Industrial Safety Manegment
Industrial Safety Manegment
Industrial Safety Manegment
MANEGMENT
23108
Index
Chapter Content Page
No. No.
1.1 I ntroduction: Management Principles and Types of
Management,
1.2 Line and staff Authority, Role, Responsibility of management,.
Span of Management, Delegation and decentralization of authority.
1.3 Planning for Safety: Planning: Definition, purpose, Nature, scope
and procedure. Range of planning, Types of plans.
1.4 Management by objective ( MBO), Policy formulation and
implementation
1 1.5 Organizing for Safety : 4
Definition, need, nature and principles. Organizing for Safety, Health
and Environment Organization structure, Functions and
responsibilities.
1.6 Directing for Safety: Definition, process, principles and
techniques, Leadership: Role, functions an attributes of a good leader
1.7 Communication: Purpose, process, types and channels of
communication, process group-dynamics and Team building.
National policy on safety, health and environment at workplace
2.1 Safety, Education and Training: Element of training cycle,
training needs Assessment. Techniques of training, design and
development of training programs module, Training methods and
2 strategies types of training. Evaluation and review of training 50
programs.
2.2 Competence Building Techniques (CBT)
Role of Multi-Media, Communication, Applications of Computers
3.1 Employee Participation in Safety :
Purpose, areas of participation, methods, Role of trade union in
Safety Health and Environment Protection. Safety committee –
structure and functions, Tool box talks, safety kaizen, one point lesson
3 62
, safety Promotion and Safety Awards(National state level and unit
level ) and Suggestion Schemes, Safety Competitions, Safety
Incentives, Publicity Schemes, Audio Visual Publicity, other
Promotional Methods
Behavior Based safety ( BBS) :
4.1 Human behavior: Individual differences, Cause of behavior
changes, Behavior as function of self and situation, perception of
danger and acceptance of risk, knowledge and responsibility vis-à-vis
4 safety performance, theories of motivation and their application to 68
safety role of supervisors and safety Departments in motivation.
4.2 Conflict & Frustration: Identification of situations leading to
conflict and frustration and techniques of management
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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Chapter 1
1.1 Introduction:
Safety Management Defined : Safety management is a management who establish,
motivate and co-ordinate the safety objectives by the process of planning, organizing,
staffing, directing and controlling to achieve those objectives and also have a continual
improvement in the same.
Safety Management Principles
1. Authority and Responsibility - Authority is the right to give orders and power. Official
authority is derived from the post one holds while personal authority is given as per
intelligence, experience and knowledge one holds. Chain of authority runs from the
highest authority to the lowest rank. Responsibility means an obligation to perform duty
(task) in a satisfactory manner. Accountability give success to management System
2. Safe operating System – Indentifying the defects of operational System, monitoring of
various procedures & Controls & taking CAPA
3. MAH Control: Necessary checks & Control on unsafe Conditions which may cause
serious Accidents or Major hazards.
4. Safety Targets: Setting Safety Targets by proper planning & Control.
5. Safety Programme: Execution of Safety Management Programme for rectifying Unsafe
Act & Unsafe Conditions which are the main causes of Accidents.
6. Discipline - Discipline must work throughout an organization for smooth functioning.
Clear understanding between workers and management regarding their Safety rules,
regulations, orders.
7. Communication: Proper communication between the top management & Bottom line
regarding Objectives & Safety Systems.
8. Initiative - Employees should be given scope for initiative to prepare and execute safety
Programme planned by safety management. It helps in growth and development of man &
management.
9. Team Spirit - Instead of 'divide and rule' management should install team spirit, co-
operation and harmony among workers to make the management united and powerful.
Types of Management: Management is an integral role in any business or organization;
They have to utilize 5M resources like Man, Machine, Material, Money & Method. The
objective for the manager is PDCA and implements those resources in a way which will
achieve the best results for the company.
Different Types of Management:
Democratic management: (Lokshahi) In this style, management decisions are agreed upon
by the majority of employees, By involving the employees, management will make the right
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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
decisions and harvest new ideas from the people who are involved in the day to day business
of the company.
Autocratic Management: Here, decisions are made quickly and forcefully without
involvement from anyone else. Other people’s judgments and suggestions are usually neither
listened to nor considered.
