THE RAMCO CEMENTS LIMITED

JAYANTHIPURAM WORKS

THE RAMCO CEMENTS LIMITED

JAYANTHIPURAM WORKS

“What we Practice

at The Ramco Cements Limited”

Management System Certificates

2.0 Workforce & Man hours Worked

Average no. of workers in Factory.

SL. NO TYPE OF WORKERS 2016-17 2017-18

1 Regular 406 393

2 Contract 1276 1016

3 Total 1682 1409

Man hours worked by all workers

SL. NO TYPE OF WORKERS 2016-17 2017-18

1 Regular 1185520 1147560

2 Contract 3725920 2966720

3 Total 4911440 4114280

3.0 Incident Statistics

TYPE 2016-17 2017-18

Near-miss 11 7

High Potential Near-miss 0 0

First – Aid Cases 02 04

LTI ( Lost Time Incident ) Nil Nil

Fatality Nil Nil

Man Hours Lost Due To LTI 0 0

Severity Rate 0 0

Frequency Rate 0 0

No Of Dangerous Occurrences

as per Factory ActNil Nil

4.0 The longest accident free period

From Period To Period No of DaysAccident Free Million Man

Hours

01.04.2016 31.03.2018 730 9025720

During the assessment period only i.e. 2016-2018

5.0 HSE Policy

The Ramco Cements Limited, KSR Nagar has documented,

implemented & maintained the Integrated Management System

policy. (QMS – 9001, EMS – 14001, OHSMS – 18001) Annexure 5.1

Policy has been approved by Manager of the Factory. IMS Policy is

displayed at Factory main gate and various locations & IMS Policy

Oath will be taken by all employees daily morning prayer assembly

point.

6.0 HSE Performance Report

The Ramco Cements Limited, Jayanthipuram works, KSR Nagar

Plant is certified under IS18001:2007 – Annexure 6.1

Top management receives the reports on HSE performance like

Daily unsafe conditions and unsafe act points, Near-miss

reporting, Monthly safety committee points, Property Damage,

Safety violations and Safety warning letters – Annexure 6.2

Top management reviews HSE performance during safety

committee meeting conducted every month and directs all the

respective concern for completion of points within the target

date.

7.0 HSE Organization

HSE Department

SL.

NONAME

REGULAR /

CONTRACTDESIGNATION QUALIFICATION

WORKING

SINCE

1 Dharmalingam R RegularDeputy Manager –

Safety

B. Tech,

Master of Engineering in

Industrial Safety

July 2013

2 Dhineshkumar S RegularAssistant

Manager – Safety

B.E,

Master of Engineering in

Industrial Safety

December 2016

3 YLRN Murthy Contract Safety OfficerB.Tech,

EOH & SApril 2017

4 B Ganesh Babu Contract Safety Officer

B.Tech,

PG – Diploma in Fire &

Safety

August 2018

8.0 HSE Trainings

The organization is identifying the training needs (TNI) for both

employees and contractors in coordination with line managers and

top management.Annexure 8.1

The effectiveness of training is evaluated through training feedback

form.Annexure 8.3

Induction method for Employees and Contract workmen:

- Classroom training.

- On the Job orientation.

- Regular pep-talk.

Visitors, Experts, Govt. Officials:

Safety, Health and Environment Instructions for Visitors is attached

as Annexure 8.4

Training Records

SL. NO. TRAININGS 2016-17 2017-18

1 Internal Trainings 44.5 51.5

2 External Trainings 43.0 31.0

3 Training Participants Company 1261.0 1466.0

4 Training Participants Contractors 638.0 454.0

5 Total Training Hours 1856.0 1766.5

6 Training Hr. individual per employee per

annum

28.0 28.0

7 Training Hr. Contractor individual per

employee per annum

24.0 24.0

8 % covered Employees 96.0 98.0

9 % Covered Contract workforce 80.0 84.0

• Being Conducted the Road Safety Awareness and Defense

Training programme among the Company, Contract Drivers and

Transporter truck Drivers. Faculty : Sub-Inspector, Chillakallu

• Apart from this, internally monthly once refresher training being

conducted to our Mines drivers at Mines Group Vocational

Training Centre.

