PSM MANUAL 2015

PRINCIPLES OF SAFETY
MANAGEMENT

MANUAL PERPARED BY
V.N.DEVKUMAR

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 PSM MANUAL 2015

UNIT-1 CONCEPTS &TECHNIQUES :

TERMINOLOGIES OF PSM

HAZARD:

A hazard is situation, condition, process; material (or)a thing may causes

and injury (or) illness to a person
Situation working alone
Condition- heat stress ,wind, heavy rain
Process - working high noise area abrasive blasting ,sand
blasting
Material - handling radioactive material
Other thing - safety officer finding during work

Classification of hazard

Hazard is classified into six groups

Mechanical hazard -moving machine

Physical hazard - slippery wet floor
Chemical hazard - spillage of chemical
Environmental hazard - exhaust fumes form diesel
Engine vehicles
Biological hazard - house hold medical waste
Organization hazard - excessive work load
RISK:
Risk is a measure of hazard
Risk=likely hoot *severity rate
R=FR*SR

WHAT IS NEAR MISS:

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 PSM MANUAL 2015

Unplanned event that under slightly different circumstances would

have result harm (or) damage

What is incident:

An incident is an undesired event that may result in injury loss of

life loss of property and damage to the environment

Accident :

An accident is an unplanned, unexpected event that result in injury

loss of life loss of property and damage to the environment , in
other words all the accident are incident but not all incident are
accident

Injury:

Injury is an external damage to the human body disturbance

Dsfunction resulted from accident , injury could be physiological and need

not always be a physical harm

classification of injury:

injury is further classification based on the magnitude of danger to life

and property
Minor injury - slight injury with no loss of life
Moderate injury - more than minor injury but no loss of life
major injury - in case where there is loss of life (or)damage
to property
Disaster - in case where there is extensive loss of life

PPT-permanent partial disability;

The victim is permanently disability but disability is not total ,he

can be given lift duty

PTD-permanent total disability ;

the disability is total can not work at all-time can`t cure the
disability

TPD-temporary partial disability

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 PSM MANUAL 2015

The victim is disabled for a short period with the minor (or)
moderate injury
The victim can regent his original working capacity with some first
aid medical treatment

TTD-temporary total disability

The disability is total and not able to work at all but after a certain period
of time the victim can work but can do only very little work here after

LOSS OF LIFE

Fatal (or) death is loss of life

Disable injury / LT injury/reportable injury

An injury due to which employee (or) worker can`t joint back for the job
within 48 hours from the time of accident is called LT

NLT-non last time accident

An injury which requires medical treatment only without causing any

disablement
The worker will be able to report back to duty before 48 hours from the
accident time is called NLT

hazard recognition

The act of recognising the dangerous (or) hazardous situation (or)

condition in a work activity is called HR

hazard identification

The process of determining whether the exposure to something /agent

/condition that can cause a change in the health condition of work is
called hazard identification

Hazard assessment

An analysis of physical chemical and biological properties of hazard is

called hazard assessment

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Risk identification

The recognising that exists and the deciding the probability of the hazard
causing incident is called risk identification

Risk analysis

The detailed procedure of risk identification assessment and evolution

performance to understand the nature of negative consequence to life
property and the environment

Unsafe act (ua)

An action of worker resulting in poor safety performance are resulting an

injury to a person. Loss of property or damage to the environment is
called ua.

Unsafe condition(uc)

The factor which can lead to an incident or to an accident such as

unguarded machine poorly protected the chemical storage etc is called uc.

Corrective action(ca):

The temporary safety measures taken to protect or control the work place
from hazard are called corrective action (ca).

Preventive action(pa):

The permanent safety measures taken to prevent the recurrence of

incident/accident for ever is called prevent action (pa).

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UNIT -3

H.W.HENRICH TRIANGLE /THEORY:(FORMED ON 1931)

MAJOR INJURY/LTFATAL
ACCIDENT

0.3% 1

8.8 % 29 INCIDENT /MINOR INJURY

90.9 % 300 NEAR MISS NO INJURY

UA=?..000 UC=?.0000

INTRODUCTION TO HENRICH THEORY:

The radio is generally denoted as 1:29:300.

There come many hazard in a work place
Some of them are trivial (or) small and you generally do not care for it
Every day you manage the hazard without any accident but this hazard
has a potential to cause an accident
We may escape these hazards without an accident hearly 300 times out of
the total 330
Out of 300 times 29 times you may meet with minor injury which also
you may not care

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But 1 out of 330 times you will have a major accident resulting in a LT
injury
The situation actually wart to you sufficiently in advanced either to
remove the hazard (or) avoidthe hazard
For you they occurrence of major accident is unexpected, unwanted,
unintended event with no fault of yours .but you conveniently over
looked of number of time you crossed the hazard (300)
You event over looked the incident (or) minor injury it had inflicted (or)
occur on you almost 29 times
These things will not go to your mind at all because they are insignificant
or (unwanted) for you
The about study was conduct by henriche in about 5.000 incident
/accident, he has conducted in the about study that in a unit group of 300
accident of the some kind (or) types and involving the some person
300 events resulted in near miss /no injury
29 events resulted in incident /minor injury
1 event resulted in a major /LT injury /fatal incident

Conclusions of henrich:

Behind every accident there is cause

Accidents do not just happen; there are caused
78% to 80% of the accident caused due to UA`s
About 20% of caused due to UC
Majority of the UC`S are either physical (or) mechanical

Moral from henrich theory:

Prevent the near misses and there can be no incident no injury

Prevent the UA`S and UC`S and there can be near misses nor incident
/injury
An injury mealy the result of anaccident the seriously (or) the cost of an
injury that resulted when an accident occurs is difficult of control
It depends on many uncertain and regulated factors such as
A. The physical and mental condition of the person who is involved in the
accident
B. The weight .size and shape of the object causing the injury
C. The part (position) of the body injury
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 PSM MANUAL 2015

Frank E bird junior (Formed on 1969)

1 SERIES DISABILITY /LT / LOSS

OF LIFE

10

INCIDENT / MINOR INJURY

30

PROPERTY DAMAGE

600

NEAR MISS/NO
INJURY

INDRODUCTION OF FRANK E BIRD THAROY

Frank e bird in analysed 17.53.498 cases reported by 297 companies

while he was working at an insurances company as a manager in North
America (or) USA
He linked property damage as a contributing factor to accidents and thus
expending the safety scope
The company represented 21 different industrial groups
The workers worked over is 3 billion man hours during the period of
analysis
Frank E bird junior concludes that 1:10:30:600 radio seen to indicate very
clearly foolish. it is to direct hour total effort at the relatively fue event
terminating in a serious /disabling injury /fatal when there are 600 near
miss 30 property damage 10 minor injuries
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 PSM MANUAL 2015

These no loss incident (600) provide a much large basis for more
effective control of accident s
You learn and prevent incident /accident without any cost while taking
action at the near miss level it self

Difference between henrich and frank E bird theories:

S.NO HENRICH FRANK E BIRD

1 1 : 29 : 300 1 : 10 : 30 : 600

2 Hen rich studied only 5000 Bird studies over 17.53.498 cases
cases

3 Only one company is Study 297 companies

studied

4 Study was conducted only Study was contacted 21 different job

one job(steel erection) activities

5 Radio`s do not apply to all Radio`s apply to almost all situation

situation

6 H.W henrich study was Frank E bird was study various man (or)
only one man (or) worker worker

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What is safety:

Safety is defined as freedom from these conditions that can cause loss of
life loss of property damage to environment by ILO
To prevent UA&UC /to prevent incident

History of safety: (safety come from England)

The rapid development of stream power lead to the growth of

employment in Great Britain (GP)
Women &children where employed including men worker `s in factories
Because of industrialization many work place injuries continued to
happen
To compensate these accident a common worker compensation law
A. In Germany 1885
B. In great Britten 1887
C. In united states 1902

Occupational health & safety in the united states(us):

The role of American govtin the safety movement is clearly understood

of various laws and regulations that had shaped the safety concept
The creations of us department of labour was as signification step in the
control of occupational safety in the us
The enactment of Williams &stagier act 1970 more popularly know as
the OSHA act was primarily responsible for the prevention of
occupational injuries and diseases in the US

OSHA because the most powerful safety law passed

It enforced safety and health standards for all places of employment with
criminal and civil penalties for violations
A new new agency OSHA was created to enforce this act

Workers rights under OSHA:

The right to request in writing for safety &health inspection in the plant
(or) site

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Right to identify by dangerous substance by labelling

The right to know about safety violations b site
Right to identify by dangerous substance by labelling
The right to know about safety violations by the employer
The right to participate in safety committee meeting

Employers right under OSHA :

The right to file an appeal in case of penalty

The right to know the reason for OSHA inspection
The right to participate in the inspection

Occupational safety &health in India :

The constitution of India contains specific provision on OH&S of worker

No child under the age of 14 year shall be employed in any factory, mines
(or) any other hazardous area
The labour ministry developed DGFASLI & DGMS director general of
Mines safety to achieve the principals written in constitution of India in
the areas of OH&S in factory, mines and ports
The DGFASLI runs and controls four labour institute for advising
factories OH&S policy
The labour institute own by DGFASLI
a) CLI-central labour institutes (Mumbai)
b) RLI-regional labour institutes at(Kolkata,Kanpur,chennai)
They conduct courses such as:
a) Industrial safety(construction also included)
b) Industrial hygienic
c) Industrial medicine etc.(MBBS)
DGMS has its heat quarters at dhanbar
Making recommendations for preventive action (pa)

Evolution of Morden safety concept:

In the present days industrial are becoming more and more complex

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 PSM MANUAL 2015

Huge investments are made for the construction of industries

Any negligence at any stage of designs erecting and operation can result
into disaster, loss of life and huge production losses
In the present days accident can be costly to the management in terms of
cost of medical facilities & loss of production
So safety aspect should be given serious consideration
Berried safety the health and environment production also should be
given importance

Need for integration of safety ,health environment :

SAFETY

HEALTH ENVIRONMENT

Today it is not only sufficient to take care of safety but the health of the
of the worker protection of environment are also equally important
On their three elements are integrated and affect each other
If the health of worker is not given important it may lead to accident
If the industry pollutes the environment around the worker place, it will
ultimately affect the health of the worker which may finally affect safety
and in turn the production

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 PSM MANUAL 2015

ss , training,
Selection
placement
Man
motivation,
discipline

Selection, design,
Machinery Effective Safety
maintenance,
operation, control production

Hazardous, chemical
storage and Martial
transportation
&handling
There are three important components in the process of achieving safety
and efficient production without accident
The machineries and equipment should be selected with proper design
easy availability of spares and easy maintenance and operations
The worker shall selected with proper qualification and experience the
proper training will motivate them to work as a safety worker
Where possible hazardous chemical shall be replace with less hazardous
once, if not possible the hazardous chemical shall be controlled at the
point of transportation storage and handling
When all the above three are controlled the company will be able the
make efficient production with higher safety standards

International certification:

Companies dealing with MNC-multinational company (or)exportingto

UK and US are going for international certification as below
1. ISO 9001 - quality product /service
2. ISO 14001 - environmental management system
3. OHSAS - occupational health and safety assessment series

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 PSM MANUAL 2015

GENTRAL CONCEPT OF SAFETY MANAGEMENT :-

There are three types of management system to implement safety

Line organisation
Safety directorate
Committee organisation

Line organisation:

Many of the small scale industry follow this type of organisation which
does not have a separate safety department (or) safety engineer
The responsibility of safety is shared from top level management to
worker level here every one is responsible for safety
The weakness in this type of organization is very often the worker is pre-
occupied with has actual work and hence resulting in the neglecting the
safety rules
The other important factories the worker of this system can`t effectively
co-ordinate with central state and local bodies

Safety directorate :

Large companies with 100`s of worker follow this type of organization

The safety manager safety officer directs this organisation

Function of safety director /safety officer:

He should have thorough knowledge on the sop and work activity of the
company he should understand the OH&S policy and implement in all
area
Work closed it other manager to achieve higher standard of safety
Developing short terms and long term OH&S activities and implementing
it
Compliance with registration and co-ordination with enforcement agency
Making available technical information and training manual for use of
managers
Conducting safety training programme and first aid, fire fighting, material
handling, ERP, gas testing etc.

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 PSM MANUAL 2015

To give specialized safety training on subject like hot work, MSDS ,

chemical safety ,PTW ,etc.to supervisor level and above either by internal
(or) external training facility
The collection &recording of datas related to work injury causes and
statistics
The inspection of work site for compliance with central state and local
regulation as per the government act
The establish SOP`S/SWP (or) any insurance company recommendation
related to safety
To participation in review meeting to decide the purchases of specific
machineries all hazards chemicals
Participating to technical meeting design (or) modify new facilities and to
advices about the necessarys safety precaution

Disadvantage of safety officer (or) director :

It`s system may not function wells when the top management fails to
support the safety management /officer
This system also wills not the effective if the safety manager /officer is
not a competent person

Safety committee organization:

c
Central safety
committee /cscchairman
so/sm/gm

Executive Technical Worker

committee committee committee

Work manager Production Supervisor

GM/ HR manager manager foreman worker
/maintances/ma representative
15 nager safety
engineer
 PSM MANUAL 2015

Central safety committee :

The membership also include CM/SM/GM the function as security

Responsibility:

Approving the safety budget as per the recommendation of executive

committee

Executive committee:

This committee include HR manager /finance manager /project manager

Responsibility :

This committee act behalf of the top management is supervising and

controlling safety officer
The safety budget are reviewed along with the technical proposal by this
committee
Once the committee is technical as well as financially the proposes of
recommended and forward to CSC

Technical committee:

The membership include it means production manager, safety engineer.

Responsibility:

The technical committee studies the proposes of the workers committee.

The study include detailed technical analysed and the financial
implication to the company
If the proposal is the technical viable the technical committee raises
quotation from the vendors (or) supplier
This report is then forwarded to the executive Committee for further
action.