Laissez-faire management: The Laissez-faire management will take a back seat role,
providing guidance when needed; the employees are allowed to let their own ideas and
creativity flourish in their specific areas. The manager is looked upon as more of a mentor
(main coordinator) than a leader.
Paternalistic Management: It encourages feedback from the workers to the leaders,
essentially to maintain good morale and loyalty. It is the manager who will make the final
decision, but the leader will listen to ideas and suggestions from the workers. Decisions are
usually made in the best interest of the employees and business.
Different Management Levels
Top-level Management: Top-level managers are the big bosses, Managing Director & Board
of Directors. They are responsible for overseeing and organizing the entire organization.
Middle-level Management: They are HODs & Managers answerable to the top-level
managers. The role of middle management is to execute and monitor organizational plans
handed down from the top-level managers.
Low-level Management: Low-level managers are usually responsible for general
supervision and motivation; examples of low-level managers are Supervisors, Safety
Representatives & workers. Low-level managers are accountable to the middle-level
managers.
Manager ultimately has to be flexible, certain situations call for a certain styles of
management. Each style of management has their advantages and disadvantages, sticking to
one rigid management model have disadvantages
Types of Safety Organization: There are seven types of organization: '
1. Line, military (Autocratic Management) scalar (Grade-wise authority) or vertical
organization. (Occupier-plant head-dept. head-line managers & staff-)
2. Line & staff organization. (Democratic management)
3. Functional organization. (More Importance is given to function)
4. Product organization. ( R & D is much involved )
5. Project organization. (Project separate or inside the existing Factory)
6. Matrix organization, and (MBO or MBR organization)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
6
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
(exercise) may affect the behavior of people. Distinction between authority and power can be
explained as under :
No. Authority Power
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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Authority Responsibility
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
identifying the hazard differs while crossing highway, open person may have correct
judgment of chances of accident lowing to the distance and speed of the vehicles coming
from sides different working have difference of opinion or judgment regarding hazard
arising out of moving machinery of risk from chemicals.
In danger then important think is the response time required for quick action to protect
our self or other from the danger or risk slow response time indicates more chance of
accidents and vice – versa. Safety training can help to improve ability of good perception of
danger and risk & help to minimize accidents.
BEHAVIOUR BASED SAFETY (BBS)
This is a psychological approach to improve human behavior for the purpose of reducing accidents.
Criteria and Strategies: Psychological concept of 'behavioral safety' or behavior based
safety (BBS) was studied and applied during the years 1968 to 1972 by Aubrey Daniels,
Wanda Myers and others. The research continued and studies during last 15 years showed
good results that by observing and changing behaviors of the workers (motivation), accidents
can be reduced significantly.
In Hawthorne studies (Part 8.3.1) it was found that 'behavioral approach' was giving good
results (accident reduction) than the changes in effects of working conditions like lighting,
working hours, rest interval etc. This is die base of BBS concept.
In BBS approach, 'safe behaviors’ are targeted, decided and explained to the workers.
Then performance of these behaviors is observed. It is also called performance management.
Feedback is obtained and reduction in accident rate is measured.
Sometimes a 'design team' is formed by selecting shop-floor workers including
representative of supervision and safety department.
This team decides following steps:
1. How to observe unsafe practices or acts and to design observation criteria for this.
2. Coaching process to give brief guidelines to improve safety -behaviors to eliminate or reduce
those unsafe acts.
3. Plan to use data of observations regarding unsafe acts.
4. Plan to support the process of improvement (motivation for target).
5. Plan training if still required.
6. Plan for maintaining the process.
Thus by such systemic planning, behavioral psychology is used to promote safety at work.
BBS approach proceeds as under:
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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
1. Observing unsafe behaviors or acts of the workers in the organization and collecting then
data.
2. Defining a set of model behaviors to reduce the unsafe acts..
3. To give short duration training to workers regarding their unsafe acts, management
observations and explaining safe (model) behaviors.
4. Observing new (improved) behaviors and recording their consistency and frequency.
5. Getting feedback and supporting new behaviors.
6. Data collected is used for recognition, problem solving and continuous improvement.
Management Techniques: Management control for implementing above
BBS concept includes following techniques:
1. Design team of selected workers to record observations, develop support materials and
provide training.
