It has been observed that a lot of accidents occur because of lack of safety awareness. Men fall from ladders, operate their machines without a guard, drop objects on their toes, or cut their hands because of misuse of tools.
These are the results of unsafe acts—the reason for these being that there had not been complete instructions on safe practices. Further accidents also occur due to unsafe conditions of operation. The supervisors have to understand that safety is a practice of good management, the safety efforts help in improving production costs, and quality.
Compensation and medical payment, damaged equipment and products, and production delays resulting from accidents all subtract directly from profits. The gains resulting from good safety effort are good community relations, lower employee turnover and absenteeism, better employee morale, and steadier work.
Good results in accident prevention can be achieved if the line supervisors include the following points in their safety programme:
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(i) Development of safe working conditions.
(ii) Creation of safe work habits on a personalised basis.
(iii) Promotion of employees participation in safety.
(iv) Corrective action when safety rules are ignored.
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To prevent accidents, safety rules have to be enforced, safe working conditions developed, workers trained to do the job safely. Any safety programme will be ineffective if any attempts are made to control accidents without first creating a proper safety philosophy, teaching safety principles, and eliminating mis-conceptions about the causes of accidents. Supervisors, safety engineers and workers must believe that accidents are caused and they can be prevented.
Safety Training:
It is generally considered that safety awareness can be developed by having meetings, posters, safety booklets, films, special classroom sessions, and some safety contacts by safety specialists and supervisors.
Though theoretically it is correct that these training techniques should make the employees to sense the existence of unsafe practices and unsafe conditions and that they should avoid them voluntarily, but experimental study shows that these mass educational methods (having weakness that it leaves interpretation and application of specific items upto the individual) fail to apply these safety messages to the actual work situation.
In this method, it is felt that the necessary transfer from the general to the specific does not occur; therefore, there is considered a great need for personalised safety training which permits the conversion of safety generalities into specific safe practices that apply to a specific job and to the individual doing the job.
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It may be appreciated that mass-raining tells what the hazards are, whereas personalised training tells what the hazards are and how to avoid them. Personalised safety training permits consideration of the workers rate of learning, his interests, his natural ability, and his physical limitations. In launching a personalised safety training programme, the first step is the preparation of job-methods improvement, elimination of bottlenecks and improved plant layouts.
In making job-hazard analysis the following should be considered:
(i) Job description,
(ii) Job location,
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(iii) Key job steps,
(iv) Tools used,
(v) Potential health and injury hazards,
(vi) Safe practices,
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(vii) Apparel and
(viii) Equipment.
Personalised safety training helps to improve the worker’s attitude about his job. The approach stresses work habits required for safe job performance. It spot-lights hazards and unsafe movements and positions. Obviously best training is one which embraces all the elements that contribute to the successful control of accidents.
Hazard Check List:
In a machine shop, the following hazard check list will help the observer to make the safety appraisal:
(a) Housekeeping:
State whether or not aisles are clear, stock properly piled, floors free from slipping and tipping hazards, and work area orderly.
(b) Machine Hazards:
State what guards are found not in use and where guards should be provided. This should include gears, sprockets, chains, bolts, shafting, etc.
(c) Fire Hazards:
(i) Are all fire-fighting appliances and fire exits ready for immediate use?
(ii) Are inflammable materials properly handled and stored?
(d) Protective Equipment:
Are goggles, respirators, safety caps, and other equipment being worn as required? Jewellery rings and wrist watch are a source of danger around moving machinery.
(e) Electrical Equipment:
Note conditions of switches, outlets, light cords, and ground wires.
(f) Tools:
(i) Are proper tools being used for each job?
(ii) Are handles missing from files; chisels mushroomed; hammers, wrenches, and screw drivers defective? Are feeds and speeds properly set?
(g) General Conditions:
(i) Are boards with nails left on floor
(ii) Are ladders, stairs, guards and other equipment in need of repair?
(iii) Is cutting fluid likely to spill on the floor?
General Safety Rules:
Every organisation or group of people require a set of rules for the proper regulation, safety, and protection of the individual who make up the group.
In formulation of general safety rules and in evaluating the need for and the effectiveness of the existing rules, the following points should be considered.
The initial points to be thought about are that:
(i) Whether there is a real need for safety rules. Does the employee appreciate its purpose, or he thinks that the rules were just imposed on him without adequate consideration of his personal feelings ?
(ii) The safety rules should keep pace with changing conditions.
(iii) The safety rules should be such which do not cause inconvenience or annoy the employees. The human nature should not be defined.
(iv) There should not be too many safety rules.