Workers committee:

The membership includes supervisor/Forman/representative.

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Responsibilities:

The unsafe conditions and

the work place hazards are informed to the supervisor (or) workers.
The ucs are studied & relevant modification proposes submitted by the
supervisors to the technical committee.

The principals of function of csc:

Planning & developing programs to make work area safe.

To follow the reasons trends and development in the industry prevent
accident.
Conduct safety programs to promote safety.
Approve the safety budget to improve work place condition on safety.
The csc must also approve appointment of safety officer as required

Conclusion:

The main advantage of safety committee organisation is the participation

of employees from worker level to top management.
This enables the csc to take effective PAs towards ucs.

Budget for safety:

Introduction:

Safety training, PPEs safety sign boards, machine guarding (or) general
safety maintenance are all the areas that should beconsidered and
included while developing the safety budget to manage your companys
day to day activities.
Planning for safety should be taken up while planning for a selection of
man power machinery etc

Three indicators which help the develop your safety budgets:

Near miss.
Incident.
Accident datas collected by your informal (or) formal
inspection.
Workers interview and feedback.

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Compliance data from government through inspection survey

audit etc

Near miss, incident, accident data:

UA and UC near miss, incident, accident datas can be

collected by conducting formal & informal inspection shall be
analysed and used for making safety budget.

Worker interview & feedback datas:

The workers shall be interviewed to find out the UCs and

relevant suggestion to improve the safety in his area.
This kind of feedback gives you useful information to make a
safety budget.
The following questions shall be normally asked to get the
feedback.
Are you had any incident (or) accident in the previous year?
(If yes explain)
Do you have any UCs in your work area? (If yes explain)
Do you have any suggestion for improving the UCS in your
area? (If yes explain)
Do you have all the necessary PPEs for your work? (If no
explain)

Compliance data from government:

The regular inspection conducted by statutory authorities such

as DYCIF, inspector of construction etcwill give you
valuable information for making safety budget.

This inspection normally cover plant site, worker camps welfare facilities etc

a. Do I have written HSE policy?

b. Do I have required PPEs for the workers performed proper reason?
c. Do I have appropriate safety equipment for the job such as LOTO
scaffolding ladder gas tester etc?
d. Do I have necessary safety sign boards?
e. Are we providing necessary training?
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Conclusion:

A right safety budgeting will give a safe work environment

which in turn result in higher quality of service and
productivity.

Safety policy:

Safety policy as per BOCW acts 1996.

The following guide line shall be followed while preparing
HSE policy for construction.
Every company the employee 50 (or) more building workers
of HSE policy and submit the same for approval of director
general.
The policy shall contain following.
The intention and the commitment is the company recording
health safety & environmental production of the building
worker.
Organisation arrangement made to carry out the HSE policy
specifying the responsibility at different level
Responsibility of the principal employer, principal contractors,
subcontractor, transporters other agency involved in the BOC.
Techniques and methods for assessment of risk to safety health
& environment and preventive measures.
Arrangements for training of building worker supervisor or
other person engaged in the construction worker.
A copy of HSE policy shall be designed by an authorised
person and sent to the central government.
The company shall revers a HSE policy as often as necessary
under following circumstance.
Whenever any expansion (or) modification has implication in
safety & health of the building worker is made in such
building (or) other construction worker.
Whenever any new building (or) other construction work,
substance, articles techniques are introduced having
implication on health & safety of building workers.

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 PSM MANUAL 2015

A copy of the policy shall be displayed at the conspicuous

place in Hindi and a local language understood by the majority
of worker.

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HSE POLICY

HSE POLICY
{REVITION-0}

[CONSTRUCTION INDUSTRY]

Kalai Construction Company recognises the importance of safety and

environment production so our company protects them through our organisation
activities by following our HSE policy.

We need the requirement applicable national and

international standards & local HSE regulation.
We will evaluate and minimize the environment safety
& health impact by our activities.
We establish &maintain the environment management
system in accordance with ISO-14001.
We strongly believe that implementing HSE production
is a line management responsibility.
As responsible and leading construction company we
are also committed to ensure the full satisfaction of the
clients consultancy and the local authority.

The management solicits the fullest co-operation of all employees,

subcontractor and public to maintain accident free work environment to
maintain.

DATE:

PLACE: SIGNATURE

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HSE POLICY MODEL-2(factory)

{REVITION-0}

HSE policy of kalai factory firmly believes that all accident are prevented the
safety of the employees, industrial operators, products, customers and the
neighbouring are important to achieve. There the company will effectively take
the following steps.

Every attempt to made to reduce the possibility of

accident and improve the environment safety.
Work place will be monitored and SWP will be
maintained.
SOP will be follow for an efficient operation of the
plant.
Safety is an operating function and all levels of line
management will have a primary responsibility for
implementing safety programs.
No job will be considered rightly done unless
employees follow safety rules to protect him and is
follow the workers.
All the relevant statutory safety laws regulation will be
complied with in letter and spirit.
The company will be always on the lookout (search) for
latest technologies in the interest of health and safety of
the workers

DATE:

PLACE: SIGNATURE OF MD

Kalaiindustrial pvt.ltd

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HEALTHE SAFETY &ENVIRONMENT POLICY

{Revision -1}

HSE policy of kalaiindustrialpvt.ltd protection of health safety environment are

prevented industrial accident and controlling environmental pollution also
worker, customer neighbouring are important to achieve there the company will
effectively take the following steps.

Comply with relevant laws and regulation as well as take any

additional measures considered
The company will provide suitable facilities and make the
necessary arrangement for the welfare of all our employee at
work.
The company plan to minimize the high risk activity.
Promote awareness among contractors, suppliers for shared
responsibility towards health safety environment.
Prevention of incident, injuries and pollution.
Co-ordination with concerned government agencies/local
bodies engaged in HSE Activities.
Continual improvement of HSE performance.

Date

Place managing director

KALAI CONSTRUCTION PVT.LTD

HSE POLICY
(Revision -1)

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We recognize that commitment of health safety and environment performance is

an essential part of our goal to become the leading kalai constructionpvt.ltd and
also heavy work through our organisation activities by following step

Identification and evolution of all HSE hazard (or) aspect

and the management of their risk to acceptable level
We need the requirement applicable national international
standards and local HSE bodies
Prevent pollution maximize recycle, reduce, wastes
discharges and emission
Review the IMS objective and target at frequent intervals
Communication of HSE policy to all employees
customer, supplier, contractors and all interested parties
including the public
Prevention of illness/injury/accident and also giving more
awareness
Co-ordination with concerned government
agency/regulatory bodies
Continual improvement HSE performance

Date

Place managing director

IRT-Incident Recall Techniques

What is IRT?

To find out the event (or) near miss that did not get report.

DEFENITION:

IRT is one of the methodologies used to help worker to

remember the near miss that could have resulted into incident/accident .these
near miss can help to learn and improve safety management system.

Objective:

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The objectives of the IRT is to uncover near miss that worker

forget to report. The main objective is to get the sufficient no of near miss. So
that you can make IRT is them to prevent incident/accident.

INTRODUCTION TO IRT:

1 FATAL/LT

10 MINOR INJURY

30 PROPERTY DAMAGE

600 NEAR MISSES

The IRT techniques is based on frank E bird theory

According to bird for every accident that result in injury there will be a no near
misses

If we can identify near misses prior to accident and take PA`S then we are
effective fulfilling our role as a HSE officer

Basic element of IRT methodology:

There are three basic element through which data`s can be collected and IRT

If safety inspection (formal/informal)

Participation &observation
Incident interview

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Daily HSE statistics

HSE parameter

Work activity day1 day2 day3 day4 day5

Worker at
height

Hot work

Excavation

San blasting

Confined
space

Safety inspection:

Formal inspection are planned and carried out by individual

(or) team
Checklist are used during formal inspection
During the inspection UA`S and UC`S are noted
Informal inspection of the same purple of the formal
inspection but they are noted planned and can be conducted

Participation and observation:

Some training of the worker shall be given before conducting

the excursive.

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 PSM MANUAL 2015

Here observations are made while selected worker performing

the normal work activity.
This deviation will be guiding you weather excessing
procedure work environment and (or) tool need to be
modified.

Incident interview:

Many of as experienced UAs, UCs, near misses etc. in our

work place but they are not normally reported because of the
following reason.
a) Fear of discipline.
b) Conurn about safety record.
c) Fear of medical treatment.
d) Desired to keep personal record clear.
e) Conurn about the attitude of after.
f) Poor safety awareness.

Interview techniques :

The name of the worker name of the interviewing .interview

location should not be disclosed
All the statement must be kept confidential
The length of the interview should be reasonable
During the interview the worker is requited to recall the near
misses with the potential for injury he has seen
The brief description of the near misses and frequency of the
occurrence is also noted
The interview should be focus wrong fact finding not on fault
finding
The interview feedback are analysed to determine the
appropriate (PA)

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 PSM MANUAL 2015

4
Column2
NEAR MISS
3

0
1 2 3 4 5 6 7

By comparing the above a graph we can identify the graph which has got
more no of near misses
If graph in than compared with bird theory of accident concept 600:30:1
This comparison use can identify the near misses that has the potential
for serious injured the required(PA)

Conclusion:

The IRT techniques can assist in lowering the level of hazard and the
probability to the actual injury
The greatest advantages is that accident situation can be examined before
it happens not after the accident
If your not conducting IRT in your organisation you may travelling in a
high way at a very high speed but on a wrong track

SAFETY SURVEY:HEALTH SURVEY(91-A section)

Safety survey made to have detailed observation of all type of unsafe

workplace condition around the industry (only watch UC)

Safety survey team:

It can be done by

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a) Internal of the site /plant

b) By third party
c) By statutory authority like DGFASILY, Directorate general
of CIF (OR) DYCIF any time during the normal working
hour after giving notice is writing

Survey procedure:

The factory act 1948 (section 91-A) provider authority for conducting
health and services in factory/construction site than the DYCIF after
giving notice to the occupier(or) the manager of the factory can
undertake OH&S survey and collected samples and other data relevant
to safety survey ,DYCIF inspect
The mechanical examination procedure of the worker during survey he
may recommended re examination of specific worker
While making safety survey the safety officer should co-ordinator with
the government official

Survey checklist:

The survey observation are discussed in a jointed meeting with the

section heads
Necessary CAPAS are suggested for resolving the observation
Observation made during the survey become very useful for
The copy of the survey report may also be summated to the state
government as required

Safety inspection:

Definition:

safety inspection is a method of discovering UA & UC in a

factory(or)construction site that has got the potential to make an
accident
suggest CAPAS eliminated accident

The inspection team

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 PSM MANUAL 2015

STATUTORY TEAM NON STATUTORY TEAM

CIF SAFETY OFFICER

DYCIF SENIOR PLANT MANAGER

ADDITIONAL CIF FIRST LINE SUPERVISIOR

JOINT CIF MAINTANCE DEPARTMENT

DIST MAGISTRATE OF THE WORKER

DISTRIC

ANY OTHER PERSON APPOINTED

BY (STATE GOVERMENT

TYPES OF INSPECTION:

a) FORMAL INSPECTION
b) INFORMAL INSPECTION

A)INFORMAL INSPECTION:

This are unannounced inspection conduct any time during the day
Checklist may not be used during this inspection
There inspection may be conducted by safety officer safety

B)FORMAL INSPECTION:-

This inspections are planned inspection conducted as regular interval

The inspection data and taming are informed in advance
Normally the checklist is used the inspection steps planning to develop

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Planning to develop

Inspection status

make Conduct the

recommendation inspection
NSPECTIO
to UA&UCS
Identification UAS&UCS
REPORT

DOCUMENT THE INSPECTION REPORT:-

Follow-up find out whether are the correction are made

INSPECTION PROCEDURE:-

Planning for inspection

Determine the area to be inspect
Establish check list for inspection

SELECT THE INSPECTION TEAM :-

Members who are familiars with equipment tools and the process and
operations and having adequate knowledge of the hazards associated
with this machineries
The team should be familiar with the company rules and policies &also
the various statutory requirements during this OH&S

CONDUCT THE INSPECTION:

During inspection identify the UAS&UCS

Inspect for SOPS(OR) Jop inspection
Record the finding

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DROW INFORMATION :-

Monitor
Plant
Machinery
Storage
Worker
Systems & procedures
Be systematic

ANALYSIS THE INFORMATION:-

Find out the consequence of the UAS&UCS that have been identified
during the inspection
Measure the hazards & risk

DRAW CONCLUSION:-

What need to be done to correct the UA&UC

Determine alternate solution or cost

SUBMISSION OF FINDING :-

Use the following table or format to submit the inspection report

S.NO Inspection UA/U RECOMMENTION EXCUTED TARGET REMARK

point BY DATE

Get the flats right

Use understandable language
Give (eg) use chart & document

IMPLEMENTAION FOLLOW:-

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 PSM MANUAL 2015

The completed safety inspection forms should be on to be concerned

department / section for necessary CAPAS
Follow up the activities to confirm the recommendation are executed
with in the target data

SAFETY SAMPLING :-

Safety sampling is systematic sampling of particular high risk toxic

chemical ,high risk activity ,high risk work place etc.....
Chemical sampling & analysis is used by industrial hygienic to assess
workplace contaminate (dust, toxic,vabour,high temperature, high noise
)and associated hazard to worker

TYPES OF SAMPLING:-

Short team sampling

Long team sampling

Short team sampling:-

Short team sampling is other voice know as (TLV-TEL SHORT TEAM

EXPOSURE LIMIT) is the maximum allowable concentration of the
toxic gas in air in which the worker can work only 15minutes STEL
values are checked only for emergency & rescue operations (it mines
closing valve ,to save valuable think )

LONG TEAM SAMPLING:-

Long team sampling other voice know as TLV-TWA is the maximum

allowable air bourn concentration of the toxic gas in which major of the
worker may be able to work continually or intermediately for 8 hours per
day or 40 hours per week (us standards) without any major hazards TWA
can be measured
Every one hours reported 8 times
Once in two hours report 4 times
Once in 4 hours reported 2 times
Eight hours once

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 PSM MANUAL 2015

SAMPLING METHODS :-

direct reading sampling:-

Direct reading online instrument provide and excellent machinery to

monitor to potential exposure of a work in a toxic area continuously

DETECTEDTUBES /PORTABLE MULTIGAS MONITOR :-

Detector tube are use

a) Then the toxic limit is high
b) When it requires a worker work continuously TLV limit of some
toxic gases (refer to factories act 1948 2 schedule)

s.no Chemical name TLV-STEL 8 TLV-STEL

HUR PPM 15 MIN PPM
1 CL 0.5 10
2 NH3 25 35
3 CO 50 400
4 H2S 10 15
5 SO2 2 5

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 PSM MANUAL 2015

UNIT -2

SAFETY AUDIT AN INDRODUCTION

What is safety audit?