2. Identify elements or targets and decide steps to focus on each of them.
3. Organize a full day meeting instead of one or two hours meeting to plan the process after
full discussion.
4. Design own steps instead of copying the same from other companies.
5. Do not waste time to complete training of all the workers. Start implementation after
training some 20% workers and continue training for others. Thus the time cycle will
begin soon to observe the result.
6. Avoid unnecessary training of team members. Those who are already trained need not
require training.
Planning for Safety: Planning is the most fundamental and the first function or element of
management process. Other functions rest on it- Need for planning is increasing because of
changes in technology, materials, methods, processes, demands, law, government policy,
procedure and competition.
Definitions of General Planning :
1.Henry Fayol - Planning refers to a preview of future activities.
2.UrWick - It is fundamentally a mental predisposition to do things in an orderly way, to
think before acting and to act in the light of facts rather than of guesses.
3.Haynes & Massie - Planning is that function of manager in which he decides in advance
what he will do. It is a decision making process of a special kind, its essence is futurity.
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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Purpose (Areas) of Safety Planning: It includes all above 17 aspects with reference to
health and safety of workers and public, safety of plant and surrounding environment, and
prevention of total losses. Some subjects of safety planning are given below.
1. To draft health and safety policy and environmental policy for the management.
2. To decide safety committee, its objectives and effective functioning.
3. To decide safety targets like zero/minimum accidents, maximum working hours
without accident, safety education, training and awareness programmes for the
workers and the public.
4. Areas of hazards and their detection, inspection, audit, risk assessment and measures
for their removal or minimization.
5. Accidents investigation, analysis, costs calculation and introducing safety measures to
prevent their recurrence.
6. Organization structure, staff, key persons and their roles for safety.
7. Standards for safety equipment, tools, permissible exposures etc.
8. Preparation, rehearsal and updating of on-site emergency plans.
9. Details of safe or standard operating procedures (SOP), close-down procedures,
methods, fire fighting procedures, emergency preparedness, first-aid etc.
10. Testing, inspection and records of lifting machines, pressure vessels, ventilation,
lighting, safe environment etc., as per statutory need.
11. Medical examination of workers, records and corrective action as directed by doctors.
12. Compliance of statutory and non-statutory safety provisions, their records and
reporting.
13. Search for safe and clean technology for the process and hazard control techniques for
detection and removal of all hidden hazards.
14. Follow-up action, evaluation of safety programmes and improvement of future plans,
strategies etc.
15. Planning to achieve national and international standards, awards etc.
Nature of Planning: Nature, features or characteristics of planning are as under
a) It is a primary and most important function of management.
b) It is goal oriented.
c) It is an intellectual or rational process.
d) It is pervasive; it encompasses all levels of management.
e) It is a continuous process (function).
f) It is conscious activity.
g) It is flexible.
h) Forecasting or forward looking is the essence of planning.
i) Accuracy is essential to planning.
j) It is a choice of alternatives.
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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Effective Planning: According to Gray Dessler, managers should consider following points
to plan effectively.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
resources. It takes a macro view of the organization and provides direction for the
growth of the enterprise. It involves uncertainty because of the long period.
Examples are environmental impact assessment, future opportunities, scientific
development and its forecasting, future need of people and market trends, future
expansion, competition etc.
Variety (types) of Plans: They are classified as under –
1. Based on objectives - Production plan, sales plan, financial plan, investment plan,
expansion plan, research and development plan, training plan, existing business plan,
reform oriented plan etc.
2. Based on time - Short, medium and long term plans as explained earlier.
3. Single use plan - Programmer projects, budgets etc.
(Fire Detection System in 1st Phase & Fire extinguishing System in Second Phase)
4. Repeated use (standing) plans - they consider objectives, policies, procedures, rules and
strategies.
Strategic planning: The word 'strategy' is used in military indicating its art (technique) of
fighting the enemy. In business or industry it means a special type of plan to meet challenges,
competitions, emergencies and other environmental forces. On-site and off-site emergency
(contingent) plans are the best examples of such strategic planning. Their details are given in
Part 7 of Chapter - 19. Strategic Plan is a master plan for the whole company and is framed
by the chief executive, top level management or experts on the subject.