(v) The safety rules should not be so broad or general in nature that they have no real meaning to employees.
Once the above points are given due consideration in the formation of safety rules and realising that the safety rules have a substantial impact on the safety of an individual or the entire work force and that a single violation might place the safety of many employees in jeopardy, the necessary disciplinary action should be taken against those who break these rules.
Some of the general safety rules are listed below which have been formulated not as restrictive measures, but as guides to workers and supervisors in their cooperative efforts to prevent accidents:
(i) Smoking should be strictly prohibited.
(ii) Acts like running, tripping others intentionally, throwing, things, directing compressed air at others, or such acts which may startle or distract other employees should not be tolerated.
(iii) Personal protective equipment such as safety glasses and respirators, provided on certain jobs because of an indicated need, must be worn.
(iv) Many times red and yellow safety tags are placed on electric switches, valves, and other controls to protect personnel and equipment. Unauthorised removal of such tags, misuse of such tags, or operation of a control that has a tag attached should be considered as a serious offence.
(v) Safety devices and guards should be used. Employees, for their personal reasons should not be permitted to make a safety device or a guard inoperative.
Other important points not to be treated as offence but very essential to promote safety are:
(i) Maintain good housekeeping, i.e., employees should keep their machines or benches and area surrounding it clean at all times, rubbish placed in containers meant for waste disposal. Employees should realise that it is safer to work in an orderly plant. Any oil or coolant spills on the floor should be wiped up immediately to avoid slipping and falling.
(ii) Chips should be swept up with brush or broom and thrown in chip or trash containers. Chips should never be handled with bare hands. Air hose should never be used to clean a machine as flying chips can be dangerous. Dirty and oily rags should be kept in closed containers and never allowed to accumulate on floor.
(iii) Prompt first-aid attention should be obtained for any injury, no matter how slight, in order to prevent the infection from developing.
(iv) Dress worn should not be loose-fitting, finger rings avoided, safety shoes worn, longhair protected from becoming tangled in moving parts by wearing suitable head coverings. The feet should be protected with shoes that prevent chip from cutting through the sole, and prevent serious foot injuries from falling objects. Gloves should not be worn while operating equipment because of, the danger of being caught by machine.
(v) Because of hazards involved, employees should never be allowed to run in plant even in case of fire; they should exercise good common sense and instead of running, walk to the nearest exit.
(vi) Employees should never operate any equipment, unless authorised.
Safety and Health Provisions of the Factories Act and Rules:
The Factories Act 1948 is a law, regulating safety, health and welfare in factories. The Act is a Central one and rules to supplement its provisions have been framed by the respective State Governments.
The Act applies to all factories. A factory has been defined under the Act as any premises:
(i) Wherein a ‘manufacturing process’ is carried on with aid of power and ten or more ‘workers’ are working or were working on any day of the proceeding 12 months.
Or
(ii) Wherein a ‘manufacturing process’ is carried on without the aid of power and 20 or more workers are working or were working on any one day in the proceeding 12 months.
The Act can also be made applicable by special notification under Section 85 to any premises where a manufacturing process is carried on, but does not fall under the two categories mentioned above. Such premises would then be deemed as a ‘Factory’.
Inspection and Certifying Surgeons:
The enforcement of the Act and the Rules is done in each state by the respective Chief Inspector of Factories with the assistance of the Inspectors of Factories. District Magistrates and certain other Government officers such as Health Officers who are notified by the State Governments are Additional Inspectors in respect of some of the provisions of the Act. Earmarked Government Medical Officers are also notified by the State Governments as ‘Certifying Surgeons’.
All young persons below the age of 18, before they are employed in factories are to be examined and certified as fit by the Certifying Surgeons. The certificates are to be renewed yearly. Similarly, Factories Rules provide that persons working in some of the specified operations which are likely to cause injury to health are to be examined at periodic intervals by the Certifying Surgeons.
Licensing and Approval of Plant:
The occupier of a factory should apply in advance of taking into use any premises as a factory, to the Chief Inspector of Factories along with the site and detailed plans, the flow chart of the manufacturing process and other prescribed documents, for the approval of the plans and the grant of a licence. Also before making extensions to existing factories or installing additional machinery, the plans will have to be got approved by the Chief Inspector of Factories.
The licence fee to be paid is based on the installed power and the number of persons employed. The licence should be got renewed by the Chief Inspector of Factories every year.
Section 11 of the Factories Act deals with cleanliness. Accumulation of dirt and refuse should be removed daily by sweeping. Further, the flooring should be cleaned once a week by washing or any other suitable methods. All walls, partitions, ceiling and tops of the rooms and also side walls and top of staircases and passages should be painted, colour washed or whitewashed at specified intervals.
