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

Stage 2 : Safety Zone Mapping :

All the Zones are categories into three categories (Red, Yellow, 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:

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.

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