Definitions:
A. McFarland - Strategy is the executive behavior whose purpose is to achieve success for
the company or personal goals in a competitive environment based on the actual or
probable action of others.
B. Stoner and Wankel - Strategic planning is the formalized, long range planning process
used to define and achieve organizational goals.
C. Koontz and Weihrich - Strategic planning means to analyze the current and expected
future situation, determine the direction of the firm and develop means for achieving
the mission.
D. L. Cleland and W.R. King -Strategy is the complex plan for bringing the organization
from a given posture to a desired position in a future period of time.
Thus strategic planning links the resources of the organization with the risks and
challenges posed by external forces and lays down a long-term direction for the enterprise.
In this sense strategic safety plans means on-site and off-site emergency plans to fight
internal and external grave emergencies and long-term s public awareness and
involvement programmes to deal with public or massive emergency due to industrial disaster.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Develop programmes and budgets for each function. Short term operational plan should b(
prepared to utilize the resources. Proper sequence and timing efforts are decided to take every
step at the right time. Performance should be evaluated, where result; are below expectations,
strategy should be reviewed and modified as per need.
Strategic Planning:
The word 'strategy' is used in military indicating its art (technique) of fighting the enemy. In
business or industry it means a special type of plan to meet challenges, competitions,
emergencies and other environmental forces. On-site and off-site emergency (contingent)
plans are the best examples of such strategic planning. Their details are given. Strategic Plan
is a master plan for the whole company and is framed by the chief executive, top level
management or experts on the subject.
Definitions:
1. McFarland - Strategy is the executive behaviour whose purpose is to achieve success for
the company or personal goals in a competitive environment based on the actual or probable
action of others.
2. Stoner and Wankel - Strategic planning is the formalised, long range planning process
used to define and achieve organisational goals.
3. Koontz and Weihrich - Strategic planning means to analyse the current and expected
future situation, determine the direction of the firm and develop means for achieving the
mission.
4. D. L. Cleland and W.R. King -Strategy is the complex plan for bringing the organisation
from a given posture to a desired position in a future period of time.
Thus strategic planning links the resources of the organisation with the risks and challenges
posed by external forces and lays down a long-term direction for the enterprise. In this sense
strategic safety plans means on-site and off-site emergency plans to fight internal and
external grave emergencies and long-term s public awareness and involvement
programmes to deal with public or massive emergency due to industrial disaster.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Develop programmes and budgets for each function. Short term operational plan should b(
prepared to utilize the resources. Proper sequence and timing efforts are decided to take every
step at the right time. Performance should be evaluated, where result; are below expectations,
strategy should be reviewed and modified as per need.
Management by Objectives (MBO) :This concept was first given by Alfred Shown in
1950 but Peter Drucker popularized it in 1954 in his book 'The Practice of Management'.
This approach is also known as management by results, goal management,
performance management and accountability management. It is a system of management
where (i) goals for the business as a whole are set and (ii) managers and staff members at
every organizational level are actively involved in goal setting. The idea is that when
employees are involved in goal setting for them, they will put their heart to achieve them.
Definitions:
a. Peter Drucker - Business performance require that each job be directed towards the
objective of the whole business.
b. George Odiorne - It is a process whereby the superior and subordinate managers of an
organisation jointly identify its common goals, define each individual's major areas of
responsibility in terms of result expected of him and use these measures as guides for
operating the unit and assessing the contribution of each of its members.
c. W. J. Reddin -It is the establishment of objective areas and effectiveness standards '
for management positions and the periodic conversions of these into measurable time
bound objectives linked vertically and horizontally with future planning.
d. S. K. Chakravarty -It is a result oriented non-specialist, operational managerial process
for the effective utilization of the material, physical and human resources of the
organization, by integrating the individual with the organization and the organization
with the environment.
Nature (characteristics) of MBO :
1. It is a system approach integrating all employees for goal setting and achievement.
2. It is a behaviorist approach where human element is recognized at each level.
3. It is democratic approach because it is participative.
4. It measures results with the standards prescribed and suggests corrective measures.
5. It focuses on goals of the individuals and the organization.
6. It has autonomous control because employees are not controlled from outside but they
themselves evaluate their performance in terms of predetermined goals and devise
corrective measures if their performance is below the norms.
