CHALLENGES IN BUILDING

TECHNOLOGICAL & MANAGERIAL

COMPETENCE IN SAFETY
ENGINEERING & PRACTICES

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1. What is R&D Task?
2. How “ Industrial Safety” is different from “Explosive Safety”.
3. Duties of Safety Professionals:
(i) To increase management enthusiasm and commitment.
(ii) To provide latest in thinking and practice in the form of useful
tools and application.
(iii) To provide management with meaningful “Before the fact”
measures for prevention.
(iv) To demonstrate supportive value to the programme/project.
(v) To suggest measures to control accidents.
(v) To assist management in their planning action particularly in
upgradation of existing facilities and creation of new infrastructure.
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4. Beginning and development of Safety Movement.
5. Safety – Safety is a field of Science and Engineering as well as management.
Experience shows 70 % improvement are due to optimizing management systems and
only 30 % from materials and machines.
6. Safety Management Stages:
(i) Aptitudinal behaviour study of the people managing the task.
(ii) Safety Analysis of the tasks/activities.
(iii) Provisioning of safety features to critical activities/stages/
components.
(iv) Safety inspection (disaster plan-mock drills)
(v) Record keeping- indicating seriousness (critical, major, minor).
(vi) Equipment safety provisioning of at the stage of spec making.
(vii) Granting deviations for limited period with conditions to initiate
suitable measures to avoid such deviations in future.
7. Safety management and Auditing:
(i) Getting defined management techniques and auditing procedures and
issuing documents to all lab/establishments.

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 (ii) Sensing extent of safety feeling developed with
(a) top management (b) middle ranks (c) staff levels
(iii) Auditing their documents.
(iv) Identifying critical/serious deviations and suggesting solutions
for immediate use and planning for permanent solutions.
8. Material handling devices.
9. Storage of stores/chemicals being handled viz. raw materials (metal powers,
oxidizers, liq substances, flammable substances, propellants, explosives,
explosive experimental samples, final products pending for proof, quality cleared
products etc.)
10. Creation/planning of proper infrastructure in anticipation of present as well as
future tasks:
“Infrastructure created is an asset not a liability.
(i) Do not congest the facilities.
(ii) Segregate the tasks/tests and create separate facilities for each
(viz. avoid static testing of small and big motors on the same test bed, avoid
acceptable/defective stores in the same store, etc)
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 (iii) Proper provisioning of Personal Protective Equipment.
(iv) Ergonomics analysis on the job.
(v) Occupational Health and Work Environment.
11. Accident reporting.
12. Disaster management – Generating a model, auditing periodically.
13. R&D in certain areas of safety concern viz. storage structure,
transportation, PPE, automation, packaging, Life assessment of the products
involved, newer fire extinguishants – more effective and less toxic.
14. Safety Literature.
15. Training.
16. Aiming to reach to the goal of achieving a status of “Safety professional”
with professional competence, technical competence Aptitude/attitudinal
competence and having regard to the task for which safety suggestion is
being made.
17. Safety rating of the establishment/lab.

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18 (a) Safety :

- A thought revolution in management

- Problem is an opportunity for improvement

- Thought revolution – focus on planning and procedures / process instead

of records and results only.

- Higher the safety level, better would be productivity (better quality of life/
better civilization).

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(b) Phases of Order of Widening Perspective :
Traditional Safety Measures
(Safety tools / appliances)

-do- + Good House Keeping

-do- + -do- + Safe Guards / Remote operation
-do- + -do- + -do- + Safety Engineering

Basic aim is “Safety Improvement”

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(c) Safety Engineering :
Safety Engineering is most essential safety appliances / tools
supplement it.

Desirable

Effort
level to
put in Traditional

Process/ Design Manufacture Problem

Product Engineering, Solving
Dev Basic Research
Effort of Activities
Basic research Newer Technology New Product
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(d) Absolute Safety : 100 % safety
- It is a concept – on par with “ Zero Defect Level”

Desired Safety - It is a compromise between the affordable resources

which can be made available for the work and the risk involved.

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(e) One of the ways to check the safety performance :
- to look out at the repair shop
- waste materials
- broken tools
- treatment of individuals in MI Rooms

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(f) Start concentrating on following issues :

- Design safety ( product design), process upgradation.