Internal & External Vehicles Drivers Training

9.0 Mock Drills

As a part of Emergency Preparedness & response planning an

emergency drill was conducted as per FactoriesAct/Law.

Totally in our plant, 20 areas are identified as potential emergency

areas like HSD Storage, HFO Storage, Coal Storage, Gas Cylinders

Storage, Magazines, etc.

SL.

NODESCRIPTION 2016-17 2017-18

1

Assuming, Coal handling H – Conveyor

counter weight area got fire and

damaged the property.

07.07.2016

2 Magazine-2 got fire and explosion. 23.12.2016

3 Boiler – 1 got fire and explosion. 07.11.2017

4Sliding of dumps at ML - 8 back filling

area.30.03.2018

Mock drill photos

Safety Control Measures Provided

The flammable storage areas are fenced at specified safe

distance.

400 Nos. of suitable fire extinguishers and fire buckets are

provided in entire plant premises.

Fire hydrant lines are provided in entire plant premises.

DSPA (Dry Sprinkler Powder Aerosol) is installed in Fine Coal

Bin to control the fire, once temp. reaches 90OC it will activate

and extinguish the fire.

Smoke detectors are installed at all Buildings and Underground

Cable tunnels & alarms will be displayed at CCR for continuous

monitoring.

CCTVs are installed at all the Coal hoppers top & Coal Mill Bag

house top for continuous monitoring.

10.0 Accident / Incidents Reporting

All incidents irrespective of its severity and nature it will be analyzed

and investigated with in 24 hrs by using Why – Why analysis.

Necessary preventive and corrective action will be taken. The

effectiveness of corrective action taken will be discussed during

safety committee meeting held every month.

Incident Investigation and Accident reportAnnexure 10.3

Incident Investigation and Root Cause Analysis team will lead the

RCA Process.Annexure – 10.4

11.0 HIRAC & SOP

Nearly 200 Nos. of activities are considered for HIRAC covering

plant & mines operations & critical maintenance activities. There

are reviewed by;

➢ Annually or Any change in the activity or Any change in

process / Technology updating or Project activities.

➢ Procedure is attached as Annexure 11.1

➢ 232 Nos. of SOPs are made across the plant and or being

followed.

➢ 252 Nos. of work instructions are prepared and also being

followed.

Work Instructions is attached as Annexure 11.2

Job Safety Analysis (JSA) Annexure 11.3

12.0 Contractors Safety Management.

Any of the contractors or sub-contractors performing maintenance or

repair, turnaround, major renovation, or specialty work on or adjacent

to a covered process within RCL premises.Annexure 12.1

Safety review meetings between the company and Contractor

management should be scheduled on a regular basis as per company

frequency (minimum once in a Quarter). Based on the evaluation, The

Best Safe Contractor Award will be given. Evaluation Criteria is

attached as Annexure 12.5

13.0 Safety Audits

SL.

NO.AUDITS 2016-17 2017-18

1 Internal

No of Observation 155 255

Compliance % 100% 100%

Variance Nil Nil

2 External

No of Observation 40 140

Compliance % 100% 100%

Variance Nil Nil

14.0 Occupational Health

SL NO NAME QUALIFICATION DESIGNATION EXPERIENCE

1Dr S Raja Kesava

Prasad

MBBS, Post

Graduate certificate

in Industrial Health.