7. It boosts up employees' morale and motivation because they are called for participation.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
In one sentence Safety Organization is defined as: Safety organization can be defined as
the structure and process by which groups of people (employees) are divided into sections or
departments, each section or department is assigned specific safety function or duty.
Authority and responsibility of everybody is clearly defined and coordination between them
is specified for the accomplishment of organizational safely goals.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
4. Scalar principle - clear chain of command from top to bottom.(Grade & reporting)
5. Co-ordination - should exist among all individuals and groups.
6. Communication - should be open and clear. (Transparent - in morning meeting)
Facilitates leadership. (HOD denoted on paper by Circular))
7. Delegation of authority and responsibility - exist by way of delegation.
8. Exception principle - only matters beyond control may be referred to higher levels.
Functions (duties), authority and responsibility of every position should be clearly
defined so as to avoid duplication or overlapping.
9. Efficiency - optimum use of resources at minimum possible costs.
10. Flexibility - should accommodate changes.
11. Stability - should resist challenges.
12. Continuity - by training and development of executives and employees.
13. Balance - between centralization and decentralization.
14. Unity of direction - clear-cut direction at all levels. Directions should be simple, easy
to understand and unambiguous.
Organizing for Safety:
Meaning: The term 'organization' is used in management in different ways as under
1. It refers an activity, process or function of management i.e. organizing.
2. It is used in a dynamic way referring to e process by which the structure is created
maintained and used.
3. It is used in a static way referring a static structure (skeleton) of responsibilities and
authorities i.e. a network & relationships among individuals and positions in an organization.
4. It refers to an ongoing business unit i.e. a unit which is purposefully created to attain some
objectives with resources.
Organizing for SHE Structure: It includes establishment of the formal structure of
authority through which work subdivisions are defined, arranged, and co-ordinate for the
planned safety objectives. An organizational set-up describes four classes of management -
Top, Middle and Supervisory management.
Organizing for Safety, Health and Environment Organization structure, Factions &
Responsibilities
1. Top Management: Company Board & Managing Director & Occupier is the Top
Management. They decide the safety policy and objectives and monitor its
implementation. Managing Director is reportable to the Board for implementation of
safety policy
Occupier: - Occupier is a person who has got ultimate responsibility on the affairs of Safety,
health & Environment on sector level, he is signing legal safety Occupational Health and
environment policy, he is nominated by board of director for the purpose.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Middle Management: Safety HOD or Safety department & Other Dept. Managers & their
HODs: Safety HOD or Safety department report to Chief executive or MD. Other Dept.
Managers are answerable to the Safety Department or Safety HOD for application of the
safety arrangements
Plant head: - Individual plant head of the plant has to implement occupier’s policy in his
plant.
Safety in charge: - He is heading safety officers as per the requirement of his plant.
Safety officers: - They prepare program to implement SHE policy in their unit. They advice
as to how SHE policy is related with the shop function
Safety Department: The safety department is found in all types of plant the function and
responsibility of the safety department are as follows:
To arrange for education & training on safety for the personal. This includes proper
motivation to the workers coupled with in calculating the spirit of safety among them.
29
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
1) To decide safety policy and planning for purchase of equipment with in-built safety
devices, relationship between departments standards to be followed in guarding,
testing designing, layout, housekeeping, material handling and placing, inspections,
accident investigation and records etc.
2) To plan and supervise programmes of safety propaganda, education, training and
maintaining interest of employees in safety.
3) To make arrangement or develop safe work practices and procedures; inspection,
audit and appraisal systems and all efforts to avoid or reduce accidents. To discuss
and control the accident rates.
4) To discuss and initiate action for correction of unsafe conditions and actions. Action
plan should be drawn and suitable dates fixed for completion of each task.
5) To suggest safety devices and protective equipment.
6) To carry out fire drill and rehearsal of on-site emergency plan.
7) To scrutinize safety suggestions received through plant safety committees and to
initiate action to implement the accepted suggestions.
8) To arrange safety competitions and to decide awards for encouragement.(In terms of
kind or money)
9) To improve co-operative spirit between management and employees and among
various departments to promote safety.
10) The safety knowledge of committee members should be increased by arranging
lectures of safety experts of the plant and outside and by sending the members to
seminars. Factories inspectors and safety specialists can be utilized for this purpose.