- Use of proper appliances / toolings and upgrading them.
- Creation of infrastructures / upgrading them.
- Proper awareness / training.
- Proper supervision / monitoring / auditing.
- Upgrading of regulations / standards.
- Deviation reporting, reducing.
- Participation in planning actions of the establishment.
- Improving communication / literature /records/updates/
inter-establishment visits /courses
- Be a concerned partner of the organisation / lab in achieving their goal
rather than an enforcement authority of the regulatory body.
- Over the years, there is dilution in work ethics and principles in most
the places, inertia of the mindset is set in. Change it by collective
efforts, be a model for others across the country.

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19. How to bring Quality in Safety Management
(i) Customer (User labs) focus
(a) Understand current and future customer needs.
(b) Strive to exceed customer expectations.
(ii) Professional leadership
Leaders at every level are those who can energize, excite and inspire
rather than control, depress and enervate (deprive of vigour).

Leaders should create an overall environment in which people are

fully involved in achieving the objectives. People must have the right
professional skills to perform job effectively.
(iii) System Approach to Management
(a) Who is responsible for the activity of day to day?
(b) Who is responsible for measurement and monitoring of
the activities?
(iv) Continual Improvement
Continual Improvement of the organization or a person should be a
permanent objective. It must be assessed yearly basis.

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(v) Ability to Adjust
Assess the work in order of importance and urgency vis-à-vis any
“Deviation” from safety angle. Be prepared to be flexible depending
on the circumstances in its implementation.
(vi) Learn new skills and learn to communicate effectively to avoid
waste of time and be prompt in your response.
(vii) To have strategy :
(a) To bring change in the behavioural and cultural forces.
(b) Time is the strategic weapon. To-days challenge lies in
compressing time. Incorporate speed into every activity/
process.

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20. For Young Safety Professionals :
-Do not be a “Passive Follower”
-Have a “high ambition”
-Have models/ideals to derive inspiration
-Give thrust to yourself
-Learn to work in team
-Have positive attitude
-Adopt “Change”
-R&D is managing “uncertainty” i.e., change management
-Pay more attention to transform individuals as Professionals/Leaders,
adopt Creative Leadership norms.
-Basic research-technology-products-power/wealth
-Enhancing / updating professionalism and infrastructure.

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 QUANTITATIVE ASSESSMENT OF PERFORMANCE OF LAB/ESTAB

S. Safety Parameters Weightage Scale of Marks Obtained

No. Marking (0-10) (III) = (IxII)/10
(I) (II) (III)
1. Ist STAGE CHECKS (35%)

(i) Incorporation of essential

features at design stage (5%)

Design safety/built-in-safety, 5% 8 (5X8)/10=4

materials safety, preparation
of “safety certificate” for compositions
to be handled.

(ii) Safety awareness initiatives (7%)

a. Training/lecture, consultancies in 3%
identification and evaluation of risk
levels.
b. Safety Literature (Internet, 3%
patents, Journals etc.)
c. Observation of Safety day/ week- 1%
by lab as well as div./ groups 15
S. Safety Parameters Weightage Scale of Marks obtained
No.
Marking (0-10) (III) = (IxII)/10
(I) (II) (III)

(iii) Safety management (20%)

a. Existence of safety policy, 2%
conduct of safety meetings and
implementation of follow up actions.
b. Process buildings operating
without deviation. 2%
c. Effort for vacation of deviation, if 2%
any (action taken with activity
wise time schedule).
d. Fire drill (by working personnel in 2%
presence of Fire men/supervisor)
frequency.
e. Emergency plan. 2%
f. No. of accident/incident occurred 2%
during the year and remedial action.
g. Siting of ESH, if any. 2%
h. Planning action for procurement of 16
PPE, safety gadgets 2%
S. Safety Parameters Weightage Scale of Marks obtained
No.
Marking (0-10) (III) = (IxII)/10
(I) (II) (III)

I. Preparation of GSD/SOP 2%
its updating. Maintenance
of log books.
j. Maintenance/certification/ 2%
calibration (periodically) of
equipment.

(iv) Information to be made

available (3%).

a. No. of Storage buildings 1.5%

with explosive limit.
b. No. of Process buildings & 1.5%
others with explosive limit.
Sub total: 35%
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S. Safety Parameters Weightage Scale of Marks obtained
No. Marking (0-10) (III) = (IxII)/10
(I) (II) (III)

2. PHASE-II : SAFETY CHECK

OF PROCESS/STORAGE
BUILDINGS (60%)

(I) Checking of Fixed

installations. (17%)
a. Electrical Fitments. 1%
b. Marking of display 1%
boards, Fire symbol & limit
boards etc.
c. Availability of proper 1%
material handling
equipments.
d. Display of building 1%
number .