Wastes and effluents from factories are to be disposed off through effective arrangements. The disposal arrangements should be approved by the local authority or the health officer.
Section 13 lays down that there should be adequate ventilation in every workroom in factories and that effective and suitable means should be adopted for maintaining reasonable conditions of thermal comfort.
Dust and Fumes:
Provisions under Section 14 require that wherever the processes carried on give off any dust, fume or other impurity of such a nature or to such an extent as is likely to be injurious or offensive to the workers, effective measure should be taken to prevent its inhalation and accumulation in the workroom.
Artificial Humidification:
Section 15 and the rules framed under it are for regulating the conditions of thermal comfort in factories employing artificial humidification. Limits for humidification have been specified. The provisions also require installation and maintenance of suitable hygrometers and recording of wet and dry bulb temperature readings at specified intervals. Lighting
Sufficient and suitable lighting should be provided wherever workers have to work or pass. The formation of shadows to such an extent as to cause eye strain or the risk of accidents as well as flare from sources of light or by reflection should be avoided as far as possible (Section 17). The general illumination levels should not be less than (Rules under Section 17).
Where workers are regularly employed ― 30 LUX (90 cms. above floor level)
Other places where workers pass ― 5 LUX (Floor level)
Drinking Water:
Arrangements should be made in every factory for providing at convenient points sufficient supply of wholesome water for drinking. The drinking water should be provided either through taps connected directly to water supply pipes or in vessels fitted with taps. For factories employing over 250 workers, arrangements are to be made for cooling the water in summer.
Laterines, Urinals and Spittoons:
Laterines and urinals of the type to be approved by the public health authorities are to be provided in all factories. The scale of accommodation has also been laid down. These shall be maintained in a clean and sanitary condition at all times. Sufficient number of spittoons should be provided in factories and they should be kept in clean and hygienic condition.
Reducing Industrial Noise:
The increased use of power and high-speed equipment has increased noise levels in recent years. High noise levels have annoying and unpleasing effects and may account for some accidents through interference with hearing instructions and warning signals.
The need for reducing noise to assure worker’s safety, comfort and attention, is catching the attention of employers due to competition for the better employees and the financial liability associated with hearing loss claims.
It has been observed that high noise level (about 100— 120 decibel) may result in an impairment of hearing by damaging the sensitive cells in the hearing mechanism; and the noise level should not exceed 85 decibels to avoid injury to hearing results. It may be noted that two significant properties of sound are its noise level and its frequency.
A decibel is a unit of measurement of noise level and is the ratio of any sound to the lowest sound pressure level an average person can hear. The higher frequency sounds (800— 5000 c/s) are more damaging to hearing than the low- frequency ones. Factory noise is composed of a wide variety of sounds at numerous pressure levels and frequencies.
In order to tackle the noise problem, there are three possible steps that can be taken.
They are:
(i) To reduce the noise level.
(ii) Where reduction is not possible, to isolate the noise source.
(iii) If neither reduction nor isolation is possible, use of personal protective equipment such as ear plugs or muffs.
Reduction of Noise at the Source:
Prevention of noise at its source provides a promising method of noise reduction. Although a change in equipment may not always be possible, supervisors can do a lot to reduce the noise by having planned maintenance programme; timely replacement of worn parts; proper lubrication of all machines to silence many annoying squeaks; proper balancing of high speed equipment; substitution of less noisy tools, e.g., use of electrical tools in place of pneumatic tools which are excessively noisy, mechanical ejection in place of air-blast ejection, grinding instead of chipping, pressing instead of forging, welding instead of rivetting etc.; replacement or repair of leaky air valve which often produces a high frequency noise, use of silencer to reduce continuous noise in case of equipment producing loud hissing or roaring noises at the air exhaust outlet.
Isolating the Noise Source:
Noisy sources can be isolated by having enclosures (the selection of enclosure material depending on its acoustic properties) which have no holes or cracks in them and have tightly closed doors, lids and hatches.
Some basic principles in sound transmission loss are summarised below:
The factors requiring due consideration in the selection of proper materials for the solution of various noise problems are:
(i) Sound transmission characteristics of various materials, and
(ii) The effect which the frequently of sound has on transmission.
Personal Ear Protectors:
In some cases it is neither possible nor economically practical to either reduce or isolate the noise. The only alternative therefore left is to wear ear protectors. This requires proper promotion of ear protection programming and education of employees because the ear plugs are unpleasant to wear and present many problems regarding fit and proper use. These should be kept clean to avoid ear infection.