11) To discuss and approve safety budget.
12) To discuss, distribute and supervise responsibilities for quick compliance of safety
remarks.
13) To suggests changes in safety organization and its activities for better performance.
14) To suggests safety aspects of new design and construction of plant, machinery and
equipment and Process.
15) To decide disciplinary procedures and disposal of specific safety problems.
Functions of Plant Safety Committees are: (Individual Plant in the Sector):
1) Percolate Safety Policy down the line
2) To review accident records.
3) To investigate accidents and to implement corrective actions.
4) To implement directives of the Central Safety Committee.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Plant Sub-safety Committees: Where the size of the plant is bigger, Safety Sub-Committees
are formed wherein the Safety Representative of the Area is a Secretary, HOD is the
Chairman & equal no. of elected workmen & officers from Production, Purchase &
maintenance are the Members. Apart from the Structure the Functions are similar to that of
Plant Safety Committee,
Line & Staff Organization : 'Line & staff organization' is a combination of line and
functional structures, line of authority flows in a vertical line, but staff specialists are attached
to line positions to advise them on important matters and these specialists do not have power
of command over subordinates in other departments, but they possess it over subordinates in
their own department e.g. Chief Safety Officer has command over safely officers in his
department but he has no command over accounts officer in other department. He has only
advisory relationship with other departments like production, personnel, HRD etc. A common
model of line & staff organization is shown in
No. Advantages Disadvantages
1. Relief to line managers Line-staff conflicts
2. Expert advice (specialization) Confusion in relationships
3. Better decisions Staff becomes ineffective or irresponsible
4. Training of personnel Expensive for small units
5. Flexibility – opportunity for advancement
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
One model of line & staff organization for safety is shown in'. For another model.
34
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
35
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
STEPS:
Planning to achieve Objective (Zero Accidents) Staffing Organization Structure
Employees are 'directed' to carry the orders. It is that part of the management process which
guides, inspires, instructs and harnesses (Supports) people to work effectively and efficiently
to achieve the goals (Awareness). (PDCA Cycle)
Definitions:
1. Urwick and Brech – Directors (Occupier on behalf of Board of Directors) guiding,
inspiring & leading to conduct core responsibility of management.
2. J. L. Massie - Directing concerns the total manner in which a manager influences the
actions of subordinates..
Process: The process of directing consists of, the following steps: (Ex. Performance
Appraisal System)
a) Issue orders (Goal Setting) and instructions. They should be clear, complete and within
capabilities of the followers. (Achievable & Measurable)
b) Provide and continue guidance and supervision to ensure that the assigned tasks are
carried out effectively and efficiently.( By Meeting)
c) Maintain discipline and reward for good work. (Performance Pay from M.I. to E.S.*)
d) Inspire and motivate to work hard to achieve the goals. (Promotions)
e) Thus motivation, supervision, leadership and communication are the main elements of
directing.
*(M.I. = Must Improve, E.S. Expectation Surpassed.)
Principles of Direction:
They are :
1. Harmony of objectives - Management should take care of personal goals of employees
with the organizational goals. (Core Objective & Dept Objective in Line)
2. Unity of command. - One subordinate should get orders/instructions from one superior
only.(Single Reporting Boss & his reporter)
3. Direct supervision - There should be personal or direct supervision.(By Immediate
Supervisor)
4. Good communication - Helps to improve understanding and speed of work. (Morning
Meeting)
5. Maximum contribution - Managers should try maximum contribution from each
subordinate.
6. Appropriate techniques - The techniques should be suitable to superior, subordinates
and situation to get efficiency.
7. Strategic use of informal organisation - Some informal groups should be contacted to
decide direction. (Outsourced Agencies)
8. Comprehension - Orders should be clear, complete and understandable.(Measurable)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
9. Good Leadership - Managers should guide and counsel subordinates to win their
confidence.
10. Follow-up - Managers should follow-up their orders and modify if necessary.(In
Meetings)
Techniques of Direction : Generally four techniques are available for directing. They are
• delegation of authority, (To listen orders)
• supervision, (To control)
• orders and (Policy)
• Instructions. (Meetings & Shop floor)
Above definitions, principles and techniques of direction are equally applicable to the area of
safety and safety managers should know and follow them while guiding, inspiring,
motivating and instructing workers to detect and remove unsafe conditions and actions and to
maintain safe environment in their day to day activities.