Safety audit is a systematic independent and critical examination of safety

activity and related result to determine whether they comply with the
planned arrangement of ISO-14001,ISO-9001,OHSAS-18001

Why Need for safety audit?

Safety audit like the financial audit should be part of the management
practice to ensure that critical operation are carried out in a safe efficient
and profitable way
Any simple measurement of safety performance in terms of FR&SR not
seen as a liable guide to safety performance
More meaningful information could be obtained from the safety audit.

Objectives of safety audit?

To critically evaluate the safety programme

To analysis and find out companies efforts to implement safety
To identify analysis and control all potential hazards
To critically evaluate the HSE police of a company and the level of
OH&S standards
To evaluate the legal requirement and the compliances
To evaluate the allocation of fund towards safety budget
To evaluate and educated the site personal
To developed data required by the out site agencies

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 PSM MANUAL 2015

TYPES OF SAFETY AUDIT :

SAFETY AUDIT

BASIC AUDIT SELFAUDIT PROFSSIONA AUDIT

CERTIFICATE AUDIT SURVIELLANCE AUDIT

CUSTOMER AUDIT

GENERAL AUDIT ELEMENTS:

HSE policy
Leadership and administration
HIRA
Statutory requirement
ERP
SOP
Safety meeting and communication
Safety inspection and procedure
Safety training
Record keeping and documentation
Management review

AUDIT TEAM:

MR-management representative
Safety officer
Process engineer
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 PSM MANUAL 2015

Project engineer/project manager

Mechanical engineer

Characteristic of safety audit:

Un biased
Independent
Periodic
Qualified
Systematic
Efficient
Document

Basic audit/first party audit;

Before fore undertaking any full fledge a management should ensure

that at least some of the basic elements of an audit program is an
operation.
The auditor must analysis qualitatively the achievement of the
company in the areas of HSE policy safety management HIRA ,
SOP,SAFETY TRAINING DOCUMENDATION.
The basic audit will be conducted by the company employer to
conform that the company is complying (or)following safety standards
and local legislation.
The basic safety audit members include , supervisor, foremen,
mechanical process , electrical ,HR etc...and safety audit.

Self audit/second party audit:

After being satisfied with the result of basic audit the management can
take-up self audit
In the audit documentation related to most of the audit element will be
checked
The audit recommendation of basic audit should have to closed at the
time of self audit.
The self audit is normally is done by a management team
The team can compile members from maintains, process, chemical
plant of project instrument training medical HR

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 PSM MANUAL 2015

The team should pre-favourably be from corporate office not from the
same site since they are likely to unbiased and are directly accountable
for the audit result
The auditor should have professional training in the area of safety
fire, OH&S, environment ,monitoring, uncontrolled
Self audit is a certification audit programme

General activity of an audit program:

Fact finding
Team approach
Audit area
Employer knowledge and safety standard
Review of written safety program
Program administration
Record of document
equipment and material inspection
general area walk through
Review of safety audit program finding
Recommendation of safety audit
Purplish the safety audit result

Fact finding:

To fact finding is used together all information applicable to audit

element
Auditor should avoid making comment

Team approach:

Lead auditor(LA)

1 2 3

Normally the auditing comprise of lead auditor and more auditors

support him

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The LA may choice a specialised auditor if he find it necessary

Each auditor of the audit team shall given different area for inspection
The auditing should have proper auditing background

Safety audit areas:

The safety audit area can be broken down into smaller section for
making focused audit

3) (A) EMPLOYER KNOWLEDGE ON SAFETY STANDARDS:

determine the employer knowledge of the safety & other operating

areas through question &MSQ
For interview and informal question may also be used to determine the
employer knowledge

3 (B) REVIEW OF WRITTEN SAFETY PROGRAM:

HSE policy &HIRA, SOP, SWP, training procedure etc...shall be

checked in the area
Risk assessment and related documented shall be checked again local,
state, central government requirement

3) (C) PROGRAMME ADMINISTRATION:

In this part of the safety audit the following area shall be checked
Safety management system for the implementing the safety program
The person responsible for managing the system
The budget allocation made towards safety programme
The following question shall be asked in the audit area
In the person assigned is trained to manage audit programme
Are his duties and responsibility defined
Are sufficient subject provided for conducting programme

3 (D) RECORDS AND DOCUMENTATION:

Records are the only means proving that specific regulatory

requirement have be met the company
Incomplete(or) Missing document good indication a program is not
working as designed

3 (E) EQUIPMENT AND METRIAL INSPECTION:

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In there safety audit inspect the storage facilities and handling

arrangement are in safe condition
Following question may be raised in the audit
Is the equipment used for storage chemical is as per designed
Are the worker for using proper PPE?
Is the storage of chemical proper maintained
Is the emergency exit, light fire extinguisher system of storage area are
designed to control the hazard effectively

General walk through area:

A general walk through of work area can be provide additional

insight of the effective of safety program
Auditor should take written notes during walk through
Safety auditor is not designed for complete inspection of the plant .so
sampling also allowed

Review of safety audit finding:

After all the documents SOP,SWP, and equipment are inspect the
audit team assemble for description on the audit report
the audit report comments and recommendation shall be prepared
the report should be based on the following question
this the safety program of commend the organization cover all the
regulation provisions (legal compliance ) and the best industry
practice requirement
are all the requirement of the requirement of the Audit program being
met
is their document proof of
is their effective safety training for employees
are the related department involve before making the audit report

RECOMMENDATION FROM SAFETY AUDIT :

Develop recommendation and (CA) for deficiency found during audit

Before developing CAS the manager /supervisors shall be involved
Records of the completed CAS should be reviewed by the
management and than filed which will be checked during the next
audit

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PUBLISH THE SAFETY AUDIT RESULT:

The audit report should be delivered manager level staff

The result should contains the audit finding that is to be followed
The audit report shall acknowledge & appropriate the department
/manger /supervisor etc who executed the responsibilities rightly
during the safety

THIRD PARTY AUDIT (OR) PROFESSIONAL AUDIT

/CERTIFICATION AUDIT :

The professional audit can be conducted by the management .if the

self audit satisfactory
This audits are generally conducted by the external auditor typically

The steps of third party /professional /certification:

PRE-AUDIT PREPARATION AND MEETING

OPENING MEETING THROUGH
FAMILIARIZATION TOUR INTERVIEW
VERIFICATION OF INFORMATION
CROSS VERFICATION OF THE SITE
CLOSING MEETING WITH MR AND OTHER EXECUTIVE
WRITTING THE AUDIT REPORT
AUDIT REPORT CONTENTS
SUBMISSION OF AUDIT REPORT

PRE-AUDIT PREPARATION AND MEETING:

Before the audit team enter into verification of the document ,the team
will have a brief meeting with a top management
The audit team & the management will plan and organise necessary
steps to ensure that certification audit is carried out in the most
efficient manner

OPENING METING:

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 PSM MANUAL 2015

The purpose of opening meeting is to introduce the audit team to the

company management
Here the review scope and objective of the audit they provide a short
summary of the procedures used during the audit
The opening meeting is indented to establish official communication
link between the audit team and the management
Opening meeting confirms the resource and the facilities needed by
the audit team
The opening meeting provides schedule of visit to individual section
(or plant)
Any procedure need classification can be discussed before the audit
The MR will ensure the support of the senior executive of the units to
be audited for the audit team

FAMILIARAIZATION TOUR INTERVIEW:

Normally the audit team makes the tour of the plant/site to get them
self familiarization with the nature of the operation various OH&S
condition and environmental related issue
If the audit team intend to find out the HSE awareness of the worker,
the may be interview the worker
Is the written HSE policy?
Is oriented towards injury prevention only?
Is it oriented for total loss control, including prevention of the
environmental damage?
Of all the supervisor familiar with it?
Are contract worker familiar with it?
How does the management support the HSE policy strong
commitment/normal support/lip service/indifferent(or)un understand?
Are the senior management meeting include safety?
Is the responsibility for safety defined is written?
Are those responsible for safety understanding?
Is safety include in SOP?
Are the first line supervisor required to submit safety report to the
management?

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Verification of information:

The information received verbally(or)through form to verified

The audit ream shall check all the element record document related to
audit element
Employer at all level shall be interviewed by the auditor shall check
the correctness of the information

Cross verification of the audit:

The audit team shall be verified the information received from

document(or) through interview the worker
The verification is usually done by making a tour of the plant/site
The verification shall be executed by the following methods
Actual count
Random sampling
Physical measurement
Professional judgement check

For example:

A toxic chemical storage shall be verified against the consumption actual

stock can be maintained

Closing meeting with MR:

The chief executive and senior manager will have the designs to
known the result of the audit finding
In order to satisfied the senior management and over view of the
incomplete audit finding shall be discussed with them
Any explanation required on the audit finding will also be discussed
In general the audit finding and resulted will be informed with the MR
representative during meeting

Written the audit report:

The audit report shall be prepared under the direction of LA

Who is responsible for its occurrence &competence
The audit finding of the audit evaluate the LA
They are ranked according to the deviation from the audit element
The ranking are subjected to ABC(analysis)

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A-HIGH RISK
B-MODERATE RISK
C-ACCEPTABLE RISK
The audit finding are related as NC conformance and observation
Audit report content:

The audit report should faithfully rejected the concept of the each
elements are copy of the audit
It should be signed by the data of LA
The audit report contains the following as applicable
Introduction
Objective
Methodology of the audit
Over view of the site
Plant description
OH&S system
Worker participation
Management commitment towards safety
Major conclusion
Recommendation

Detailed audit report:

The audit report shall contained the following items

The scope and objectives of the audit
Detail of the audit meth lodge
Audit team members
MR(or)section co-ordinate
Audit data
Id which the identification of reference documentation against which
the audit were conducted(SOP,SWP,SAFETY STANDARDS)
Conformity(good practices)observation NCR
Audit team judgement oft he audit through applicable
OH&S standard
Recommendation for improvement

Submission of audit report:

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The detail audit report along with required finding form and document
should be submitted with in one month after the audit
This will facility the management to review the OH&H system and
effect change factor

Certification of audit report:

In order to have growth among completers the will call the

certification bodies with audit my company
The following certification are available for industry &construction

A. ISO 9001-QUALITY OF PRODUCT(OR)SERVICE

B,ISO 14001-ENVIRONMENT MANAGEMENT SYSTEM
C.OHSAS18001-OCCUPATIONAL HEALTH AND SAFETY
ASSESSMENT SERIES
D,PSM-PROCESS SAFETY MANAGEMENT(FOR CHEMICAL
INDUSTRY ONLY)
Certificates ABC are issued for UK and D issued for USA
Surveillance audit:

This audit conducted by certification bodies

If the company issued any of the above certificate (or) ISO-9001,ISO-
14001,OHSAS18001)with some bending document verification then it
under go surveillance audit
The surveillance audit shall be conducted by the certification bodies
with 6 month to one year all the relevant element shall be checked
during this once the company pass the surveillance audit the
certification will received

Customer/product audit:

Before planning with the company the customer may verify the
competency of the supplier either by qualified auditor from his one
company(or)external auditor
The purpose of this audit to find out the ability of the company to full
fil the order should specified quality and without any delay
If the company to passes the audit will get the order

Benefits of the safety audit:

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 PSM MANUAL 2015

When properly conducted by the audit can help to identify and correct
regulatory deficiency which can improve the work place safety and
reduce accident cause
Audit can improve employer awareness towards safety
The audit process will demonstrate the company commitment towards
safety and their by welfare the worker
Workplace safety will be received favourably by regulatory agencies such
as DYCIF directorate general of health services welfare officer during
regular inspection and services

NCR-NON CONFORMITY REPORTING:

It refers to any non fulfilment of any element given the under the ISO
standards
The NC includes system deficiencies lack of the recorded action
An observation in left uncorrected will likely to result in an NC

TYPES OF NCR:

Major NCR
Minor NCR

MAJOR NCR:

The major NCR is an identifiable deviation from the ISO standards which
possess through a serious threat to work or the environment and requires
immediate action
EXAMPLE: the company did not carry out load test (TPI-SWL) of its
lifting machines, tools and tackles and did not test pressure safe valves or
(PSV) which are legal violations

MINOR NCR:

The minor NCR is an identifiable deviation of non serious nature

EXAMPLE: modified procedure not included in the sop and old
procedure are still existing
Although CAS are taken and evidence are available for the NCR of
previous audit
The NCR copy is not available for reference

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BENIFITS OF NCR:

It can find out the deficiencies in procedure and recommended CA

This ensure such problems do not record
It helps to initiate action by suitable notifying the consult people who
are authorized to CA

REVIEW OF INSPECTION:

Making inspection in a factory /site is a legal inspection (4.3.2) under

OHSAS 18001
This is carried out by CIF ,DY-CIF and construction inspector the
inspection report recommended given by the statutory authority will
be checked during the audit process
This verification is done to make sure whether the company has
complied with all legal requirements
Normally health, safety hazardous chemical storage handling
operation of the equipment ,employees welfare records checked
during this audit

Remark by government agencies:

Safety survey
Safety inspection
Health inspection
Welfare facility related record are checked by DYCIF of health
service as per the legal requirements
The legal requirement are given under the relevant section of factories
act 1948, BOCW act 1996 etc
Reporting of accident through form 14,18 and accident investigation
are also checked during this audit
The ERP conducted as per section(41 B)factories act 1948 are
reported to DYCIF, this records will be review during the audit( FA
schedule 123)

Remarks by consultant:

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Self audit and external audit are conducted by consultant there are
reviewed by the audit team class 4.5.5 under OHSAS 18001.
This to make sure that the company has full filled the requirement of
certification audit 4.5.5 under OHSAS 18001.
Some companies prepare risk assessment of flammable and toxic
chemical through consultancies.
Such risk assessments documented are checked 4.3.1 under OHSAS
18001

Remarks by reports:
TPI inspection ,lifting machineries, tools & tackles , pressure vessels ,
pressure safety valve etc should be conducted as per legal
requirements either ones in six months are ones an a year.
Normally the test are conducted by certified expect know as
competent person.
Since the test form the legal requirement under the classes 4.3.2
OHASA 18001 the audit team shall verified the document also.

