Case Studies

A Success Story on Achieving Zero Hazards in Manufacturing Industry

 

Kavach

Safety Practice Implementation (ISO 45001:2018)

 

Case Introduction :

The client is a leading manufacturing company in Gujarat has been reporting frequent Fatal and Major accidents almost every quarter. The management wanted real implementation of Best Safety Practices in line with ISO 45001: 2018.

Tetrahedron conducted the preliminary Safety Audit and charted a six-month project to see through the ground-level implementation with total employee engagement and sustenance of Best Practices.

 

Approach Detail

Stage 1: Organisation Development and Safety KPI Finalisation :

A dedicated core team consisting of Client Dept Heads and Tetrahedron Industrial Safety Expert was formed and the Role and Responsibilities, Managing Points (MPs) and Checking Points (CPs) of each individual were finalized and signed off.

Total 29 Safety KPIs were developed for Overall Organisation like

1. Number of Reported Accidents & Incidents 11. Lost time (in hours) due to non-fatal accidents 21. % of health and safety representatives (HSR) positions filled
2. Lost Time Injury Frequency Rate 12. Number of fatalities per e.g. 100,000 hours worked 22. % of issues raised by H&S Reps actioned
3. Lost Time Injury Incidence Rate 13. Number of non-conformance with legal or internal standards 23. Percentage of OHS committee recommendations implemented
4. Monthly Health and Safety Prevention Costs 14. Number of reportable accidents 24. Total of hours in safety and health training in the month
5. Productive Days % 15. Number of reportable non-fatal accidents 25. Reporting of near misses
6. % of Management Trained in Health & Safety 16. Number of safety inspections for the month 26. Number of safety meetings and toolbox talks attended
7. Average Time to Resolution of Risks & Issues 17. Number of solved safety non-conformance for the month 27. Number of training courses completed
8. Cost of solved safety non-conformances for the month 18. % of attendance at OHS committee meetings 28. Number of inspections conducted and submitted
9. Health and safety prevention costs within the month 19. % of corrective actions closed out within specified time-frame 29. Number of closed out corrective actions
10. Lost time due to accidents (including fatalities) 20. % of fatal accidents relative to all accidents per    

Stage 2 : Safety Zone Mapping :

All the Zones are categories into three categories (RedYellow, and Green) based on Severity (For People, Environment & Asset), and Probability (Chances of Incidence).

Stage 3: SOP Development for Safety KPIs Measurement :

SOPs for monitoring all KPIs and Safety Performance was finalized.

Some Important KPIs calculation is

LTIFR ( Lost Time Injury Frequency Rate)= No of lost time injuries X 1000000) /Man-hour per year

LMHCIR (Lost Man hours case Incident Rate)= Sum of (lost time injury X man hour loss) * 1000000/ Total number of hours worked in an organization

Stage 4: Safety Training to All Employees :

Training is an integral part of ISO 45001: 2018. Tetrahedron developed 50+ Safety Training Modules for all employees.

List of Training:

Office Safety And Health Personal Protective Equipment Vehicular Operations Violence In The Workplace
Walking-Working Surfaces Hazard Communication Control Of Hazardous Energy Sources (LOTO) Permit Required Confined Spaces
First Aid And Cardiopulmonary Resuscitation Hearing Conservation Program Fall Protection Respiratory Protection
Ergonomics Electrical Safety Protection During Incident Investigation Road Safety
Permit To Work System Tools & Equipment’s Safety Machine Guarding Carbon Monoxide Gas
Hot Metal & Fire Safety Assembly Point No Drug & Alcohol Emergency Preparedness Plan
General Safety Fire Fighting HIRA Site Emergency Plan
Reporting & Investigation SAFETY” & “HIRA Safety Awareness Tools & Tackles
Heavy Vehicles EOT Cranes Operation General Safety Awareness Safety – LOTO

Stage 5 : Hazard Identification & Risk Assessment (HIRA) Analysis : 

Hazard Identification & Risk Assessment(HIRA) is a proactive safety tool which facilitate workmen to visualize the hidden hazards, potential incidents, risk assessment of the top events and implementation of effective countermeasures. It makes the workplace safe and operations as safe as possible and to keep employees from being harmed

The Major Benefit by HIRA was 

– Employee recognized Workplace Hazards

– Started working on TMS HIRA template

– 1500 workplace Hazards Identified

– 2000 potential incident (Top Event) visualized and countermeasure implemented

Stage 6: Accidents Reporting & Investigation : 

The accident is any unplanned event that results in injury/ill health to people or damages. Equipment/property/material or causes interruption of work.

Accident Reporting means systematic communication of accidents and victim details with the work supervisor and safety team along with the record-keeping and analysis.

Accident Investigation means to identify the root cause of the accident, identifying the hazard caused injury and prevent its future occurrence through effective corrective and preventive action implementation

Stage 7: Near Miss Reporting & Investigation :

Near Miss: These are dangerous occurrence which fortunately did not result in an injury but could have resulted in one.

Near miss, Reporting means systematic communication of near-miss with the work supervisor and safety team along with the record keeping and analysis.

Near miss Investigation means to identify the root cause of the near-miss incident, identifying the hazard caused near-miss and prevent its future occurrence through effective corrective and preventive action implementation.

On an Average 50 Near Miss Reported on Monthly Basis and respective CAPA were developed and implemented.

Stage 8 : Lock-Out & Tag-Out (LOTO) :

Machine Connected to an energy source or containing residual or stored energy are the cause of potential hazard.

Lockout: The use of a padlock to lock the controls to an energy source in an “OFF” or “de-energized” position.

Tagout : The use of an identification tag placed on the padlock identifying the person working on the equipment and warning others not to start up the equipment.

-Prepare for shutdown

-Notify Others

-Shutdown Equipment

-Isolate Equipment

-Install Locks and Tags

-Verify stored energy is shut-down

-Verify Equipment Isolation

-Perform Servicing

-Release from LOTO

Employee Started Identifying average 100 LOTO opportunity and total 272 LOTO Opportunity Implemented
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