Fire Prevention:
For preventing fires and keeping them small, it is essential to have knowledge of the various classes of fires and the various fire-fighting equipment suitable for each class. A volunteer fire-fighting team should be trained on the use of fire extinguishers.
The success of the fire prevention programme depends much on good housekeeping, maintenance of fire-fighting equipment, the enforcement of rules like ‘No smoking’, and the segregation and reduction of combustible materials.
The first thing to learn about fire is that usually it takes three things to start a fire; fuel, heat and oxygen and a fire can be put out by eliminating any of these three factors.
Generally first can be classified into three categories:
(A) Fires in ordinary combustible materials such as wood, paper, textiles etc. Such fires can be extinguished by the quenching or cooling effects of water or solutions containing large proportions of water (foam or soda acid) or gas cartridge.
(B) Fires in inflammable liquids such as gasoline, solvents, oil, grease, paint, varnish etc. Such fires can be put out by producing blanketing or smoothering effect by foam, vaporising liquid, carbon-dioxide, dry chemicals, etc.
(C) Fires in electrical equipment such as motors, generators and switch-panels. In such cases, in order to avoid electrical hazard, a non-conductive extinguishing agent like vaporising liquid, CO2, dry chemical is required.
The common causes of ignition sources that can be found in a manufacturing plant are:
Fires caused by arcing or over-heating, due to:
a. improperly installed or poorly maintained or worn electrical equipment, by electrical fittings installed in areas containing inflammable vapours or dusts;
b. By hot bearings, misaligned or broken parts, grinding and sanding operations, by heat of friction;
c. Matches, lighted cigarettes, hot metal, sparks or globules of molten metal from gas cutting and welding torches, spontaneous ignition of oily waste or rubbish, faulty gas and oil burners, abnormally high process temperatures due to faulty operation;
d. Molten metal escaping from ruptured furnaces or spilled during handling etc.
In order to keep ignition sources at a minimum it is essential to have the proper teaming of maintenance programmes and use the equipment of a safer design. A productive approach to fire prevention is to keep the accumulation of combustible materials at a minimum, so that once the fire starts, the loss will be minimised because it will be easy to get at the fire.
It is very important to follow the practice of good housekeeping i.e.
i. Avoiding oil deposits on machines,
ii. Rubbish-and waste under benches and in corners,
iii. Inflammable packing materials,
iv. Open containers of inflammable solvents, etc.
Guarding of Machines:
No safety procedure is complete or satisfactory if does not provide for the guarding of machines, the provision of safe tools, adequate light ventilation, and sanitation, and for the correction or elimination of other mechanical and physical hazards.
In machines, the hazards to the operators arise from the unguarded points of operation, such as punch and die of a press, the cutting edge of a shear press; and from belts and pulleys, gears, projecting parts, shaft ends, clutches, and other moving parts.
The machine should therefore preferably be designed so as to facilitate guarding and the guards should be incorporated as an integral part of the entire unit. Suitable bosses, or extensions for the attachments of covers and hoods, may be cast with the frame or body of the machine.
The basic objective of machine safeguarding is to prevent personnel from coming in contact with any revolving or moving machine parts such as belts, chains, pulleys, gears, flywheels, shafts and spindles and any working part of the machine which creates a shearing or crushing action or may entangle the worker.
The next item is the guarding of point-of-operation. Its purpose is to prevent injury to the operator at the part of the machine where the work of shaping, forming, cutting, blanking, shearing, squeezing, drawing, or manipulating the stock in any other way, is actually done.
Safety at the point of operation may be accomplished by one or more of the following principles indicated below:
(i) Designing and constructing tools so that guards are not required.
(ii) Providing enclosures, covers, and barricades.
(iii) Providing mechanical feeding devices.
(iv) Providing devices that prevent or interrupt the movement of tools when the operator’s hands are in the danger zones.
(v) Providing mechanical devices that remove the hands from the danger zones.
(vi) Providing remote-control operating mechanisms.
These methods are described below in brief:
(i) Design of tools for the purpose of eliminating or, at least, minimising the danger of injury is not, strictly speaking, a part of guarding, but its objective is similar.
Some examples of this principle are:
In presses the operation of forming, shearing, or stamping small metal objects be performed inside the body of the tool so that the blank or stock has to be inserted through an opening that is too small to permit the entry of fingers or the hand.
Dies on presses may be so designed that many unnecessary handling operations are eliminated, thus reducing the possibility of injury. The dies may be so arranged that the piece is pierced, formed, swaged, or drawn on the same machine and completed without re-handling.