Perusal of accident & safety record and format verification of accident

record (classes 4.5.3):

The audit team shall review the record of the major accident LT / disable
injury and it happens the premises.
The inspect supervisors accident report from such as( form 14 as per the
BOCW ACT 1996 ) from 18 as per factories act 1948 is followed as per
the legal requirement
They also check accident investigation process &the methodologies used
for RCA-root cause analysis 5W&IH (OR) FTA
They check the fire prevention &fighting equipment first aid &medical
facilities in correction with accident records

Safety records:

Various less prevention techniques such as IRT, JSA ,HIRA etc.

verified to conform the effectiveness of the study.

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 PSM MANUAL 2015

Various training method such as TPM, TPI, PEP TALK induction

training interview etc related records are verified to access the
safety awareness among the worker.
Records related to the PTW,SOP,SWP are also verified.

Formats:

Formats related to accidents prevention methodology such as JSA

,HIRA, IRT etc are verified .
Formats related to PTW cold work ,hot works ,confined space entry
excavation , scaffold erection, crane operation permits are also
verified.
Formats related to gas detection procedures also verified.

Implementation audit indication:

All CA recommended in the audit report should executed.

The departments and the supervisor in charge of executive the
recommendation well be communicated for the proper implementation
Target date well be included for proper follow.
The commitment of the management is more important to implement
the recommendation by providing necessary resource.
The following format should be used to indicate the completed
recommendation which will we check during the next surveillances
audit.

S.n Audit Action by Targeted Remark reason Sign

o Recommendation Section/department date Implemented/non date
details implemented

Liaison with department to ensure co-ordination

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 PSM MANUAL 2015

The CAS recommended by the audit team has to be executed by

various departments like mechanical civil, electrical safety
administration depending upon the nature of the work.
The MR (or) safety officer has to discuss the audit document
recommendation with related department.

Recommendations:

S.n Audit Action by Target Responsibilit Remark

o Recommendatio department date y s
n
1 Risk assessment Safety One Technical
procedure in /technical month engineer and
adequate against department safety officer
toxic chemicals
used
2 Explosive licence Safety and 10 days Safety officer
was not renewed administratio and admin
records couldnt n department officer
be identifies
3 Power press Mechanical 1 month Supervisor
indication hazards and safety /maintenance
due to inadequate department departments
guarding system
recommend to
install to proper
guarding
4 Previous audit Safety and ASAP Safety
observation production (as soon production
related to PTW department as supervisors
was not dissolved possible
document to be )
produced

Previous audit observation corrective action documentation could be produced

INTRODUCTION OF OSHSAS-18001:2007

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 PSM MANUAL 2015

it was develop in response to demand for single universally applicable

and externally verifiable system for the management of OH&S in the
work place
it was developed april1999 by( BSI-British standard intuition )
HISTORY OF OHSAS-18001:

prayer to prepare OHSAS-18001 many companies were following BIS

8800 IN 1996
this British standards for OH&S MS is just a guide
the BIS 8800 system can neither nor be certified many customers and
companies wanted a common system for OH&S MS be developed
they want the system when once followed can be audited & certified by
the third party
in response to the demand OHSAS-18001 was developed which is an
auditable certification system for OH&SMS
DEVELOPMENT OF OHSAS STANDARDS :

several organisation developed and publish their own standards for

OH&SMS against which auditing and certification will be issued
some Spanish Malaysians ,UK companies developed the OH&SMS
system
they were demanding common specification for OH&S MS which
could be recognized world wide
so the leading certification organization joint together and developed

WHICH CAN BE REGARDED AS :

this procedure was developed with the input from Spanish , malaysian&
UK
UK accreditation services are formed & developed the system for
OHSAS certification system
This accreditation bodies developed training procedures for OHSAS
auditors & qualified auditors where recognized

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 PSM MANUAL 2015

STRUCTUE OF AUDITING PROCESS:

UK-GOVERNENTM

ACCOREDITION BODY

CERTIFICATION BODY IRCA

LRQA BUQA DNV BIS TUV

LEAD AUDITOR (LA)

MANAGEMENT REPERSATATIVE (MR)

ORGANIZATION

1, BIS-BRITISH STANDARARDS INSTIUTION

Introduction

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 PSM MANUAL 2015

Conformity assessment and accreditation, along with standards are

important parts of the nations quality infrastructure. By providing
confidence in goods, services, management systems and people, they
make a significant contribution to the economy, health and safety, and
environment.
BIS is responsible, on behalf of the government as a whole, for the
horizontal policy on these activities. What follows is a short guide for
business and other government departments that are looking for tools to
help them provide re-assurance to customers about their products or
services, or win contracts where conformity assessment and accreditation
are specified as requirements, or in delivering government policy. The
guide provides a brief explanation of what these activities are as well as
where to go for more detailed information, and explains BIS role.
Conformity assessment

Conformity assessment is the demonstration that what is being supplied

actually meets the requirements specified or claimed. Conformity
assessment can be applied to a product (which for these purposes includes
a service), a process, a system, a body or persons and includes activities
such as testing, inspection and certification. The organisations
undertaking these activities are referred to as conformity assessment
bodies.
Accreditation

Accreditation is given when a conformity assessment body is recognised

as competent, in accordance with recognised standards, to carry out
specific tasks. Accreditation is used in both the regulated sector to meet
the requirements of certain legislation and the voluntary area where there
is no specific legislation. It is generally accepted that for an accreditation
body to be authoritative it must have the support of government. In
Europe, governments are required to appoint a single national
accreditation body to carry out the accreditation of conformity assessment
bodies.
Accreditation increases trust in conformity assessment and thus reinforces
the mutual recognition of products, processes, services, systems, persons
and bodies across the EU.
Where to get accreditation in the UK

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 PSM MANUAL 2015

The UK government expects UK based conformity assessment bodies to

be compliant with European legislation and seek accreditation from
UKAS (United Kingdom Accreditation Service) the body appointed by
BIS to be the UKs national accreditation body.
BIS encourages and recommends UK businesses, government and local
authorities requiring third party conformity assessment services to source
such services, where they exist, from conformity assessment bodies
accredited by a national accreditation body.
Where to get further information on accreditation

The UKAS (United Kingdom Accreditation Service) has more detailed

information on what accreditation is, the benefits of accreditation for both
business and government, as well as how to apply for accreditation. It
also has, for those seeking to employ an accredited conformity
assessment body, a list of those conformity assessment bodies that have
been accredited by UKAS.
What is the quality assurance infrastructure

Conformity assessment and accreditation are integral parts of the quality

assurance infrastructure in the UK which also includes:

National Measurement System that has a network of laboratories and

process that provides measurement standards and calibration testing
facilities. It maintains the measurement infrastructure, represents the
position of the UK measurement internationally; influences the
development of standards; and is responsible for stimulating good
measurement practice and enabling business to make accurate and
traceable measurements.

British Standards Institution, the UKs national standards body, that

works with many different industries, businesses, governments and
consumers to develop British, European and international standards, as
well as representing UK economic and social interests across all
European and international standards organisations.

The role of BIS in accreditation

BIS has a number of roles in:

policy

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 PSM MANUAL 2015

promotion

appointing and sponsoring the UKs national accreditation body

owning, and sublicensing, the accreditation logo and symbols

monitoring the UKs national accreditation body, UKAS

Policy

Domestically BIS leads, on behalf of government as a whole, on general

accreditation policy (horizontal policy - ie across all departments),
while individual government departments and agencies are responsible
for accreditation policy for their specific areas of responsibility (vertical
policy).
BIS also pursues the UKs accreditation interests in Europe in
communications with other member states and the Commission. BIS is
also closely involved in the development of guidance in the application of
European accreditation regulation, in particular Regulation .
Policy - Health and Social Care

There is a strong focus in the current UKAS business plan on advancing

the use of accreditation in the health and social care sectors. BIS has been
in discussion with the Department of Health about where accreditation
can be used and to ensure that UKAS role and status in delivering
accreditation is fully understood. To ensure clarity, BIS and the
Department of Health agreed a statement that was submitted to the UKAS
Policy Advisory Forum Health and Social Care Sub-Group, in July.
Promotion

BIS seeks to encourage and promote the use of accredited conformity

assessment, mainly by responding to enquiries from other government
departments who are considering how to deliver a government objective
and are thinking of using accreditation but also by directly supporting
UKAS in extending accreditation into new areas.
UKAS, the UKs national accreditation body

A Memorandum of understanding ( MoU )

BIS sponsors UKAS and provides a small amount of funding to UKAS
for it to undertake some public interest activities (ie non-fee earning
activities) in representing the UKs interests in the international
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 PSM MANUAL 2015

accreditation infrastructure, and in raising awareness of the benefits of

accredited conformity assessment in SMEs and government. Otherwise,
UKAS is expected to be self-financing.
BIS is also active in all the UKAS stakeholder representative
mechanisms.
Monitoring

Both the MoU and Regulation (EC) No: 765/2008 require that BIS
monitors the UKs national accreditation body, UKAS.
The MoU sets out how BIS will formally monitor UKAS. In addition BIS
seeks every opportunity to receive feedback from UKAS direct and
indirect customers to supplement the formal monitoring.
Legal framework for accreditation

Regulation (EC) No: 765/2008 provides for the first time a legal
framework for the provision of accreditation services across Europe,
setting out provisions for the operation of accreditation in support of
voluntary conformity assessment as well as conformity assessment
required by legislation.
What does Regulation (EC) No: 765/2008 contain

In essence, this regulation:

states that accreditation can be used in both the voluntary and regulated
sectors

requires member states to appoint a single national accreditation body

(NAB) recognised by government to deliver accreditation as a public
authority activity

requires the NAB to be a not-for-profit organisation

requires that NABs do not compete with each other

requires conformity assessment bodies requesting accreditation to do so

with the NAB of the member state in which it is established

sets down requirements that NAB must fulfil

requires member states to monitor their NAB

requires NABs to undergo regular evaluation by their peers

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establishes a European accr

Notification

Notification is an act whereby an EC member state informs the European

Commission and the other member states that a body (the notified
body), which fulfils the relevant requirements, has been designated to
carry out conformity assessment required by EU legislation. Notification
of these bodies and their withdrawal are the responsibility of the notifying
member state.

STRUCTURE & FEATURES OF OHSAS-18001:

OHSAS-18001 mostly follows the demings PDCA cycle for

continual improvement

PLAN

ACT DO

CHECK

Deming cycler of plan do-check-act ensure that risk management

activities are planned controlled implemented and results checked with
CAPAS and than improvement are made
The cycle when repeated can derive continual improvement in the
system as well as in OH&S
The Deming cycle describes the four activities :

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 PSM MANUAL 2015

PLAN -establish goals standardization working practise (or)

SWP&SOP and training the employee to deliver results in
accordance with the companies OH&S police
DO-carryout the according to the plan
CHECK-verify conformance with OH&S policy goal legal and
requirement & report the result
ACT-take action to continually improve performance of the
OH&S management system OHSMS try to reduce the impact of
cast of the accident before it happen
the impact of major accident to an organization is not just huge
cusses but also the impact on it image and business which
threatens its survival
OHSAS standards prevent this types of accident & losses when
followed properly
It is a systematic approached to change and induce
improvement which focuses on identifying hazards , risk
assessment ,risk control and also ensure company with
legislative requirement

OHSAS MODEL

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 PSM MANUAL 2015

OHSAS 18001 defined the critical management element

It allows the company to develop their own procedure to achieve the

certification
The structure of OHSAS defines the key elements which could be
addressed by the management

The successfully implementation of OHSAS is there depends upon the

highest the management commitment

Certification of OHSAS insist on document system

Continuous improvement of management system is another key concept

of OHSAS.

The company has to comply with appropriate legal provisions also.

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 PSM MANUAL 2015

Risk assessment is one of the supporting documents of OHSAS 18001.

OHSAS 18001 allows maximum use of internal resources and knowledge
for developing OH&SMS.