SDGM –Medical &

Occupational Health

Services

27 Years

2 KV Padmavathi General Nurse MDeputy officer

paramedic (Nursing)27 Years

3PSCH Naresh

Kumar

B.Sc , Diploma in

Pharmacy

Asst officer

paramedic -

Pharmacist

14 Years

4 G Raja SekharDiploma in Medical

Lab Technician

Asst officer

paramedic –Lab

Technician

25 Years

5 MVV RamanaB.Sc , Diploma in

Pharmacy

Asst officer

paramedic -

Pharmacist

12 Years

6K Satyanarayana

Rao

M.Sc , Diploma in

Pharmacy

Junior Officer

Paramedic –

Pharmacist

9 Years

Visiting Doctors

• Gynecologist : Visits our OHC twice in a Week

• Dental Doctor : Visits our OHC On Every Sunday

• Homeopathy Doctor :Visits our OHC twice in a week

Pre-medical check procedure

We are doing pre-employment medical examination to

our employees before taking them for the job. Apart from general

medical examination certain common blood tests and specific tests

based on their nature of Job. Specific test is attached as Annexure

14.2

Frequency of re-medical check-up Once in a year for all employees.

Vision test for drivers once in a year for less than 45 years. Once in

six months for more than 45 years drivers.

15.0 Safety Promotional Activities

SL. NO. LIST OF PROMOTIONAL ACTIVITIES-2016 & 2017

1 Road Safety Week Celebrations

2 National Safety Week Celebrations

3 Best Suggestion awards

4 Safety Committee awards

5 National Level Safety Competition

6 State Level Safety Competition award

7 Best Driver award

8 Fire Safety Week Celebrations

9 Selfless action for Emergency Situation

10 Safety News Letter Sharing

11 Special Safety Speech by Employees

12 Safety PPE Exhibition Room

13 Accident case studies sharing

14 Defense Driving for Drivers

National Safety Week Celebrations

Observed National Safety Week from March 04th to 10th

March, in this regard the following events are conducted;

EVENTS PARTICIPANTS

Training programme on

“Industrial Safety”

Company Employees

5 Minute Talk on EHS Company Employees

EHS Skit competition Company Employees & Contract workmen

Safety slogan Employees, School children & family members

EHS Essay competition Employees, School children & family members

Safety Poster competition Employees & School children

Safety Poems / Songs Company Employees

Safety quiz competition Company Employees

NSW Flag Hoisting and Message

➢ Safety Message given by Mrs. USHASRI, DCIF, & Mr. T

Raju, IF, Vijayawada.

➢ Mr. N Ravishankar, President – Mfg.

Safety ProcessionOrganized Safety Procession with

Safety Slogans speaking out with

loudspeaker. IF, Div. Heads, All

HODs, Safety Committee Members

& Mentors along with all

employees and contract workmen

were participated.

PPE Exhibition Inauguration

On NSW, Safety PPE Exhibition

was inaugurated by Mr. T Raju, IF,

Vijayawada and Mr. N Ravishankar,

President – Mfg.

Road Safety Week Celebrations

Observed Road Safety Week from January 1st to 7th, in

this regard the following events are conducted;

EVENTS PARTICIPANTS

Road safety slogan Employees, School children & Family members

Road Safety quiz Employees & Family members

Road safety training programme with film show

Local auto drivers, company drivers & contract drivers

Road safety Poster Employees & School children

• Being Created on Road Safety Awareness among the

Jaggaiahpet people and also conducted Road Safety

Campaign near JPT bus stand and Toll Gate on National

Highway.

Road Safety Campaign

Safety Suggestion BoxThe objectives of the Suggestion Scheme are:

➢To encourage innovations, creativity and value addition by

individual employees for overall improvement.

➢To improve safety culture, quality, productivity, profitability

and service through employee participation.

31

Safety Flag Hoisting,

Safety Pledge & Slogan

➢ Every Monday, Safety Flag

hoisting and 5 minutes Safety Talk

by Company or Contract

employees.

➢ Everyday, Safety Pledge and

Slogan by Company employees.

Pep Talk

• 5–Minutes Safety Talk is being conducting on each and

every day at all sections of plant premises.

• Creating awareness on the particular risky job before

going to do that work.

Work Permit System

Work Permit System to carryout the hazardous work

activities in a safe manner. The following Work Permit

System is implemented.

Hot work

Work at height

Confined space entry

Electrical works

Jam clearance

Excavation

Barrel cutting.