(ii) Solid sheet metal, transparent plastic, fibre-board, non-shatterable glass, perforated or expanded metal, wires or wire mesh may be placed about punch-press tools in blanking or piercing operations, and in many kinds of forming work, leaving room only for the insertion of strip stock or flat pieces.
The basic requirements for design and construction of barriers and enclosures are:
(a) Enclosures and barriers should be simple in design and sturdy in construction. The guard should be easy to install and to adjust, and it should be firmly attached to the machine by means of cap screws, bolts or welding.
(b) Construction should be such that there is no interference with the repairing, oiling, or adjusting of the machine.
(c) The enclosure or barrier, itself should not create a hazard such as a pinch or shear point with any moving part.
(d) Openings in enclosures or barriers should be such that it is not possible to place any part of the hand through the guard and reach a shear or pinch point.
(e) Any hinged or movable section of a barrier or any barrier which is hinged, pivoted, or easily removed by hand should be interlocked so that the machine can’t be operated while the operator has access to the danger zone.
(iii) Many ingenious mechanisms have been designed to supplant hand-feed methods with resulting increase in production, decrease to spoilage through uniformity in hand ling, saving in production cost, and less danger to employees. Various mechanical feeding devices include rolls, gears, dials, chutes, hoppers, magazines, slides, air pressure or vacuum, gravity flow of liquids, principle of magnetism and many combinations of these and other means.
(iv) The photoelectric cells can be applied to the operating mechanism of power tools, by placing them such that the interruption of the beam will prevent starting of further movement.
(v) Manually operated punch press is usually provided with positively operated pull back type safety device. This type of device is a mechanical linkage which derives its motion from the movement of the press ram and transmits it to hand strap which is attached to the press operator’s wrists. The movement, so transmitted is multiplied so that the hands are pulled back at a rate faster than the descent of the press arm.
(vi) In machines where the operator has to have an access to the point of operation, the remote-control devices (push-buttons, switches, levers, or handles) are provided as tripping or operating controls. The ideal safe practice employs the use of both the operator’s hands.
If he removes either hand from the push buttons or other control device, the motion of the tool is prevented. In other cases the control buttons are located so far away from the machine that the operator can’t reach the danger zone.
Principles of Safe Machine Design:
(i) Dangerous moving parts should be enclosed.
(ii) Parts subject to wear, adjustment, and hand lubrication should be conveniently accessible.
(iii) Lubrication, wherever possible, should be automatic and continuous when machine is in operation.
(iv) Consideration should be given to individual drives so that hazards due to driving mechanism may be minimised.
(v) Sharp contrast between light and shadow and glare in the vicinity of the point of operation should be avoided.
(vi) Wherever possible, materials should be conveyed mechanically.
(vii) Provision should be made for automatically conveying dusts and gases away from machine.
(viii) Noise should be eliminated or reduced to the minimum.
(ix) Vibration should be minimised.
(x) Machine motions tiring to eyes should be avoided.
(xi) Exterior shapes of any parts of the machines that require frequent handling or contacting should be such as to facilitate convenience in handling and corners generally rounded.
(xii) Point-of-operation should be guarded.
(xiii) Consideration should be given to the safe location or isolation of machines that can’t be made safe otherwise.
(xiv) Whenever possible individual motor drive should be employed.
(xv) The prime-mover and transmission mechanism should be guarded properly.
(xvi) Screen of substantial fireproof material should be installed where hot chips are likely to fall as in the case of shaper.
General Precautions for Safety on Powered Machines:
(a) A full understanding of the nature of all risks involved in the operation of a particular machine is essential.
(b) The correct setting up of the machine, and the securing of all nuts, fixing bolts and clamps necessary for the safe operation of the machine and the firm holding of the work are also essential.
(c) The use and correct adjustment of all guards is necessary for safe operation of the machine. Defects and omission if noticed should be reported immediately. No attempt should be made to work a machine unless all guards are correctly positioned and functioning properly.
(d) No loose or flapping clothes, finger rings or gloves should be worn in close proximity to moving machinery.
(e) No tools should be left on the way of movement of slides, rams, carriage, etc.
(f) Work-holding methods should be reviewed before making cut. Fastening of the vise to the work-table should be checked properly.
Precautions taken by Operators for Safe Working:
i. Drilling Machines:
The spindles, chucks and as much of tools as possible should be guarded. It should be ensured that all set-screws are recessed. No neck-ties, loose or flapping clothing, long hair-styles or finger-rings should be allowed. Spindles or chucks should be stopped by hand only after machine is switched off.