Everyone including the worker will fell they have ownership of the
system & there will not be opposition

Every purchasing policy needs to ensure that OH&S risk consecrations

are take into account while purchasing hiring materials equipment (or)
personal

BENEFITS OF CERTIFICATION:

Certification of OHSAS 18001 provides the following benefit ----

a Planned documented approach on health & safety
Clear OHSMS structure defining all the requirement of an industry
Developing knowledge on health & safety at all level of the workers
Provision of healthier safety & working environment
A reduction risk of accident & occupational ill health
A reduction is loss time through employee illness & injury
Complaints with legislation which reduces likelihood of paying legal cost
& compensation

OH&S-MS ELEMENTS,SPECIFICATION,SCOPE

CLAUSES DESCRIPTION
1 Scope

2 Reference publication

3 Term & definition

4 OH&SMS requirement

4.1 General requirement

4.2 OH&S police

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 PSM MANUAL 2015

4.3 Planning

4.3.1 Hazard identification & risk

assessment &determining control
4.3.2 Legal & other requirement

4.3.3 Objective & programs

4.4 Implementation & operation

4.4.1 Resources roles responsibility

accountability & authority
4.4.2 Competence, training & awareness
4.4.3 Communication ,participation &
consultation
4.4.4 Documentation

4.4.5 Control of documents

4.4.6 Operation control

4.4.7 Emergency preparedness &

response
Checking
4.5
4.5.1 Performance measurement &
monitoring (FR/SA)

4.5.2 Evaluation of compliance

4.5.3 Incident investigation NCR,CA,PA

4.5.4 Control of records

4.5.5 Internal audit

4.6 Management review

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 PSM MANUAL 2015

1. SCOPE:
The OHSAS standards specifies requirements for OH&SMS to enable an
organization to control it OH&S risks and improve its OH&S
performance
In order to achieve risk free OH&S environment ,organization should
demonstrate its conformity with OHSAS standards by-
The company should have OH&S police and follow it
It can seek confirmation of the conformance with OH&S
standards by customer (or) by some external parties
Seating certification of its OH&SMS by external certification
bodies
the OHSAS standards is intended to address OH&S this is not intended
on other health safety area property damage (or) environment impact

2. TERMS&DEFINITION:

HAZARD:

A hazard is situation ,condition ,process, material (or) a thing that may

cause and injury (or) illness to a person
Situation working
Condition heat stress, cold stress wind heavy rain
Process-working high noise area abrasive plasting ,sand
Material handling radio active material
Other think safety officer finding the job
Classification hazards :
Mechanical hazard
Physical hazard
Chemical hazard
Environment hazard
Biological hazard
Organization hazard
INCIDENT :

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An incident is an undersized event that may result in injury loss of life

loss of property damage to the environment
ACCIDENT:

An accident is an unplanned unexpected ,unwanted event that result in

injury loss of life, loss of property and damage to the environment.
In other words all accident are incident but not all incident are accident
HAZARD IDENTIFICATION:

The process of determining whether the exposure to something agent

/condition that can cause change in the health condition
CORRECTIVE ACTION:

The temporary safety measures taken to protect (or) control the work
place from hazard
PREVENTIVE ACTION:

The permanent safety measure taken to prevent to reoccurrence of

incident /accident for ever

AUDIT :

Audit is systematic ,independent and critical examination of safety

activities and related result to determine weather they comply with the
planned arrangement of various documentation
ACCEPTABLE RISK:

The term tolerable risk has been changed into acceptable risk
The risk that has been reduce to a level that can be tolerated by the
organization with respect to it legal obligation & its own OH&S policy
CONTINUAL IMPROVEMENT :

Process of enhancing the OH&S-MS to be achieve improvement in

overall OH&S performance in line with organizations OH&S policy

DOCUMENTAION:

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 PSM MANUAL 2015

Information and its supporting medium. The medium can be paper

,magnetic, electronic ,CD, photograph (or) samples are a combination of
this.
ILL HEALTH:

Identifiable adverse physical & mental condition arising from work

activity or work relative situation /work condition
INTERESTED PARTIES:

Person or groups or inside or out side the work place concerned with area
affected by the OH&S performance of an organization
NC (NON CONFORMITY):

Non fulfilment of the requirement.

Non-conformity can be any deviation from...........
Relevant, work standard practices procedure legal requirement and
etc....
OH&S-MS requirement
OCCUPATIONAL HEALTH & SAFETY (OH&S)

Condition and factors that affect could affect the health &safety of
the employee or other worker (temporary worker and contract
worker) visitors and any other person in the work site
RISK ASSESSMENT:

Process of evaluating risks arising from hazards taking into account

any existing controls and designing whether or not the risk is
acceptable.
WORK PLACE:

Any physical location in which work related activities are

performed under the control of the organization.
4.OH&SMS AND REQUIRMENT:

4.1GENERAL REQUIRMENT :

The organizational activities are established documented

maintained and continuously improved in occurrence with
requirement of the OHSAS standards
4.2OH&S POLICY:

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The top management shall defined and develop the organizations

OH&S policy as per the following guideline

a) It is appropriate to the natural and scale of the organizations

OH&S risk
b) It includes the commitment to the prevention of injury & ill
health and continual improvement and OH&SMS
c) It include the commitment to at lest comply w with
applicable legal requirement and with other requirement
related to its OH&S hazards
d) It provides a frame work for setting OH&S objectives &
commitment
e) It is available to interested parties
f) It is reviewed periodically to ensure that it reminds relevant
and appropriate to the organization

4.3PLANNING

4.3.1 HAZARD IDENTIFICATION RISK ASSESMENT AND

DETERMING CONTROL :

The organizations are established and maintained procedure for the

ongoing hazard identification risk assessment and determination of
necessary control.
The procedures for hazard identification and risk assessment shall
take in to account
a) Routine and non-routine activities .
b) Activities of all persons having access to work place
(including contractors visitor)
c) Human behaviour capabilities and other human factors
d) Identified hazards originating outside the work place capable
of adversely health & safety of the person with in the
workplace .
e) Hazards created within the work place by work related
activities.

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f) Infrastructure equipment and materials at workplace whether

provided but your company or other .
g) Changes proposed changes in the organization it may be
activity or materials
h) Modification to the OH&SMS including temporary changes
and the impact an operation process and activity
i) Any applicable legal obligation relating to risk assessment
and control measures
j) Design of work area, process ,installation /equipment
operating procedures (SOP,SWP)
k) The organization methodology for HIRA shall be defined
with respect to its scope &nature and it should be pro-active
rather than re-active
l) Provide for an identification prioritization and
documentation of risk and the application of control as
appropriate.
m) The organization shall ensure that the result of the
assessment are considered when determining controls,
n) When determining controls are considering changes the
existing control measure should also be taken into account
and then the risk should be controlled according to the
following HIERARCHY.....
Elimination method
Substitution method
Engineering control
Safety sign board /administrative control
PPES
O) the organization shall document and keep the result of
identification of hazard and risk assessment and determine the
control up to date

4.3.2 LEGAL AND OTHER REQUIREMENT:

The organisation shall establish implement and maintain the procedures

for identifying for accessing legal and other OH&S requirement that are
applicable do it
The organisation shall ensure that applicable legal requirement such as
THE FACTORY ACT 1948
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 PSM MANUAL 2015

BOCW ACT 1996

THE GAS CYLINDER ACT 1998 etc....

Other requirement to which the organisation submersible (or) taken to an

account is establishing implementing and maintaining in the OH&SMS
The organisation shall keep this information upto date
The organisation shall communicate the relevant and legal information to
persons working and risk control and other interested parties
4.4.3 OBJECTIVES AND PROGRAM:

The organisation shall establish implement maintain and document

OH&S objectives and relevant functions at the levels within the
organisations
The objective shall be measurable and concerned with the OH&S policy
including commitment to prevent injury and ill health and to comply with
applicable legal requirements and with other requirement and to continual
improvement
When establishing and reviewing the objectives the organisation shall
take it account legal and other requirement and its OH&S risk
It shall also considered it technologies option its financial operational and
business requirements and views of interested parties
Workers shall informed about their participation arrangement on OH&S
matters
4.4 IMPLEMENTATION AND PARTICIPATION

4.4.1 RESOURCES ROLES RESPONSIBLITY ACCOUNTABLITY

AUTHORITY

Top management shall take ultimate responsibility for OH&S MS the top
management shall demonstrate the commitments by.
Ensuring the availability resources, essential, to establish , implement and
maintaining improve the OH&S MS.
Resources includes human , resources, specialised skills organisational
infrastructures , technology and financial resources.
Defining the roles of employs allocating responsibility and
accountabilities and detecting authority to facilitate effective OH&S MS
.

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 PSM MANUAL 2015

Ensuring that report on performances of the OH&S MS are presented to

the top management and use as a bases to improve of the OH&S MS.
The management shall demonstrate their commitment to the continual
improvement of OH&S performances.

4.4.2 COMPETANCE TRAINING AND AWARNECES :

The organisation shall ensure that any person under his control
performing task that can impact OH&S is competent on the basics
of appropriate education training or experience and shall retain
association records
The Organisation shall identify training needs associated with its
OH&S risk it shall provide training after evaluating the employees.
It should also evaluate the effectiveness of the training and
retrained associated records.
The organisation shall make sure that the person working under his
control are aware of:

The OH&S consequences actual / potential in there work

activities and there benefits after the training .
Their roles and responsibilities and importance is a
achieving conformity to the OH&S policies and
procedures including ERP and other requirement.
The training shall be contacted for different level of
conformity ability language skill , and education.
4.4.3 COMMUNICATION PARTICPATION AND CONSULDATION

4.4.3.1COMMUNICATION:

The organisation shall establish implement maintain procedure for :

Internal communication among various levels and
function of the organisation.
Communication with the contractors and other visitors to
the work place.
Receiving documenting and responding to relevant
communications for external interested parties.
4.4.3.2 PARTICIPATION AND CONSULDATION:

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 PSM MANUAL 2015

The organisation shall establish implement maintain procedures for

participation of worker by their :

Appropriate involvement in the AIR and control

measures.
Appropriate involvement in the incident and
investigation (II).
Involvement in the development and the review of
OH&S police and objectives .
Consultation where there are any changes , which
can affect the OH&S of the workers.
Representation of the OH&S matters and worker
shall informed about their participation assignment
who is representative on OH&S matters.

4.4.4-documentation:

The OH&SMS shall include:

OH&S policy objective
Description of the scope of the management system
Documents including records requirement by OHSAS standards
Documents including record determines by the organization for
the effecting planning and operation process control

NOTE:

It is important that the documentation is proportion to the level of

hazard and risk and it kept the minimum required for the
effectiveness and efficiency

4.4.5 CONTROL OF DOCUMENT :

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 PSM MANUAL 2015

Document required by OH&MS OHSAS standard shall be controlled the

procedure should be developed implemented and maintained to-
Approved document only to relevant users
Review and update as necessary and reapproved document
Ensure that relevant version of applicable documents are available
at the point of view
Ensure that document remain legible or good and readily
identifiable
4.4.6OPERATIONAL CONTROL :

The organization shall determine those operations& activity that are

associated with the identified hazards are controlled to manage the OH&S
risk by
Controls related to purchase goods equipment & service
Controls related to contractors other visitors & work place
Documented procedures such as SOP ,SWP to control the deviation from
the OH&S policy & objective

4.4.7 ERP-EMERGENCY RESPONSE PLAN :

The organization establish implement, maintain the procedure

To identify penitential emergency situations
To response to such emergency situations
The organization shall respond to actual emergency situation to prevent
associated adverse OH&S consequences
In planning the ERP the organization shall take into account the needs of
relevant interested parties
The organization shall also periodically test its procedure to respond to
emergency situations involving relevant interested parties
The organization shall periodically reviews & where necessary revise
the ERP after periodically testing and after the occurrence& emergency
4.5-CHECKING (TITTLE ONLY)

4.5.1 PERFORMANCE MEASUREMENT &MONITORING

(OR)FR/SR

Organization are establish implement & maintain procedure

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To monitor & measures the OH&S performance on a regular basis

these procedures should full the following requirement
Both qualitative & quantitative measures
Monitoring to the extent to meet the OH&S objective of the
organization
Appropriate to the needs of the organization
Monitoring the effectiveness of control health as well as safety
To develop proactive & reactive or CAPA measures to
control ill health & incident
If an equipment is required to monitor or measure
performance
The organization shall establish & maintain procedures for
the calibration &maintenance of such equipment
Records and relevant documents of the above activities shall
be maintain
4.5.2 EVALUATION OF COMPLANCE :

The organization shall give the records related to the periodically

evaluation
The organization shall evaluate and comply with other requirements
which is subscribed
4.5.3.1 (IIR)INCIDENT INVESTIGATION,CAPA

The organization shall establish implement & maintain the procedure

The records investigation and analyze incident in order to (like foam
14&18)
Determine the OH&S deficiency and other factory that might be
contributing occurrence of the incident
Identifying the need for CA
Identifying the chances for continual improvement
Communicate the result of such investigation
Investigation shall be performed timely manner
4.5.3.2 NC,CAPA:

The organization shall establish maintain , implement the procedures for

dealing with actual & potential NCS &taking CAPA the procedures
shall defined requirement for-
Those activities which can develop into OH&S risks

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Investigation the NCS determining the cause & taking actions in order
to avoid reoccurrence
Evaluating the needs for action implementing the NCS
Recording and communicating the result of CAPA
Reviewing the effective of CAPA
4.5.4-CONTROL OF RECORDS :

The organization shall establish implement ,maintain records as

necessary to demonstrate conformity to the requirement of its
OH&SMS and of the this OH&S standards
Te organization shall establish implement and maintain in the
procedure for identification of storage protection and retrieval,
detection and disposal of records
Records shall be and remain legible identifiable and traceable
4.5.5 INTERNAL AUDIT :

The organization shall ensure that internal audits of OH&SMS are

conducted at planned intervals to determine whether the OH&SMS :
Conforms to planned arrangement of OH&SMS including the
requirement of this OHSAS standard has been properly implemented
& maintained
OH&SMS is effective in meeting the organizations policy and
objectives
Provide the information on results of the audit to the management
The audit procedures shall establish implement & maintain to address
The responsibility & requirements for planning and conducting audits
to reports results and retraining associated records
The determination of the audit scope , frequency & methods
Be lection of the auditors & conducted the audit shall ensure
importantly of the audit process
4.6 MANAGEMENT REVIEW:

The top management shall review the OH&SMS at planned interval to

ensure its continuing suitability adequacy and effectiveness &
opportunities for improvement.
Need for changes to the OH&SMS policy and OH&S objectives
Records of the management reviews shall be maintained
The management shall reviews the following inputs