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S. Safety Parameters Weightage Scale of Marks Obtained
No. Marking (0-10) (III) = II)/10
(I) (II) (III)

e.Checking display of 1%
Fire Classification Boards
at prominent positions.

f. Checking of lightning 1%
protection systems
and its maintenance record.

g. Checking condition of 2%
transverse, growth of
trees, grass, shrubs
firebreak etc.

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S. Safety Parameters Weightage Scale of Marks obtained
No. Marrking (0-10) (III) = II)/10
(I) (II) (III)

h. Checking condition of 2%
transverse, growth of
trees, grass, shrubs
firebreak etc.

i. Checking of explosive 1%
limit board.

j. Checking of personal 1%
tester

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S. Safety Parameters Weightage Scale of Marks obtained
No. Marking (0-10) (III) = II)/10
(I) (II) (III)

k. Checking clean area 1%

condition in the buildings.

l. Checking doors are 1%

opening outside and
wire net provided to the
ventilators.

m. Checking condition of 1%
of lighting fittings.
Ensure that the wiring
is through conduits &
switches are located
outside. 21
S. Safety Parameters Weightage Scale of Marks obtained
No. Marking (0-10) (III) = II)/10
(I) (II) (III)

n. Checking of first aid fire- 1%

fighting equipment

o. Checking of fire hydrants. 1%

Ensure that fire hydrant is
approachable.

p. Checking of the static water tank. 1%

q. Checking of electrical earthin 1%

pits, easy approachability.

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S. Safety Parameters Weightage Scale of Marks obtained
No. Marking (0-10) (III) = II)/10
(I) (II) (III)

(ii) Process Checks (10%)

a. Inclusion of Process equipment 2%

safety clause in specification
while procurement.
b. Task & Safety briefing of 2%
personnel before operation.
c. Deviation Records. 2%
d. Check for safety equipments. 2%
e. Check of GSD/SI has been 2%
displayed in the buildings &
whether they are approved
ones and matching with the
work being carried out.

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S. Safety Parameters Weightage Scale of Marks obtained
No. Marking (0-10) (III) = II)/10
(I) (II) (III)

(iii) Check of Process/Storage

Buildings (30%)

a. Adherence to safety practices, 3%

regulation/acts. Use of safety
gadgets and safety gear by
personnel.
b. Disposal of explosives. 3%
c. House keeping. 3%
d. Observation of explosive limits. 3%
e. Observation of man limit. 3%
f. Status of Labyrinth. 3%
g. Checking of compatibility group. 3%
h. Whether the general layout in 3%
process buildings and distribution
of explosives inside can be
improved. After inspecting
the building also use your 24
S. Safety Parameters Weightage Scale of Marks obtained
No. Marking (0-10) (III) = II)/10
(I) (II) (III)

judgment whether additional

safety measures can be
recommended.
i Checking of stacking, dunnage 30%
dunnage and bin cards in
process buildings. Clearance of
stacks from the walls, verifying that
only serviceable items are being
stored & unserviceable or non
explosive items are not being
stored along with explosives.

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S. Safety Parameters Weightage Scale of Marks obtained
No. Marking (0-10) (III) = II)/10
(I) (II) (III)

j. Checking that there are no 3%

overhead electric line upto a
distance of 15 metres from the
building & no overhead telephone
connections.

(iv) Transportation of Explosive (3%)

a. Within Process/Storage Building. 1%

b. Within complex. 1%
c. From Establishment to another 1%
Establishment.

Sub total 60%

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S. Safety Parameters Weightage Scale of Marks obtained
No. Marking (0-10) (III) = II)/10
(I) (II) (III)

3. PHASE III : ACTIVITY (5%)

a. Discussion on salient 2%
observation made during
checks/audit.

b. No. of buildings checked. 0.50%

c. No. of deviation cases noticed. 0.50%

d. Follow up of previous audit 2%

observations.

Sub total 5%

GRAND TOTAL 100% 27

S. Safety Parameters Weightage Scale of Marks obtained
No. Marking (0-10) (III) = II)/10
(I) (II) (III)

NOTE : This assessment may be used for “Ranking/Rating of

the Lab on Safety Scale”

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Ranking of Establishment

Very good: > 90% Average: 60 - 69%

Good: 85 – 89% Below average: 50 – 59%
Fair: 80 - 84% Poor: <50%
Just Satisfactory: 70 – 79%

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 “Do not learn Safety rules simply
by the “Accidents”

“World`s longest fire can be extinguished

by pouring a cup of water at right time”

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THANK YOU

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