The work always be clamped securely to table. One should never attempt to hold work by hand while drilling. If work slips from clamp, the machine should be stopped. All burrs from drilled holes should be filed.
Properly sharpened drills should be used and it should be ensured that they are running true to avoid broken or splindered drills. Correct speed should be selected and drill should be never forced or fed too fast. If drill stops in work, machine should be stopped and drill started by hand. Chuck key or wrench should be removed from machine before starting.
ii. Power Presses:
In order to avoid trap between tool and die, fencing should be secured and access to the danger zone should be out of reach of personnel. Guards should be kept in position whenever the press is under power, whether it is for production or for after setting up.
In order to avoid trap between ram and part of guard, care should be taken that guards are not so constructed that a trap exists between the ram or any projections on it and the guard itself. Improper functioning of the interlocks should be immediately reported.
iii. Grinding Machines:
In order to avoid chattering of the wheel it should be tested correctly, mounted at the right tension (i.e., grip between flanges should be neither too tight nor too loose) and run at prescribed speed. If wheel chatters or vibrates, it should be stopped. The face of the wheel should be flat and under-grooved. The face should be dressed with proper tool. Even pressure should be applied as the tool is moved smoothly across the face of the wheel.
To avoid contact with the wheel; or trapping between the wheel and the machine casting, the tool-rest should be correctly set. Wheel should never be allowed to run when not in use, nor left unattended during the run-down period after switching. Eye protection i.e., fixed vision-type guard rigidly attached above the wheel itself, and goggles/spectacles should always be used.
iv. Milling Machines:
It should be ensured that the cutter is sharp and in good condition. Guard should also be in good condition and correctly adjusted. Arbor nut should not be loosened or tightened when machine is running. Setting of work should not be done in close proximity to cutter. The chips of metal or swarf should be removed by brush.
v. Lathes:
Machine power should not be used for putting on or removing the chuck or face plate. Work should be properly clamped. No attempts should be made to adjust the tool or for measurement when the machine is running. Gear should be never changed when the machine is running. Strips of sand never be used for polishing work in lathes.
Wrench or other tool from the chuck should be removed before switching on machine. All stock bars must be adequately guarded for the whole of their length. The correct location and working of the feed rod and its attachment should be ensured. Adequate clearances should be checked for and ways kept clear of materials and tools.
vi. Shaping Machines:
The following precautions should be taken:
Properly secure in position the ram, tool head, vice, work and table support, clamping screws before starting machine; always check that the adjusting nuts are tight after setting the stroke length and position. Do not reach over or across a machine whilst it is under power. Do not attempt to remove metal shearings or chips while the machine is moving and stand to the side of the ram, not in front of it.
Precautions in the Maintenance Work:
Many fatal accidents have occurred through maintenance men being struck by moving cranes. Men working in noisy shop can’t be expected to hear an approaching crane and the driver’s attention is often concentrated on the load he is carrying. Therefore effective measures have to be taken to prevent the crane from approaching the area where men are working.
Maintenance work sometimes has to be done in confined spaces such as chambers, tanks, vats, flues etc., where there is a risk of workmen being confronted by fumes or by lack of oxygen for respiration.
Where such conditions are liable to be present then the following precautions should be taken:
(i) Adequate means of moving out through bigger manholes,
(ii) Provision of breathing apparatus for persons entering unsafe spaces with a safety belt and line held by a person keeping watch outside,
(iii) Deposits likely to give off fume should be removed if space has been blocked off from the source of fume,
(iv) No work in the furnace or flues be allowed until the space is sufficiently cool to work safely.
Another frequent source of accidents is explosion during hot repairs of the fuel tanks. Therefore, no welding should be allowed on tanks that have carried inflammable liquid or gas until all substance and fumes are removed to make it non-explosive.
The employer must provide suitable goggles or screens to workers employed on following processes:
(a) Dry grinding of metal by hand or a revolving wheel or disc.
(b) Dry turning of cast-iron or non-ferrous metal.
(c) Welding or cutting of metals by electric, oxy-acetylen or similar processes.
(d) Use of hand tools in turning, fettling of castings, cutting out of cold rivets on boilers or other plant, breaking of slag, concrete or stone.
Legislations on Safety:
The present day industrial scenario is full of mechanization, automation and computerisation, automation and computerisation, in which life of the workers is threatened by the occupational hazards caused by accidents which sometimes may be fatal. In the last century, when life was not as fast as today, the accidents used to take place as a matter of consequences.
With magnitude of this problem, growing more lives were lost in industrial accidents, and a campaign started to make the workers safety conscious. Detailed study of the causes of accidents has concluded that most of the accidents do not happen but are caused by human error or mis-judgment.