General Work

LOTO System➢ All electrically connected equipments to ensure that they

are properly isolated for hazardous or potentially hazardous

electrical energy sources during servicing and or

maintenance and properly protect against re-energisation.

Safety Committee Activities

To identify and suggest control measures for the

hazards in their area / department.

To suggest changes / modifications, if any, to ensure

safe working conditions.

Review of corrective and preventive actions regarding

the accidents / incidents in the concerned departments.

To carry out Internal Safety Audits by Safety Committee

Members (7 Teams) once in a month. To submit a

report on periodical basis on the above matters to the

Top Management.

Cont.,

Safety Committee Members for the Year 2018 – 2020:

S C Chairman -Plant - Head

S C Secretary -Safety - Head

Staff & Officers - 15 Members

Company Workmen - 14 Members

Contract Workmen - 6 Members

Safety Committee awards are presented to Safety

Committee members for following categories;

Highest attendance percentage.

Highest no. of points referred by a member.

Safety Committee Mentors

To educate the co-worker, regarding the safety practice

associated with the work.

To inform the unsafe activities & unsafe condition to the

section – in charges & safety dept.

To co-ordinate the safety related function.

Safety Committee Mentors for the Year 2018 – 2020:

Staff - 04 Nos.

Company workmen - 17 Nos.

Contract workmen - 04 Nos.

Safety PPE Exhibition Room

To inculcate safety awareness / PPE to

the new comers and visitors, Safety PPE

Exhibition Room is inaugurated on

21.08.2013.

Safety Training Videos

DSPA (Dry Sprinkler Powder Aerosol) is

installed in Fine Coal Bin to control the Fire and

Explosion, once the temp. reaches 90 - 100OC it will

activate and extinguish the fire.

Helmet Colour Coding System

Company Workmen

Electrician

Visitor

Staff and Officers

Contract Workmen

Safety Members & Mentors.

Welding Curtain

Welding curtain was implemented on 12.06.2017 at Mechanical

workshop. The purpose of welding curtain is to control splash of arc

and fumes on others while crossing the welding area during welding

process.

Safety Management System

Hazard Entry Details

Injury-Free Man-Hours Display Board

➢Injury -Free Man-Hours board displayed at in front of prayerassembly point. For the purpose of each and every day Injury-Free Man-Hours to be updated. Even small First aid injury alsowe consider as accident and mention zero hours in that board.

16.0 Awards & Rewards

Mr. Rambabu – Company workmen got 3rd Prize in

Safety Slogan, Awarded by NSC – AP Chapter, State

Level Safety Competitions.

Best Management Award to Sri P R Ramasubrahmaneya Rajha,

Chairman & Managing Director, Ramco Cements Limited and the award is being

received by Sri P B Gopala Krishna, President-Mfg., and Executives of Ramco

Cements on the occasion of MAY DAY on 01.05.2016.

Better Environmental Practices being followed

by Cement Sector for the year of 2016-2017 in the

State of Andhra Pradesh

Performance in 5 ‘S’ Surveillance audit for

the year 2016 - Par excellence

“Best Supporting Organization for QC Movement” Award receiving

from Sri T. Harish Rao, Irrigation Minister, TS Government, Sri C. Vidyasagar Rao,

Governor, Maharashtra and TN State, Sri Ch. Balakrishna Rao, Chairman, QCFI by Sri T.

Sridhar Reddy, AVP-Works, and Executives from M/s The Ramco Cements Limited, KSR

Nagar on the occasion of 30th chapter convention on Quality Concepts, Hyderabad on

Dt:01.09.2016

On the occasion of Viswakarma Day celebrations “Best Workmen

Award” receiving from Hon’ble Labour Minister Sri.Bandaru

Dattatreya by Sri.P.Yedukondala Rao, HEO and Sri.K.Satyanarayana,

Sr.Fitter on 18.09.2016

Thank you for Attention & Pleasant

Listening..

Thank you for Attention & Pleasant

Listening..