving guide & entangled which resulted cut injury in right wrist. Immediately sent to Hospital for treatment.
1. Uncovered rotating part.2. Loose Arm sleeve
1. Replaced all the arm sleeves with skin fit sleeves.
Guarding of all the rotating parts done.
2.3- CAPA
Loose arm sleeve near moving part. Fit sleeve with guards on moving part.
WRONG RIGHT
SITUATION BEFORE
Wrong method of using Arm guard which causes exposed arms
SITUATION AFTER
Right method which improves the guarding of arms.
LOCATION AREA DATEBBH FEEDING/ SIGHTER
AREA12.11.14
Team: Kavach TeamSAFETY IMPROVEMENT
2.4 start horizontal expansions of actions to similar areas
34
Pillar master plan
Step 3 sub step 3 sub activities step 3 status
Hazard Identification and Risk Manage
ment
3.1 Prepare, plan and perform hazard Identification and risk assessment across the site
RA done as per planPillar KPI's
3.2 As priority define and implement risk management for " risk of death and serious Injury" Done
3.3 Prepare " Operational risk reduction " team roll out plan for site and execute. ORR @ gemba
3.4 Prepare safety approval eg: CILT, OPL, SOPS and maintenance standards to maintain safe work practices
safety sop's , OPL @ gemba
3.5 Introduce safety Visual Management, signages and physical eg: Walkways, PPES, Machine Poka Yoke..
Visual management on safety@ gemba
3.6 Rewiew work permit & LOTO procedures.LOTO review doen during pass auidt-
monthly
3.7 Improve Ergonomics and environmental conditions light, noise, temperature
LUX level monitoring and DB monitoring
and appropriate countermeasures
takenEvidence @ gemba
35
3.1- Prepare, plan and perform hazard Identification and risk assessment across the site
Function Area Done Q1 Q2 Q3 Q4
Packaging 8 5
Process 9 2
Utility 12 2
Admn. 7 3
Warehouse 3
Stores 5 2
Lab 1
CTC 1
Shared services 1
36
3.2- As priority define and implement risk management for " risk of death and serious Injury"
Activity Action Taken Score Current Dept.
Truck parking by driver at parking outside the gate.
1. Parking at 10m distance from access road of factory. 2. Admin. Control through security & Safety KPI monitor.
200 140 Admin.
To align the bottle if get stuck/ fall in between test lamp to PLC.(sub activity- Removal of stuck bottle.)
1. PPEs, PVC strip, PVC net on conveyor. (existing).2. Acrylic guard to contain the hazard.3. SOP/OPL for handling bottles. (done)4. Only trained and experienced person to be deployed. (done)5. Emergency s/w at operator point(3-phase). 6. Guide alignment, conveyor alignment, wear strip replacement.7. SS hood cover on post labeler conveyor. (done line-2)8. Preventive maintenance for conveyors and guide.
300 84 BBH
Broken bottle removal, Fallen bottle removal.(Remove the bottle and dispose in cullet drum.)
1. PPEs, PVC strip, PVC net on conveyor. (existing control)2. Acrylic guard to contain the hazard.3. SOP/OPL for handling bottles. (done)4. Only trained and experienced person to be deployed.
(done)5. Emergency s/w at operator point(3-phase).6. Guide alignment, conveyor alignment, wear strip
replacement.7. SS hood cover on post labeller conveyor. (done for line-2)8. Preventive maintenance for conveyors and guide.9. Synchronization of conveyor as per labeller speed.
300 84 BBH
37
3.3- As priority define and implement risk management for " risk of death and serious Injury"
W45 W46 W47 W48 W49 W13 W14 W15 W16 W17 W18 W19 W20 W21 W22 W23 W24 W25 W26 W27 W28PlanActPlanAct c c c cPlanActPlan P P P PActPlan P P P P P P P P P P P PAct c c c cPlanAct c c c cPlanActPlan P P P P P P P P P P P PAct c c c cPlan P P P P P P P PActPlan p p p p p p p p p p p pActPlan P P P P P P P PAct
2015April May June July
Casepacker Line 2 Parmeshwarpa MSM
Pasteruizer-Line 2 Ramanna AN
Tank Farm Sanjeev G A MANJUNATH,
fabrication and welding operations RN RKV,AN
Fall arrest system AN Veranjanelu
Lab BKS RKV, UNDRU, VIRENDRA,
Conveyor Pasteruizer to labellor MSM
Truck Loading MSP
Bottle unloading and empty bottle feeding AN Chalpathy, Mahesh
Conveyors Labellor to Taping RKV
December
Manual palletizing in warehouse (completed-Jan'14)
RKV AN, MSM,BNG,RN, VIJAY
OPERATIONAL RISK REDUCTION ROLL OUT PLAN - SAFETY PILLAR
Area Team Leader Team Members2014
Project Done Area Type StatusPVC hood BBH, post labeler-2 Kaizen Done
Slop removal feeding and old stores Kaizen Done
Caustic unloading Stores Kaizen Ongoing
Rotating parts guard BBH, Refrigeration, ETP Kaizen Done
Automation of Sugar addition to wort kettle-2 Brew House Kaizen On going
38
3.4- Prepare safety approval eg: CILT, OPL, SOPS and maintenance standards to maintain safe work practices
SOP and OPL
39
3.5- Introduce safety VM, signage & physical e.g walkways, PPE, machine poke-yoke…
40
3.6- Review work permit & LOTO procedure.
1. Work permit is being issued at Gemba after evaluating the hazards and mutual understanding with all signers (contractors & area incharge).2. Daily alert in morning meeting on total work permit issued.3. Audit of Work permit system & LOTO is being done by Unit head & HODs on weekly basis.
SWP monitor SWP review form
41
3.7- Improve ergonomics & environmental conditions, light noise, temp….
1. Conveyor modification at palletizer for manual handling2. Lighting improved at loading bay, filtration and labelling area.3. Ear plugs provided at all high noise areas4. Provided fan at slighter, palletizer area.
42
Learnings
1. Revised Safety Pillar Route2. Team Building3. Communication skills4. Visual Management5. Why-why Analysis 6. Audit Planning.