COST OF ACCIDENTS

Industrial accidents – accident costs – identification of

accident spots; remedial
measures; identification and analysis of causes of INDIRECT LOSSES
injury to men and machines –
1. IDLE MAN POWER
accident prevention – accident proneness – vocational
guidance, fault free 2. INVESTIGATION
analysis. Fire prevention and fire protection. 3. FOLLOW-UP
4. PUBLIC RELATION
5. COMPANY IMAGE
DIRECT LOSSES 6. MORAL
7. SOCIAL
1.PRODUCTION LOSS
8. INSURANCE CLAIM
1. DAMAGE TO PLANT &
9. INVENTORY COST
MACHINERY
10. TRADE UNIONS
2. RAWMATERIALS, FINISHED
11. GOVERNMENT
GOODS ETC. LOSS
12. POLITICIANS
3. OTHER ASSETS DAMAGED
13. PUBLIC
4. MAN-DAYS LOST
5. MEDICAL COST Dr.V.Jaikumar, SSNCE
SAFETY
Freedom of not accepting risk of harm.

Elimination/control of occupational diseases, accidents

and thus subsequent losses to

People
Equipment
Materials
Environment

PEME

Dr.V.Jaikumar, SSNCE
 KEY DEFINITIONS….continued
HAZARD
Source or Situation with a potential for harm in
terms of Human Injury, ill health, Damage to
Property, Damage to the Workplace Environment
or a combination of these.

LOSS TO PEME
Dr.V.Jaikumar, SSNCE
 KEY DEFINITIONS….continued
RISK

Combination of the Likelihood and Consequences

of a specified hazardous event occurring.
Dr.V.Jaikumar, SSNCE
 RISK ASSESSMENT

Overall Process of estimating the magnitude of

risk and deciding whether or not the risk is
tolerable.
Dr.V.Jaikumar, SSNCE
Risk Assessment and Control
Activity Hazard Risk Severity Occurren Control
ce
Maintenance Bursting Injury to Harmful Highly Issue of
of battery of battery man and unlikely proper Work
truck due to gas loss of Instruction
cutting property (WI)
operation
in shop

Dr.V.Jaikumar, SSNCE
Risk Assessment and Control
Activity Hazard Risk Severity Occurre Control
nce
Operation of Breakage Injury to Harmful Highly 1. Periodic testing
crane of man and Unlikely of the lifting
chain/wire Material devices.
rope 2. Maintenance of
a register for the
same.

Dr.V.Jaikumar, SSNCE
Risk Assessment and Control
Activity Hazard Risk Severity Occurre Control
nce
Material Slipping of Injury to Harmful Unlikely Issue of proper
shifting with vehicle due man/ WI and regular
the help of to wet/oily damage to cleaning of
fork floor material floor/path way
lift/Lister

Dr.V.Jaikumar, SSNCE
Dr.V.Jaikumar, SSNCE
ROLE OF THE MANAGEMENT:
 Commitment
 Vision
 Resource Availability
 Information
 Communication
 Motivation
 Support
(Moral,Financial,Organizational)
 Training
 Skills(Conceptual,Human
Dr.V.Jaikumar, SSNCE
Relations)
ANECDOTE:

For safe and efficient

running of a system;
organizational discipline is
more important than
technical prowess.
Dr.V.Jaikumar, SSNCE
 GENERAL SAFETY

IN

CARRIAGE REPAIR WORKSHOPS

Dr.V.Jaikumar, SSNCE
SAFETY IN MACHINE SHOP
Dr.V.Jaikumar, SSNCE
 Use of industrial shoes.
 Use of aprons.
 Use of goggles.
 Use of hand gloves.
 Safe moving in between the
machines.
 Machinery covered/guards on
machines.
Dr.V.Jaikumar, SSNCE
 Proper stacking/storing of materials.
 Nominated areas for scrap.
 Proper cleaning of shop floor for non-
accumulation of water, grease, oil,
other liquid substances.
 Using of cranes/EOTs/fork lifts for
hoisting heavy materials.
 Using of pallet trucks.
Dr.V.Jaikumar, SSNCE
 SAFETY
IN
CARRIAGE FITTING SHOP
(LIFTING & BOGIE SHOP)

Dr.V.Jaikumar, SSNCE
 Use of goggles for grinding.
 Use of full welding shields while
welding.
 Floor area should be cleaned daily
with proper care.
 Signaling during movement of EOT
while movement of coach body from
one place to another.
Dr.V.Jaikumar, SSNCE
 J-Hooks to be checked thoroughly
before using as a daily practice & to
be tested in regular interval.
 Use of water shoes while washing the
bogies by water properly.
 Use of compressed air in proper
manner.