Leadership : Meaning:
It is a tool to make direction effective. Leadership Manages business by instill in them
a) desire to achieve the goals,
b) desire to improve their performance
c) sense of co-operation
d) and If the managers fail to provide such 'leadership the employees will search the
leadership outside which may lead to conflict or distraction.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Authority of
Superior
Autocratic Democratic
Leadership Freedom leadership
of Subordinates
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Autocratic leadership: Relationship of two types of leadership is useful for untrained and
secrecy in decision making is required. Its features are retention of power, relying on orders
only and close supervision.( Training to Apprentices as untrained. Also used in War for
secrecy : Captain & subordinates have to follow orders of Major in Army Example : Hum
Dono )
In democratic or consultative leadership method: The manager consults his subordinates
and invites their suggestions before making decision. Formal or informal meetings are also
held. Here subordinates work heartily because their views and opinions are respected.
Develops trust, co-operation and leadership among employees. This stage is useful when
subordinates are literate, have sense of responsibility and organized. It requires much time in
decision making. (Viz. Steering Committee Meeting: Chairman takes suggestion from HODs
of different shops)
In free - rein leadership technique: The manager delegate authority to his subordinates and
they are encouraged to develop and contribute independent thought and action. This method
is preferred mostly by highly educated and independent (free minded) persons. Here details
are prepared by the subordinates. There is a free communication between superior and his
subordinates. They don't feel difficulty in consulting each other. It is more creative and
develops latent abilities of subordinates. (Viz. While preparing Safety Policy, Factory
Manager or Plant Head signing Authority takes help of Safety Officer . Similarly, while
preparing Corporate Legal Policy Occupier consults Safety HOD + Legal Dept. )
Selection of leadership style depends on (1) force in Manager (2) force in Subordinates and
(3) force in Situation.
In Safety Management, autocratic leadership style is not suitable as safety is not to be
imposed like military discipline, and involvement of employees (educated or uneducated) at
all levels is required. The concept of employees participation, safety committee, safety
education and training and "Safety is everybody's duty" can be well implemented by
democratic or consultative leadership style. In designing safely guard or its improvement by
ergonomic factors, developing safe work method, meeting safety targets by group co-
operation, celebrating safety programme, creating and maintaining safety awareness and
emergency preparedness, suggestions and involvement in decision-making of employees are
most useful. Therefore, democratic leadership style at workers and middle level and free-rein
leadership style at higher (executive) level are desirable for safety management.
Communication :This is another element of the management 'directing' and also useful for
effective motivation, supervision and getting the work done.
Motivation cannot succeed without communication. It is a process involving the
transmission and-reception of message, eliciting meaning in the mind of the receiver and
resulting in appropriate action which is desired.Though one way communication such as
speech, posters, instruction, radio, TV has their uses, two way communications is the only
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
effective way to transfer an idea from one mind to another. Two way communications allows
for clarification and amplification.
Safety communication should be more clear, loud and effective. By good efforts
create responses, desires, insight and action as soon as possible. Audio visual display,
transparency arid modern teaching aid should be used for effective communication.
Definitions and Meaning:
1. Haimann - Communication means the process of passing information and understanding
from one person to another. It is the process of imparting ideas and making oneself
understand by others. It is fundamental and vital to all managerial functions.
2. Newman and summer -It is an exchange of facts, ideas, opinions or emotions by two or
more persons.
3. Koontz and O'Donnell -It is an intercourse (Contact ) by words, letters, symbols or
messages, and is a way that one member shares with another.
Chester Bernard has stated "'The first executive function is to develop and maintain a system
of communication". (If a particular man is not there then also Sy. Shall work)
It is communication when we speak, tell, write, read, watch, listen, hear or act or
convey or transmit our message by expression or any other way of understanding feeling,
attitudes, wishes, ideas, opinions, emotions, thoughts etc. Poor communication creates
problem and good communication solves it.