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result of the internal audit

result of participation & concentration
relevant communication for external interested parties
including complains
the OH&S performance of the organization
the status of IIR,CAPA
follow up action from previous management review
change circumstance including developments in legal and
other requirements related to the OH&S
RECOMMENDATION FOR IMPROVEMENT:

the inputs from management reviews shall include any discussion

action related to possible changes to
OH&S performance
OH&S policy and objectives
Resources or man power/money power
Other elements of OH&SMS
CERTIFICATION PROCEDURES:

Phase1 audit planning phase2 conducting audit

a) Initiate a)opening meeting
b) Research b)site tour
c) Prepare the plan c) meeting with the senior
d) Communication management
d) Management audit
e) Filed audit
f) Report preparation
g) Closing meeting

h) Communicating audit
Report recommendation & result

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 PSM MANUAL 2015

A) INITIATE:
What is the objectives of the audit from audits or company view
Against which requirements of the audit is conducted
Legal company requirements / international requirements
Clear about the scope of the audit
B) RESEARCH :
The auditor shall review company document such as SOP description of
the company activities etc which where informed by the company
Past audit reports findings and recommendation
Internal /external
Technical literature , books relevant to the industry (or) sector
Local /international applicable legislation
Culture ,language climatically conditions
Interacting or doubt with client & stake holder
Supplier /contractor, subcontractor vendors (supplier) ,NGO-
NON GOVERMENT ORGANIZATION government etc ....
Output of research helps to prepare the plan
c) PREPARE THE PLAN :

Prepare detailed audit plan :-

No of man day 8 hours (excluding tea break & launch break )
Working hours etc based on the number of sites
Selection of the team relevant to the organization
The auditors may prepare checklist this helps them to keep focused ,time
management value adding and to keep the audit system on track

C) COMMUNICATION :

The auditing plan should be formed two weeks in advance to the audit
team and the auditee (or) company
In case the audit team plan to conduct an internal audit prior to the
certification audit it shall be communicated one month in ING advance
CONDUCTING AUDIT (PHASE-2):-

A) OPENING MEET:

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 PSM MANUAL 2015

Opening meeting shall be conducted to a maximum of 20 mints

The lead auditor & MR shall introduce both team
Company policy and audit objectives shall be briefly discussed
If any major complaints & issues from the previous audit can also
be discussed
B) SITE TOUR:-
The audit team along with MR may take a site tour to understand the
filed activities /condition with reference to the document supplied
By interviewing the worker audit team can also opportunity to
understand the commitment of the management towards OH&SMS
If it is the one man day audit they step to may not be required
The site tour is mainly conducted to verify the companies documents
with respect to the actual work activities in the field and to understand
the work awareness towards OH&S

C) MEETING WITH THE SENIOR MANAGEMENT:-

The senior management meeting is conducted mainly to know about the
HSE policy and objective of the company
Compliance if any outstanding issues related to OHSAS -18001
Will also be discussed during the meeting
The meeting may be conducted for period of not more than (15 mints)
D) MANAGEMENT AUDIT :-
Most of the documents related to OHSAS clauses will be checked during
this audit
The internal audit conducted prior to certification audit to CAPA
/recommendation issues and the status of the recommendation will be
checked
The risk assessment completed and implemented assessment management
review and the assessment and this input of the interested parities on risk
assessment shall be check
If there are more number of auditor based LA the document review will
be divided among the auditor
E) FIELD AUDIT :-
Once documentation review are competed related area will be check to
verify conformity

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 PSM MANUAL 2015

Core or important areas such as protection engineering ,work shop, utility

or boiler material handling (loading &unloading) OH&S clauses shall be
checked by the individual auditor for the conformity with OHSAS
standards
The area shall be distributed among the auditor by subject knowledge and
filed experiences

F) REPORT PREPARATION :-
Once the filed verification is completed all the auditor along with LA
prepare and unfinished /in completed shall assessment for discussion on
the auditor report with
Note worthy effort (or) say good
Observation
NCS

G)CLOSED MEETING :-
The closed meeting will be chaired by LA
The audit finding shall be discussed with MR and the management team
by the LA
Any clarification against the audit finding it also be explain by the LA if
necessary by the individual auditor also
Once the issues are settled the audit finding should be agreed by MR
and signed in the relevant audit form
If there are major finding (NCR) because of which a certification can not
be recommended the client will be given 90 days (13) weeks to rectify
the NC
If the correction satisfactory the major NC will become void (or)cancel
certification shall be r recommended
If there are minor finding and if it can be rectify through (RCA-root
cause analysis) and CAPA by MR and certification shall be
recommended
If it CAPA cant be done on the same day they client will get 1week to
10 days to address issue
The audit report along with note worthy effort / observation /and
NCS has to been signed by both LA and MR to make the acceptable
tans to the report

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The closing meeting can be conducted 45 mints to 1 hours deepen ting

upon the audit output
H) COMMUNICATING THE AUDIT REPORT RECOMMDATION
AND RESULT:-
The audit report along with recommendation shall be sent to the
accreditation body for technical review ,accreditation member will review
the audit reports for certification through sampling
If the audit reports get the approval of the accreditation body the reports
will be sent to the client
The certification will be issued with in 4 weeks
The certification is valid for a period of 3 year
A minimum to surveillance visit is required before recertification
PRILIMINARY AUDIT :-

If the company opts (or) new for preliminary / pre audit (optional) before
the certification audit separate contract will be initiated for this audit it
will not have any bearing on the certification
The preliminary audit indicates the deficiency against OHSAS standards
& related document
The client will be given 6 month time to addressee
Once the correction are accepted the company can more on to
certification
If the pre audit is not opted company maven on certification

UNIT 3 ACCIDENT INVESTIGATION REPORTING

Concept of an accident :-

Refer to heinrich& frank E bird theory

REPORTING TO STSTUTORY AUTHORITY

s.no Description According to bocw According to

act Act factories act 1948
1 Reporting incident such as Loss of life loss of life
Disabling disabling
injury injury

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 PSM MANUAL 2015

exceeding 48 exceeding 48
hours hours
desapliety
injury
exceeding 21
days
2 Reporting through 1)telegram, 1) loss of life
telephone fax or 2) for fatal
similar other means immediately and
including special written report (18)
messenger within 48 with in 12 hours
for fatal 3) disabling injury
2) other accidents exceeding 48 hours
with in 72 hours within 72 hours
through foam (14)
4)not return to work
before 21 day inform
through foam (18-B)
to DYCIF 28 days
3 Reporting authority 1)building workers 1) CIF ,DYCIF
welfare board if the 2)next of kin
victim is in member 3)DM OR SDO-sub
2) chief inspector of divisional officer
according to BOCW 4) office in charge of
act 1996 building & the according to
construction factories act 1948
3) the next of kin or policy station
closed relative
4) office in charge
of the nearest police
station
5) DM OR RDO
4 Reporting through foam foam 14 rule 14 sub foam -18
rule (210)

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 PSM MANUAL 2015

UNSAFE ACT AND CONDITION DOMINO SEQUENCE

Example (in case emergency may

stop, like ERP )

according to this theory the injury is variably cost by an accident & the
accident in turn is a result of an factor that immediately precedes it
The occurrence of a preventable injury is considered as a result of serious
of events or circumstance which occur in a fixed& logic order
The several factors for the occurrence of the accident is arranged in a
chronological or order

(chart attached for this page )

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 PSM MANUAL 2015

These factors are arranged in such way one depended the other domino
constituting the sequence
These factors give a row of dominos placed at one end & in such an
alignment in relation is one to another the fall of entre row an accident
nearly one factor in a sequence
If the serious is interrupted by the elimination of event one of the several
factors injury probably cant may not occur an accident due to UA & UC
(OR ) both
By creating unsafe condition by our UA knowingly or unknowingly

CONCULTION OD DOMINOS:-

The dominos serious theory suggest that the accidents can be

prevented by correcting the basic or immediate causes
The causes of the accident are visible before the accident by
H,W haenrich

ACCIDENT INVESTIGATION &ANAALYSIS :-

Accident Immediate causes Basic cause or root cause

cause causee
WHAT IS ACCIDENT :-
An accident is an unplanned unexpected , unwanted event that
result in injury loss of life, loss of property and or damage to the
environment , in other words all accident are incident not all
incident are accident

OBJECTIVES OF AN ACCIDENT INVESTIGATION:-

The primary objective investigation is to find out the facts not fault

The investigator there should conduct this enquiry in a manner as

to bring out all facts

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 PSM MANUAL 2015

Cases to investigating:-

All fatal accident & damage occurrences should be investigated

About 10% of non-fatal disabling injury (LT) shall be
investigated

QUALIFICATION NEED FOR INVESTIGATION OFFICER &

MEMBERS:-

The investigation officer / member should have :-

Technical knowledge
Familiarly with the job/process/operation
Effective communication
Honestly & unbiased approach
Analytical approach to problem
The first line supervisor is a man on this sport & he is in the
position to ascertain all fax immediate he is there for suited to
enquire about the event
The safety officer by virtue of his qualification training unbiased
approach is the most appropriate person to enquire into accident &
make reports
For serious accident an investigation team may be formed steps of
investigation
a) Preliminary site visit
b) Collection of background information
c) Examination of damage
d) Interviewing of witness
e) Research analysis (FTA or 5W 1H) / final report

LETTER FOR INVESTIGATION:-

Purpose of investigation should be clearly defined and clear letter for

investigation should be forward
During the cause of investigation a letter for investigation may be
renegotiated according to the circumstances

PRELIMINARY SITE VISIT:-

The investigation team should visit the accident seen before the
physical evidence is disturbed
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 PSM MANUAL 2015

Accident reported items should be preserved

This may belong critical evidence if there is a litigation

COLLECTION OF BACKGROUNG INFORMATION :-

Make comprehensive visual records

Visual photography ,videos shall be taken from many different angels
Accurate & completed sketches or diagrams should be used before the
accident seen is restored

EXAMINATION OF DAMAGE:-

Property damage such as equipment , machinery or vessels shall be

recorded
Any interlocking system that may how failed to operate properly or was
damaged should be recorded and prescribed
Documentation such as supervisors accident report ,logbook and other
written report should be prescribed these data s visually cant be
disturbed

INTERVIEWING OF WITNESS:-

INTERVIEWING DOS:

Could the witness at ease

Explain the purpose of the interview
Have another person presented in the room during questioning
Let the witness talk
Confirm that your have the statements correct
Conducted the interview to private with no interruption
Make only short notes only during the interview
Communicate the language the witness can understand

INTERVIEWING DONT:-

Dont intermediate the witness

Dont interrupt
Dont ask directional questions

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 PSM MANUAL 2015

Dont show your emotions

Dont take long notes while the witness is talking
Identify the people who were involved in the accident
Also identify all the eye witness who saw the accident happen and those
who come to seen immediately after the accident
These people should be interviewed
Immediate interviewed minimized the possibility of witness adjusting the
story to fit to the interviewers concept or to protect someone involved
Tactfully or manner & skilled investigators usually get uninhibited
cooperative from the workers
Witness must be convinced that the investigator wants to find the causes
of the accident dont want to blame any one

RESEARCH ANALYSIS:-

The root cause analysis of the accident is carried out by using of FTA

FTA- FALL TREE ANALYSIS:-

FTA is a defective top down approach to analysis root cause of an

accident for system failure

HISTORY OF FTA:-

FTA was developed by scientist at bell telephone laboratories USA

in 1982 for the us air force to identify the system failure
Boeing or rocket companies used this FTA for missile operation
system failure now it is used in( NASA- national aeronautics and
space administration)

How to use FTA:

It being by defining un undesirable event know as top event such as an

accident .fire are any system failure
Analysis project by determining how the top event can be caused lower
level failure such as immediate causes

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Top event

It is end of the programme

In complete simple

FAILRE RATE
RA=7.4*10-4

RB=6.3*10-5

RC=5.9*10-5

RD=8.6*10-6

RE=9.1*10-5

RF=3.2*10-6

The analysis knowledge imagination an professional judgement required

to develop FTA
The tree is developed from top down but rate from bottom to top
Boolean algebra methods is used to find out the RC (route cause)of the
accident involving complex tree with many branch
The basic event are given numerical values defending upon the degree of
probability an the paths are developed
The relative significant of several paths may be determine by calculating
the probability values of each paths

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The path that is responsible for triggering the an wanted event is the one
of which source the highest value
This value are usually expressed as failure RA.RF this value are
derived from performance test field procedure accident records and
professional estimate

Limitation calculation of FTA{

More durable properties should be substitute

Human error which could effect the result also should be controlled

INVESTIGATION REPORT:

the report must be presented in a search a way that the key point are
essily establish and the conclusion essily drawn
the format should follow logical sequences
samples report format
a) title
b) scope
c) list of content
d) executive summary
e) introduction
f) Description of the plant (or)construction activity
g) Details of the accident
h) Finding
i) Methodology used to identifying RCA (or)FTA
j) Conclusion
k) Recommendation
l) Appendices photograph, video, sketches test report
the report should be signed taken by the team leader is members an
approved by manager

AN ACCIDENT INVESTICATION MUST BE CONCEPT:

an accident investigation must be answer following question

i. who was injured?
ii. When did accident occur ?
iii. Where did accident occur?
iv. Why did accident occur?

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v. What happen?
vi. What are the contributing?
vii. How to prevent such accident from happening agene?