The word accident, therefore, seems to be inappropriate. There can never be an accident without a cause. There is always a cause and when investigated it may be observed that there is something which if could be anticipated and done away with in advance, the accident would have been avoided.
It is a well-known fact that number of accidents at workplace reported are generally more in the developing countries than that in developed countries. One possible reason may be that, in developing countries the industrial and technological changes are take place as a fast face for which there is neither enough preparedness nor adequate planning.
Therefore the safety aspect is neglected, probably because of the feeling that the productivity will be reduced and the cost of production will increase if a subject like safety is considered for implementation, at the stage of adoption of new technology.
As a result is rarely thought of and often neglected, which, of curse, is at the cost of human life. This can be well understood with an available statistics published by International Labour Organization (ILO). Even with the gross under-reporting of industrial accidents, every three minutes a worker dies somewhere in the world due to occupational hazards and sickness and every second at least four workmen get hurt in industrial accidents.
With the tremendous development taking place in the sphere of industry and technology during the last few decades, life has become more and more complicated. Development in any sphere of life is always associated with risk, risk, of loss of time, money, power, life, etc. This risk only makes one more anxious and prompts to be more active and cautious, and often makes the life full of tension and worries.
This is, of course, one way of looking at it; but if we look at it from another angle, that is, how are we going to minimise the risk, the first word which comes to the mind is ‘Safety’, a tool to prevent accidents, minimise risk, and in other words preparedness for the complications arising out of developments or any changes in the system.
There is a general human tendency to forget or overlook the aspect of safety. This may be due to the fact that accidents do not happen every day. As a matter of fact when safety measures work, accidents don’t occur; and in absence thereof, accidents take place. So as a common human tendency, one, quite often, neglects ‘Safety’. One looks at it only when an accident takes place.
Legislation on Safety in India:
Many statutory organization in India are working for promotion and observance of industrial safety. Directorate General of Factory Advice and Labour Institute set up under the Factories Act, provide assistance and looks after all matters relating to health, welfare and safety of workers in all industrial establishments. Training of factory inspectors and safety officers, survey of toxic hazards relating to operations in factories and industrial health are some of the areas in which the organization has been providing valuable guidance and assistance.
It has also been giving guidance to indigenous manufacturers of personal protective equipment on modern scientific line. Safety relating to manufacture, transportation, possession and use of explosives is regulated by the Chief Inspectorate of Explosives under the Explosive Act.
The Directorate General of Mines Safety is responsible for health and safety of workers in mines. For fire safety State Governments are expected to enact legislation and some states have already enacted Fire Services Act, which are enforced by them.
The National Safety Council has been setup for promotion of safety consciousness. The council has played a complementary role to that of statutory organizations through involvement of public support of attainment of the goal of total safety at work. In India concern about unsatisfactory working conditions in the industrial sector had been expressed by several humanitarians and social workers.
It was the enlightened public opinion inspired by human considerations which led to the first factory legislation that came into force with effect from 1 July 1881. This Act gave a limited protection to children, as employment of a child below the age of 7 years was prohibited and children of age 7 to 12 years were allowed to work only for 9 hours with an interval of 1 hour for recess.
Since then the act has undergone seven major amendments in 1891, 1911, 1922, 1934, 1948, 1976 and 1987 and subsequently, progressively enlarging the range and depth of coverage of the different aspects of the working conditions with increased emphasis, first on safety and subsequently also on health of workers. The Public Liability Insurance Act, 1991 is a recent legislation in this field which seeks to provide immediate relief to victims of accidents occurring while handling hazardous substances and on matters connected therewith or incidents thereto.
India is one of the few developing countries in the world to have included significant elements relating to improvements of working conditions in its national labour policy. The policy for safety states that working conditions include not only wage structure, fixing of minimum wage and protection of income, but also the fixing of working hours, period of rest, paid holidays, provisions of canteen facilities and provisions of creches for children.
Industrial Safety:
‘IS 3786: 1983 Methods for computation of frequency and severity rates for industrial accidents’, prescribes basic methods for recording and classifying industrial accidents. It also includes details of work injury and gives methods for computation of frequency, severity and includes rate of work injuries in the industrial premises. This enables adoption of a uniform system of recording events associated with injuries and determination of corrective action. Further standard codes of sare practices for industrial plant layout including the facilities inside and outside the plant (IS 8089 : 1976 and IS 8091 : 1976) have also been published by BIS.
While developing and designing machines with high performance factor and with the use of sophisticated system and devices, it is also necessary that improvement in safety devices, to guard against inherent hazard associated with the system, is not overlooked.