Dr.V.Jaikumar, SSNCE
 Tracks inside the shop floor for
movement of bogies/coaches to be
thoroughly cleaned daily.
 Proper lighting during night working by
providing portable stand lights.
 Storage / disposition of waste material
in a proper manner.
 Heavy machineries are to be properly
guarded. Dr.V.Jaikumar, SSNCE
 SAFETY
IN
WHEEL SHOP
Dr.V.Jaikumar, SSNCE
 Floor should be free from grease
/oil/water.
 Grease drums to be properly
stored/disbursed.
 Using of proper tools & equipment.
 Heavy machines should be guarded
properly.
 Necessary tactics should be used for
handling axles, wheels, discs, bearing
etc. Dr.V.Jaikumar, SSNCE
 Industrial shoes should be provided.
 Goggles for welders/grinders.
 New wheel discs to be stored with
proper manner.
 Axles are to be properly stacked with
proper packing for not rolling.
 Using of pallets for movement of
small but heavy materials.
Dr.V.Jaikumar, SSNCE
 SAFETY
IN
ELECTRICAL SHOPS
Dr.V.Jaikumar, SSNCE
 Shop floor should be cleaned daily.
 Using of proper aprons/hand
gloves while working on live line.
 Using of nose masks whilst in
battery charging section.
 Charging section is to be properly
ventilated.

Dr.V.Jaikumar, SSNCE
 Using of safety shoes in the battery
charging section.
 Regular medical check up for battery
charging staff.
 Electrical connections are to be
properly insulated.
 Extensions for power cables/wire
should have proper joints.
Dr.V.Jaikumar, SSNCE
SAFETY IN CBR SHOP
Dr.V.Jaikumar, SSNCE
 Shop floor should be kept properly
cleaned.
 Waste materials should be properly
disposed off to their nominated
place.
 Path ways between coaches, kept
for attention, should be free from
waste materials.
 Materials should be properly
stacked.Dr.V.Jaikumar, SSNCE
 Safety precaution should be taken for
chemical fire during adhesive
application on coach floorings.
 While manufacturing, proper
jigs/fixture should be used.
 Extension cable for welding should
be properly insulated with proper
joining devices.
 PPEs should be provided to all.
Dr.V.Jaikumar, SSNCE
SAFETY IN PAINT SHOP

Dr.V.Jaikumar, SSNCE
 Nose masks are to be used during
spray painting.
 Paint shop to be well ventilated.
 Regular medical check up should
be undertaken for the staff doing
spray painting work.
 During spray painting, the
concerned areas should be kept
traffic free.
Dr.V.Jaikumar, SSNCE
 Coaches after painting should be
kept aside for drying.
 Aprons should be provided to the
staff.
 Paint shop store should be provided
with tested fire extinguishers.

Dr.V.Jaikumar, SSNCE
GENERAL SHOP SAFETY
Dr.V.Jaikumar, SSNCE
• Fire hydrants should be provided
at nominated places inside the
shop floor.
• Fire accident attending squad
should be formed and kept
ready for any unwanted fire
accidents.
• Fire service vehicle should be
kept ready always with full
equipments.
Dr.V.Jaikumar, SSNCE
• Nominated staff should be
properly trained from time to time.
• Time to time refresher training
should be arranged.
• Safety seminars should be
arranged with regular intervals.
• PPEs should be kept ready all the
time.
• Industrial safety shoes should be
provided to all.
Dr.V.Jaikumar, SSNCE
• Cotton dresses should be provided
with helmets to all staff.
• Safety cell to be activated under
the supervisors of safety office
with proper assistance.
• Safety banners/routers are to be
pasted/hanged at all distinctive
places for awareness.

Dr.V.Jaikumar, SSNCE
• Static safety cell to be properly
coordinated for their help during
mishaps, specifically during fire
accidents.
• All fire service stations are to be
well connected both with the road
and with telephonic information
with numbers.

Dr.V.Jaikumar, SSNCE
• Inspector of factories of the state
concerned should be requested
from time to time to visit the
factory for compliance of any
drawbacks.
• Feed back for any suggestions
from the staff should be a regular
practice.

Dr.V.Jaikumar, SSNCE
• After any accident (may be fire or
any other type), review should be
made to avoid future accidents.
• Accidents are to be attended
wisely, without panicky, in order to
minimize the damages.
• Records should be kept for
provision of safety equipments.
Dr.V.Jaikumar, SSNCE
THE TRAINED &
ALERT WORKER

IS SAFER
IN AN
UNSAFE CONDITION

Dr.V.Jaikumar, SSNCE
UNTRAINED
&
UNALERT
WORKER

IS UNSAFE
IN A
SAFE CONDITION

Dr.V.Jaikumar, SSNCE
THE FOOTNOTE

Dr.V.Jaikumar, SSNCE
THINK SIMPLE
BE ACCURATE
REMAIN SAFE
Dr.V.Jaikumar, SSNCE
Dr.V.Jaikumar, SSNCE