PRINCIPLES OF ACCIDENT PREVENTION:

5ES method can be used for the accident prevention, the 5E are
Engineering
Education
Enthusiasm
Evaluation
Enforcement

ENGINEERING:

Project stage is a right time for planning safety

Latest technology which has more safety future should be given
performance over the out dated one even if they are costlier
Poor lighting and ventilation of the work area poor layout unguarded
machine etecan best eliminated at design stage itself
Wherever possible substitution elimination ete .. can be through of in
case of the dangerous material ex
Used water based emanation paint

DANGERUSE PROCESS:Eg

Painting by brush in case of spray paint

Department like purchases, QC and production shth sould work closely
with safety department so that UCs can be lately reduced

EDUCTION:

About 98./. of the accident are due to human failure

If adequate steps are taken to over come human failure for proper
education when accident prevention will be relate
Safety training such as condition TBM,TBT,OJT, inhose training
external training etc.on PTW,FPC,PPE first-Aid measure importance of
IRT, JSA, etc.can be given
New worker are to be briefed about the dangerous involve in the job in
the they are employed

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They should be trained to do the job for SOP,SWP

Existing employer are to be educate in the safety field by conducting
safety seminar
Safety expo safety week programme improve knowledge of worker,
supervisor etcin the field of safety

ENTHUSIASUM:

As a human failure account for most of the accident it is possible to

eliminate by CA
All kinds of motivational technique like individual safety awards
,departmental safety contact, safety slogan competition report the
hazard contact goes along way to motivate the people
Safety suggestion scream of improved the safety permance shall be
develop the workers
The individual shopping can be rewarded for best house keeping
accident free performance shall be given in group of safety awards
Promotion of the workers and supervisor can be given on the basic of
the safety in merit of safety field

EVALUTION :

Continuous evaluation of safety programme , performance procedure is

a must for improvementing safety
Safety committee can also assist JSA and statistical approach like IRT
can also be utilizes of evacuate the worker
Quality And usage of the ppes can also be evaluate.

ENFORCEMENT:

When employees failed to observe safety practice which they have been
tight should be instructed to follow the procedure
Everyone should enforced to follow safety rules& this can be achieved
by
The management should try to provide alternative employment for
prone employees
Worker who are knowingly OR will full fill indulging in UAs on the
workers who come to work in drunken mode OR drunken person
should be punished as per the legal prevision

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RECORDS FOR ACCIDENTL:

Supervisor accident information report

If disabling/injury/death records related to the information given to the
government authorities &relatives of the victim should be maintained
If the accident is in a factory form no;18 and construction form no;14
If the investigation is required document related to investigation:-
a. Letter for investigation
b. Collection of information during site visit
c. Cost of the damaged machineries & tolls
d. Cost of the LT accidents as per the compensation act
e. Document related to witness interview
f. RCA (Route Cause Analysis) report (FTA,5W1H)
g. Recommendation
h. Test reports of unknown chemical vapours ,dust etc
i. Visual records such as videos, photographs, diagram etc
DEPARTMENTAL ACCIDENT REPORT:-
All fatal disabling injuries dangerous occurrence should be
investigated by the safety department
Non fatal, non LT, near misses etccan be investigated either by
the safety department OR first line supervisor of the concerned
section such as MECHANICAL,CIVIL,ELECTRICAL

ACCIDENT REPORT FROM SAFETY DEPARTMENT:-

Form no;14 (or) 18

Evidences such as photographs ,videos, diagrams etc
Test result
Witness interview
Previous accident record
RCA methodology

ACCIDENT REPORT FROM RELATED SECTION (DEPARTMENR)

Preliminary accident report by the supervisor

First aid report
Machinery equipment report

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Witness report

DOCUMENTATION OF ACCIDENT :-

Preliminary site visit

Collection of background information
Examination of damage
Interviewing of witness
Research analysis (FTA) final report

UNSAFE ACT AND CONDITION DOMINO SEQUENCE :-

UNSAFE ACT:-

Operating without authority

Failure to warn or secure
Operating at improper speed
Making safety devices in opera able
Using defective equipment
Using equipment improperly
Failure to use PPE
Improper leading or placement
Improper lifting
Taking improper position
Servicing equipment in motion
Horseplay
Drinking or drugs

UNSAFE CONDITION:-

Inadequate guard or operation

Defective tools equipment substance
Congestion or improper
Inadequate warning system
Fire and explosion hazards
Substandard housekeeping
Hazardous atmospheric condition gales ,dusts ,fumes ,vapours
Excessive noise
Radiation exposures
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Inadequate illumination or ventilation

SUPERVISORY ROLE;-

Collection and analysis data of accidents

1.asking why accident is happen:-

Investigation accident to determine the causes

2.asking whether the following failures accused to accident :-

Inadequate procedure
Inadequate training etc to be analysed by IRT,JSA, safety sampling
etc
Analysis accident searching past accident records for trained analysis
And using the data to develop control measures

3.select remedy:-

selecting improved controls in the area

inspections
proper placement
training
safety education
motivation
proper maintenance
PPE/ I

APPLY ERIC-PD

Apply methods for ERIC-PD

E-elimination hazard
E.g. using water balled paints instead solvent baled
R-Reduce the risk
E.g. using 24 v DC lamp instead of 220 v AC
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I-Isolate the hazard

E.g. machine guarding
C-Control the extent of exposure (or)contact
E.g. by means of ventilation controlling hazardous atmospheres
P-PPE
E.g. use necessary PPE
D- Discipline
E.g. to comply with rules and regulation, SOP, SWP

MONITOR RESULTS:-

Monitor through:-

Formal inspection
Informal inspection
Safety sampling
Safe work practices
Bettors safety records(it means FR* SR)

ROLE OF SAFETY COMMITTEE IN ACCIDENT PREVENTION

CHAIRMAN

SECRATORY OR SO

Member for management member for worker

1 1

2 2

3 3

As per section 38 of BOCW ACT 1996 the safety committee should take
the following actions

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To identifying probability causes of the accident unsafe practices in the

construction site and suggest remedial measures
To stimulate interest of employer and building worker in safety by
organising safety safety week ,safety computation ,safety talk ,safety
films shows ,safety posters
To go around the construction site to the view to check UAS & UCS
and recommend CAPAS including first aid ,medical and welfare
facilities
To look into health hazards handling difference type of explosive
chemicals and other construction materials & to suggest remedial
measures including the use of proper PPEs
To suggest measures welfare facilities in construction site
To bring to the notice to the employee the hazard associated with the use ,
handling and maintenance of equipment used during the course of
construction work

COST OF AN ACCIDENT :-

COST OF ACCIDENT

ON THE WORKER ON THE SOCIALITY ON THE EMPLOYER

DIRECT INSURED COST INDIRECT UNINSURED CAST

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ON THE WORKER;-

1) Health care cost

2) Pain & agony due to injury or illness
3) Suffering
4) Humiliation or insult
5) Loss of income
6) The possible loss of job

ON THE EMPLOYEE DIRECT /INSURED COST ;-

1) Composition cost
2) Medical / hospital cost
3) Emergency expense
4) Payment for work not performed
5) Repair or replacement of damaged machinery tolls equipment etc..
6) Reduction or temporary hast in production
7) Increased training expenses & administration cost

INDIRECT / UNINSURED COST :-

Cost of lost time of injured employee

Cost of lost time by other worker who stop work :-
a. out of curiosity or interest
b. out of sympathy
c. to assisted worker
d. for other reasons
cost of time lost by Forman ,supervisor or other executives:-
1) assisting the injured employee
2) investigating the case of accident
3) arranging for the injured worker production to be continued by
some other employee
4) selecting & training a new worker to replace the injured
workers
5) preparing accident reports or attending hearing before state
officials
cost of time spent by first aider ,hospital staff when not paid by the
insurance company.

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Cause due to the loss of profit & injured worker productivity & on the
idle machines.

ACCIDEN COST TO THE SOCIETY :-

Society as consumers pay the increased cost of production due to direct

and indirect cost to the management
The society bares the social & financial Barden of maintenance of all
injured person and their families

CONCLUSTION:-

Thus knowingly or unknowingly every member of the society bares a

proportion of the cost of the accident
There fore employee employees & the society all have to work
correctively for accident prevention

unit 4- SAFETY PERFORMANCE & MONITORING

INDRODUCTION:-

ANSI American National Standards Intuition(Z16-1) guide line

they given and developed safety performance & indicators
safety performance and indicators were developed to indicate the safety
conditions of a company in numerical
these formulae that developed by industrial scientist by field observation
trial and error calculations etc..
the constant figure with there formulae can be explained some extend
only
there for formulae are generally known as empirical formulae

1.SAFETY PERFORMANCE FORMULAE:-

frequency rate question how often the accident and happening your
industry? can be answered through this formulae

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FR= TOTAL NO.OF REPORTABLE LT *10-6

TOTAL MANHOURS

TOTAL MANHOURE = total no of worker *no of shift *work

hours per shift * no of days worked

2.SR-SEVERITY RATE:-

for a Question how serious the accident are can be answered through

SR= NO,OF DAYS LOST DUE TO LT *10-6

TOTAL MANHOURS

The above FR and SR higher results indicates poor safety

Two results are required for compared

3.ACCIDENT RATE / INCIDENT RATE :-(AR/IR)

The accident per worker is expressed by AR/IR

AR/IR= NO OF LT INJURY *103

TOTAL NO OF AVERAGE WORKER EMPLYES

4.DISABLING INJURY INDEX /FREQUANCY /SEVERITY/INCIDENT

/ACCIDENT RATE INDEX OR (FSI):-

FSI= FR*SR
100

5.SAFETY T SCORE OR T TEST:-

SAFETY T SCORE = FR now FR past

FR past million man-hours
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Safety t score should be between -2 to +2 any score greater then +2

indicate safety needs improvements (it is measures of one year to another
year is called t score)

SAFETY ACTIVITY RATE(SAR)

SAR= SAFETY ACTIVITY *5*10

MANHOURS WORKED *AVERAGE NO OF WORKER

Here safety activity is the sum of UA reported +UCS reported +no. of

safety meeting held

SIGNIFICANTS OF SAFETY PERFORMANCE INDICATORS/INJURY

RATES :-

Injury rates are useful:

To measure the injury experience of a given department branch or

company
To determine month to mount ,year to year safety performance whether
they are getting better or worse
Compare the injury experience of one operating unit with others
Serves as a basics for accident prevention contest between to more
operating units.
The FR and SR variable information and the safety situation of the
factory or industry in absolute numbers they are useful in planning the
immediate measure to control accidents in the industry
FR can be used to compare safety performances with the past best or
good performance of our own industry or other
The high FR is a proof that action to reduce it needed but its unable to
given any hint as to what action
Reduction in SR indicates reduction in deaths and other serious injury.
Increase in SR although the FR decrease indicates a definite need for
effective PA to eliminate hazards.
SR is much more a matter of good or bad luck than is FR.
There it is said that care of FR than SR will take care of itself.
FR is a good basic for comparing two or more units in a safety
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It is not a good basic for comparison except when the SR only is to be

compared in all units for safety contest.
Promote first aid to injured worker decrease the man days lost by him and
intern decreases FR and SR.

SAFETY OFFICER/SAFETY ENGINEER CAN USE INJURY RATES:

To compare the unit safety performance with the average for the
industries
The periodical safety improvement
To find less hazardous operation
To check now all the departments are doing on increasing rates indicates
lack of supervisory control.
To determine which department had the best safety department

Limitations or drawbacks of SR and FR:-

A serious accident has a considerable effects on SR but doesnt greatly

the FR.
the FR indicates the no. of accident per man hours worked only type
cause severity factors of the accident can be mound from it.
SR indicates the ratio of the total man days lost due to total man hours
only type, cause ,factors
A high FR is a proof that action to reduce it needed but it is unable to
give any kind as to what action

Conclusion:

Thus the injury rate are the practical indicates are injury cases only many
NM,NLTs many accidents and property damages or not indicators by
them ,so a professionally judged approach is required while using FR,SR
for including safety

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UNIT - 5 SAFETY EDUCATION & TRAINING

Safety education is a tools to develop safety consciousness ,awareness of

the importance of identifying hazards and eliminating accident
Safety education is primarily a process of importing knowledge on UAS,
UCS SOP, SWP and accident prevention measures
In short education is one that types to import accident preventing
knowledge on worker

SAFETY TRAINING:-

Safety training is a process of developing safe work practices special

skills and applying these skills in to specific work activities through
Safety training is teaching precisely or short specific work activities
through various tr training methods

IMPORTANCE OF SAFETY TRAINNING:-

Well trained and careful worker may avoid injury or dangerous work
where us un trained and careless workers may be injured under the safety
possible condition
The under the safety possible condition
The necessity for safety training inn the industry is justified primarily
because employees are not informed of the safe work practices because
they dont know how to apply this knowledge
The requirement of ISO-9001 ,ISO-14001 AND OHSAS 18001
Will be full filled by the safe training report and documents
Similarly statuary requirement it will also be fulfilled by conducting
safety training and producing relevant document
What ever the form the safety training takes it should be kept mind that
the supervisors are in the best position to covey the safety message to the
workers to the worker and to interpreter or transmitting for the worker in
shop language or practical approach
It can said that if the supervisors are thoroughly or completely sealed or
sales on the safety ,they in turn will sell it to the employee who work
under

OBJECTIVES OF SAAFETY TRAINING :-

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To communicate the message on safety to the individual worker at the

work place
To create safety awareness among the employee
To update the technical skill in the field of application
Given orientation (or)specific training to the new employee
The bridge up the gap between the required level of performance and the
present performance level of the worker
To fulfil the mandatory or violation

TRAINING NEED IDENTIFICATION PROCESS:

PERSONNEL DATA

JOP PROFILE

ERP MOCK JOP REQUIREMENT

DRILL REPORT

JOP SPECIFITION
SAFETY
INSPECTION
AUDIT REPORT
TRANING RECORS
/HISTORY
ACCIDENT
/INCIDENT
ANALYSIS DATA
TRAINING NEED

BASIC STEP IN TRAINING NEED ANALYSIS:

Preliminary survey of the work place which includes

A. Types of business of organisation which includes

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B. Accident injury history

C. Types work materials equipment used
D. Potential hazard of business
E. Existing HSE training and awareness programme
F. The analysis can also include from ERP, mock drills safety
inspection audit
G. Basic on the above inputs the training programme can be
develop to said the various level of the worker

STEP IN DEVELOPING TRAINING ADDIE METHOD

ANALYSING

IMPLEMENTING EVLUATING DESINGNING

DEVELOPING

ANALYSING :-

To identifying training need and constrains

DESIGNING:

Specify training activities .asses and choose the training method medium
of instruction training standards level of participants
Course outline materials ability of the trains the lesion plan
Evaluation method of training programme verbal question answers MCQ
or etc

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DEVELOPING:

Outline training programme on specific job &task

Being preparation of course material
Prepare evaluation method
Arrange for rooms and resources
Arrange for faculty or teaching person
Notifying booklet soft copy like CD etc.
Store all programme and make it available to the employee develop
revision re-training methods

IMPLEMENTING ADDIE:

To put the plan into action meaning conducting the training programme
Using audio visual aid or PPT such as projector programme
Conducting training in a language understood by the majority of the
workers
Distributing hard copy of the training of the materials
Referring to E-library or wify or net

EVALUATING :

The training programme should be evaluated at the end evaluation

method such as spot or picture the hazardous oral question answer
MCQ etc..can be adopted defending upon the level of the participants
Those who couldnt get the minimum marks shall be allowed to
participate in the re-training programme
All the activity should be recorded And documented for legal /OHSAS
compliances

WHO CAN CONDUCTED TRAINING :

HSE training programme can be conducted by safety specialized

Statutory authority occupational physicians trained by RLI (he is
medical inspector for industrial medicine )
Expert in the environmental engineering

INDUCTION TRAINING ;-

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can be conducted to all the new employees of construction as well as

factories
before allowing the new employees to enter inside the site or the
factories they are informed about
dos and dont inside the site of the factory
action during emergency situations
welfare facilities such as canteen ,first aid and restroom area
in a construction site no new employees is allowed inside without
attending an inducting training
normally the induction training is conducted by the safety officer or a
person trained by him
the induction training has to conducted in a language understood by the
new employee
for person attendance registered records shall be maintained and
documented
where an induction training is not possible the video, tapped programme
shall be used for this purpose

TBM-TOOL BOX MEETING OR TOOL BOX TALK:-

tool box meeting is the pree job meeting and it is one of important daily
activity of the construction site
before starting the work the worker has to been informed about
I. what to do
II. what not to do
III. how to do
fall step of the jop and possible hazards in each step of the top and
medication measures precautions to be taken to the job safety
relevant PPES to be used or to be identified the JSA before TBM the
above subjects shall be discussed with worker
all doubt of the worker shall be cleared
any suggestion by the worker to improve safety of the job may be
implemented it ,it is fount veiled
due to their personal problem the worker may come to the site with
different types of mental felling ,because of this they may not be able to
concentrate ,fully on the job and they may forget safety precaution which
may lead to safety

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the TBM will be help the workers to remind the safety precaution to be
taken for the job
the TBM topic should have direct relationship with the job to be
performed
the immediate supervisor of the contractor ,foramen , safety officer or
safety engineer can be conducted this training
adequate training should be given to the supervisors by the safety officer
for conduction TBM properly
attendances of all workers has to be taken every day

PEP-PERSONALITY ENRICHMENT PROGRAMME /ONLY

CONDUCTED SPECIFIC SITE :-

PEP talks are similar to the talks TBM except that this programme is
conducted at the work site itself
In this programme the worker are reminded to avoide UAS& UCS to
prevented the accident
An attendance may all so be maintained for this programme

IN HOUSE HSE TRAINING PROGRMME FOR WORKER ;-

For a construction industry this training programme can be conducted

in construction site itself or in a training room
Before going for this training the training need analysis shall be
conducted to identify the training need
The in house training shall be conducted for various work group such
as workers technicians ,supervisors ,engineer , managers etc..
Before conducting in house training programme model has to be
submitted
Proper attendance it has to be maintained of the training programme
Appropriate evaluation method has to be adopted learning skills
The main topics for worker :-
HSE training programmme
The use of warning signs & symbols
Productive guards & productive devices
Basic fire fighting and first aid practices
Need for wearing PPES maintained & storage
How to maintained good housekeeping
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Safe use of hand tools and power tools

Need for machine guarding
Safety while working at height
Safe martial handling operation
Safe in excavation work
Safety in painting operation
Safety while working in confine space
Safety in welding cutting operation
Safety in use of electricity
ERP-(emergency response plan )

IN HOUSE TRAINING FOR ENGINEER /SUPERVISOR /FIRST LINE

MANAGEMENT :-

Special attention should be given while providing training to first line

management person (train the trainers)
Because the knowledge these received by training will be given to the
worker
If the training that will result in negative impacts

MAIN TOPICS FOR SUPERVISOUR IN HOUSE TRAINING:-

Principals & methods of accident prevention

Need for safety training
Statutory requirement
HSE requirement of clients consistence
Identification ,evaluation prevention & controls of fire hazards
Need for JSA
Need for HIRA
Need for PTW
Need for machine guarding
Need for TBM ,TBT ,PEP TALK
Need for job inspection
Communication & motivation
Human values & human relation
How to face advance weather condition
Safe method for major work activity

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ERP-emergency response plan

Need for safety inspection and audit
Environment production procedure
Need for reporting & investigation of near miss ,incident ,accident
,diseases & dangerous occurrences
Safe use of electricity

SAFETY TRAINING PROGRAMME MODEL:-

S.NO SUBJECT DISCRIPTION

1 Topic safety orientation training

programme for engineer

2 Level of new graduate engineers

participation

3 No of participation 20

4 Objective To understand the

importance of safety
at work
Familiarization with
the company safety
policy and procedure

5 Training controls Introduction to safety

and company policy

Common causes and

accident and their controls

accident investigation
report & investigation
procedure

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industrial hygiene &

occupational health

does & dont during

training & in site the factory

6 Training duration 5 days (30 hours )

7 Faculty Internal

8 Training methods Lectures with the help of

slides ,films, shows, PPT
presentation

9 Evaluation methods MCQ

10 Immediate follow Industrial assignment for

plan safety inspection

EXTERNAL HSE TRAINING /SPACALISED :-

Hse training by consultancy or expert (ca-competent person )

After evaluation of training in the in house training ,if it is found that
specialized or external training is required it can be arranged
Some types of training cant be conducted with in your site due to the non
availability of equipment
Normally specialized training programme conduct by external faculty or
third party organization
Some types of specialized training are given below
Safe erection and dismantling of scaffolding
Safe operation of cranes
Basic first aid

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Basic fire fighting

Risk assessment

SAFETY TRAINING BY PRIVATE CONSULTANT AGENCIES :-

Scaffolding erection dismantling training can be given at the consultants

training centre
Various calculation of crane lifting gears and scaffolding can be given
by consultants
Different types of sling various sling method shall be given at the training
centre
TPI by competent authority and legal requirements of testing cranes and
lifting gears training also can be given
Basic first aid training can be given by ST.JOHNS
Fire extinguisher ,fire tender and pump house operation training can be
given by TNFA
Risk management technical such as HAZAP,JSA ,HIRA,ETA.FTA
,etctraining also can be conducted by external
ISO-9001,ISO-14001,OHSAS-18001 ,standards and certification
procedure training can be given by certification bodies

ROLE OF GOVERNMENT AGENCIES IN SAFETY TRAINING :-

CIF ,DYCIF ,inspector of construction can conduct training on factories

act 1948 the BOCW ACT 1996 AND the legal compliances of the acts
The above authorities can also conducted training on accident reporting
and accident investigation procedure
DGFFALI trained experts can conduct specialized training on cranes
lifting gears and testing of SMPVS etc..
Basic fire fighting DYCIF operation procedures can be given by
TNFSRS
Air ,water ,land ,pollution regulations and penalties for violation
information can be given by TNBCB training

OJT ON THE JOP TRAINING:-

It is a training methods of teaching additional skills required by a new

employee or to do

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The training is normally given by the first line supervisor of a particular

This training is normally conducted by first line supervisor or a specialist
The important advantage of this training of is that the starts immediately
before the worker starts the job, there by preventing the worker from
training wrong methods

The OJT has get two phase:-

Introduction training
Job instruction

INDRODUCTION TRAINING :-

Introductory training mainly concentrates in making the new worker

familiar with has new work area
This phase has got the following step
Enquiring the workers experiences and background
Discussing the wages and work hours
Location of company facilities such as wash room ,lock room ,first aid
canteen etc
Company policy
Safety regulation company benefits
Plant visit
Introducing the new worker to his fellow or coo-worker
Job instruction safety technical usually executed in four step
Tell the trainee how to do the job ?
Show the trainee how to do the job?
Lead the trainee try to do the job?
Check the trainee temporary whether he capable of doing the job before
allowing him to work independent

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SAFETY SIGNS & SYMBOLS:-

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Displaying of safety instruction ,sing symbol at the relevant and

permanent place of the construction site and worker camp is one of the
legal requirement
In addition to the will increase the safety awareness among the workers
The main advantages of the safety sing are is it to identify the hazards
diamond and the types of hazards in a work place
It gives warning against danger and gives instruction to avoid UAS&
UCS
It shows the need to wear PPE
It informs what to do & how to do in case of emergency
It shows the location where the first aid the fire fighting equipment are
provide

TRAINING PROGRAMMES:-

Notes refer to OJT,PEP,INHOUSE TRAINING ,TBT

SAFETY SAMINOR:-

Notes refer to in house training for worker / engineers external specialized

training

CONFERENCE:-
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Notes refer to in house training for worker/ engineer

COMPETENTION:-

Notes refer to safety slogan ,safety quiz , best safety worker .best safety
supervisor of your of promoting safety poster TBM,TBT,OJT

RE TRAINOING:

At the end of each training process the trainers are evaluator through spot
the hazards verbal question answer and MCQ methods etc..more format
given (attach the format)
The trainer whos performance are well about to the minimum
requirement are given advance training in the work area
The performance of the trainers which are below the minimum
requirement are consist for the retraining to improve the safety standards
Various safety training is which can used for the retraining are-charts
,diagram posters ,slide films models and the job itself

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SAFETY TRAINING EVALUATION OF TRAINEES

Name of the Training Programme: In-House training on PPE

Conducted by:
Company Name SOMA Chennai Metro Rail Limited (CMRL)

Trainee Evaluation Form # D-01

Name of the Trainee: Employment #
Department/Section Date of Training
Marks Maximum:20 Secured:

SECTION: A TRUE/FALSE

FALSE TRUE

1) You insert cotton into your ears in a high noise area.

2) Helmet protects you from falling and flying objects

3) Making holes in the helmets give good ventilation.

4) Use chemical goggles while unloading liquid chemicals.

5) Sun glasses give good protection during grinding operation

SECTION: B MCQ (Multiple choice questions)

6) At 20 ppm H2S concentration in the work place use _____ PPE

a) Dust mask
b) Chemical canister
c) Chemical cartridge
d) None of the above

7) Name the colour of the Chlorine canister

a) Blue
b) Red
112 c) Yellow
d) Green
 PSM MANUAL 2015

MOTIVATIVATION:

ABRAGAM MASLOS need hierarchy theory

Abragam maslos proposed the theory of motivation in turns of need
stratification
He proposed that people are continuously in the motivation stage
stimulated by the needs
He explained that human being at shall them reach a state of completed
stratification except for a short time as one need become satisfied
another one raises to take It place
This never ending sequence procedure a hierarchy of needs are
1. A basic need water ,food ,shelter,

2.Security /safety need job security

3.social need affection acceptance friendship

4.exrime need states recognition appreciation ,salary,

promotion etc.

By satisfying this needs by salary, increases, promotion pones external

training etc.we can motivated the worker

BENEFITS OF MOTIVATION:

Dedication to work
Loyalty to organisation
Voluntary conformance to rules regulation and order
High degree of interest in the job
Team sprit

THE RESULTS ARE :

Higher level of productivity without accident

Greater confidence &security
Low absenteeism
Improve the mental health and since of well being

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Freedom from stress and tension

Enhanced efficiency

SAFETY BLUDGE(NSC)

SAFETY AND HEALTH BLUDGE:

on this day , I solemnly or sincerely affirm that I will detected .my self to the
causes of safety ,health and production environment and will do my best to
observe rules ,regulation &procedure develop the attitudes and hap pits
conduced or favourable for achieving this objectives

I fully realised that accidents and diseases are a trine of the national economy
and may lead to disablements deaths ,harm to health & damage to property
,social suffering and general degradation of environment

I will do every think possible for the prevention of accidents and occupational
diseases and protection of environments in the interest of self ,family,
community ,organization and the nation at large

NATIONAL SAFETY WEEK CELEPRATION

Date ACTIVITY DURATION BUDGETS

RS

4,march Safety week inaugural

function
2015
Display pannier distribute
bags
3000
9to11 am
Invite MD as chief guest

NSC flag hoisting by MD

Safety pledge by all L&T site

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4 march personal
2015
Declare safety week activity
by MD

Display OH&S policy in

contractor office

Sweet distribute to all

employees

Invite customer as a 1000

chief guest organise the
4 to 6pm
OJT on talk .
Person moments or gift

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Organise safety posters

and safety slogan
5 March 9 -10.30am
competition
2015
1000
OJT on hot work gas
cutting 4-6pm

6 march
Organise ERP mock drill on
2015
any of the following topics
12-3pm
fire ,gas leakage, collapse of
structure, snake pit and 500
medical emergence

Visit to labour camp along

with site in charge of
contractor L&T 5-6pm

7 march
2015 Organise training on trigging
plan ,accident prevention
programme ,elimination of 10-7am
hazards 500

Training on civil work safety

4-5pm

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8 march Organise training or JSA 10-11am

2015 and legal requirement
500
Collect the suggestion
from site personal for
displaying safety signs 4-5pm
Training on road safety for
drivers
10-11am
9 march Training for winch operation
500
2015 and supervisor
4-5pm

Closing ceremony by project

manager
10 march
2015 Awards to winners safety quiz
,safety posters ,safety slogan
,competition etc

Best worker best steward, best

supervisor of the year issue 10-11 am 4000
awards

Sweets distribute to All

workers 20 Rs per head

Total amount
10000

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Safety officer sign project manager sing safety manager sign

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