Like design, manufacturing of equipment, as per design criteria and specifications to ensure adherence to prescribed norms, is of equal importance for the machinery and equipment to operate safely. BIS have formulated guidelines for sare handling, operation, installation and design of various types of machines frequently used in the industry.
Technological, economic, organizational and human factors affect work behaviour performance and well-being of people as part of the work systems hold. The design of the work system should, therefore, satisfy human requirements by applying ergonomic knowledge in the light of practical experience. BIS hang published S 102258 Ergonomic principles in the design of work systems.
Chemical Safety:
Chemical processes have inherent hazards leading to fire, explosion, toxic release and other events when deviations occur from the normal operating/design conditions. After gruesome Bhopal disaster in December 1984, the Environment Protection (EP) Act, 1986 was enacted. Further under EP Act rules for control of hazardous substances were framed in November 1989.
Safety in Electrical and Electronics Sector:
Electric shock and short circuit are the major causes for some of the very fatal accidents. The Electro-Technical Department (ETD) has formulated a number of standards covering the accident prone areas of electrical operations and installations. Recommendations on safety procedures and practices in electrical works are covered in IS 5216 (Part 1): 1982.
Further standards have been formulated by the ETD on classification of hazardous area for electrical installations and guide for selection of electrical equipment for hazardous areas. Standards for protection against electric shock, mechanical hazards, unwanted or excessive radiations, explosion hazards, excessive temperature, fire and other hazards have also been formulated.
With the rapid growth of the electronic industry associated with very fast technological changes, it is of utmost importance that the persons working in this sector are aware of the hazards and accident prevention techniques.
Casualties due to occupational diseases occur more often as compared to that due to industrial accidents. The BIS through its various technical committees has formulated many important standards in the field of occupational ‘IS 8964 (Parts 1 to 24) safety for wood working machines.
Hazard due to radiation from X-ray tube, TV picture tube and data processing equipments have been considered and standards have been laid down to minimise/avoid the same. Realising the seriousness of occupational hazards from electronic equipment standards have also been formulated on protection against possible hazards in radio transmitting equipment flash operators for photographic purposes.
Asbestos is a known hazard for health and therefore a need for formulations of guidelines of working conditions in asbestos units was realized and accordingly standards on safety and health requirements relating to occupational exposure to asbestos, control of emmission of asbestos dust in premises manufacturing products containing asbestos, personal protection of workers engaged in handling of asbestos and method of determination of airborne asbestos fibre concentration in work environment have been formulated.
No doubt occupational safety in industrial sector is a matter of great concern, but this aspect also deserves due attention for the people working in the offices. Sick building syndrome (SBS), has been described as the office workers’ biggest hazard. Recognized as an environment health problem by the World Health Authority, it was first observed in the USA complaints seem to have become significant since late 1970s.
This appears as a multi symptomatic conditions of generally non-specific symptoms, which include lethargy, eye-trouble, headache, stuffy nose, dry/sore throat, wheezes, coughs, skin rashes and nausea. In one of the survey up to 80 percent of those questioned, experienced symptoms of ill health which they associated with being at their place of work.
The causes of SBS are as diverse as the symptoms themselves. There is rarely one specific reason; usually a combination of factors contributes of ill-health, among them the following causes such as thermal discomfort, noise, lighting, indoor pollutants, ventilation, biological and psychological aspects.
Role of OSHA (Occupational Safety and Health Administration):
OSHA regulations in United States establishes regulations which would require the addition of guards, sound enclosure, barriers, colour schemes, and electrical control features that would physically impede the worker from contact with potentially hazardous machinery.
In general, the use of mechanical barriers is limited to preventing machine operators from area of defined hazards (belts, pulleys, sprockets, chain, pinch points are typical hazardous areas during normal operation). Not only should these be guarded in a way as to prevent access, but colour schemes should be used to warn that hazards lie beneath the barriers.
OSHA regulations have taken a strong stand on restraining industrial noise. These recommend the towering of noise levels in industry to 90 decibels.
In addition to mechanical barriers, use of optical and electrical barriers is also recommended for safety of operations. Electrically activated sensors stop the machine whenever anyone enters a hazardous area. It may be in the form of an electrical floor mat which will shut down a machine when anyone stands near enough to the machine to be able to reach into the moving equipment.
Another way is the use of capacitive or radiation type fields generated by an antenna. Anything entering these electrical fields will change the characteristics of the field, and thus stop the machine. Light curtains are also found to be very useful. Light curtain walls can be placed in close proximity to moving elements of the machine and visual access to observe machine behaviour is excellent.