Purpose (Role or significance) of Communication:
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
7 Feedback
Nature of Communication :
1. It is a continuous process. Its stoppage means stoppage of human activity (Telephone)
2. It is a two way process between sender and receiver. .(Confined Place)
3. It creates mutual understanding and human relation.(HRD using Appraisal Process)
4. It is a pervasive function i.e. required in all managerial functions(Adjective Influence)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Communication
Channels Media
Oral
Formal Informal Written
(Grapevine, Electronic
in all Gesture
Downward
directions)
Upward
Horizontal
Diagonal Gesture = Deaf & Dump
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
43
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Difference of Types with Media:- Which media will be used for Oral & Written
communication
Oral Written
Downward Communications :-
Personal instructions, lectures, meetings, Orders and instructions, letters, Email,
conferences, interviews, employee circulars, memos, posters, bulletin, house
counseling, bells, whistles, telephone, organs, handbooks, CDs, manuals, annual
movies, slides, public address system reports, policy statements, union
(PAS), social and cultural gatherings, union publications, informational racks.
activities.
Upward Communications :-
Face to face talk, oral report, exit Personal letters, Email, written reports,
interviews, phone, meetings and CDs, suggestion scheme, grievance
conferences, social and cultural affairs. procedure, surveys, unions publications.
Horizontal Communications :- ( To all concerned)
Lectures, talks, meetings and conferences, Letters and memos, reports, carbons,
phone and intercom, movies and slides, memo, graphs, posters, bulletin, handbooks,
social affairs, union activities. manuals, house organs, union publications,
Email.
Diagonal Communications :-
Inter-departmental oral inquiry, talks and Inter-departmental letters, memos, reports,
meetings, phone and intercom to other suggestions, objections. Email etc
department, social gatherings of mixed
groups.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Information
Feedback
SENDER RECEIVER
Adjusted Information
Understanding
46
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
47
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
48
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Chapter -2
Safety Education is for developing Safety Tr. is for developing the worker's
awareness of correcting unsafe skill in the use of safe work techniques and
conditions and practices that practices. It is a detailed extension of the
educational safety programme applied to
might lead to injury
specific Product, Activities & Services.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Quality Systems talk about PDCA Cycle*which. In line with above cycle
Steps 1,2 & 3 covers Planning part,Step 4 & 5 covers Do part,Step 6 covers Check part &
Step 7 resembles to Act, Audit for Continual Improvement * Plan, Do, Check & Act
Above 7 steps are explained as under:
a) Determine if training is needed or any other tool is required for improved Training
programme.
b) Identify training needs - Analyze the worker's duties and what he or she needs to
perform the job more skillfully and safely.
c) Identify goals and objectives –After listing duties, + & - Points about knowledge and
skill is known from Step-2, will fell employers what workers should do & not to do.
d) Design & Develop training programme - After listing precise objectives and goals, as
per the available resources Training programme is designed w.r.t. Job-Knowledge,
Attitude & Behavior.
e) Conduct the training – Relevant Training by suitable Methods & Types to be conducted
w.r.t. Skill used to achieve the worker's goals..
f) Evaluate programme effectiveness - By knowing trainee's opinion, supervisor's
observation, work place improvement, hazard reduction, performance improvement etc.,
it should be checked whether the training has accomplished its goals.
g) Improve the programme - Based on feedback from the workers, supervisors etc., and
from evaluation and observing the gap, the training programme should be improved
(revised) as per need.
Assessment of Training Needs :This is first step / Element of any training cycle.
Following four questions should be considered:
1. Any Hindrance to performance? (Viz. unsafe conditions, acts, Personal Factors &
efficiency).
2. Is it important to the Company? (w.r.t. of cost of accident, hazards, losses etc.).
3. Is it important to the employees? (viz. basic training to new employees, refresher course
for old employees, Tr. to Accident Prone persons )
4. Whether above 3 points are correctable through training? (If yes, then only the training
becomes useful and cost effective.
How General training needs are assessed ?
Gen. Tr. needs are assessed on following ground:
1. Tr. is must for new employees as they don’t know about routine work.
2. Old employees require knowledge of new topics, new technology, process revision, new
methods and forgotten old items. Training for emergency preparedness, safety audit, fire
fighting, HIRA (Hazard Identification & Risk Assessment), OHSAS, EMS, BBS &
Sustainability.
3. Transferred employees in new Depts.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Also given in Tr. Types. Training Techniques (Teaching Methods=Types) are classified in
two types such as
a) Off-the-job Techniques
b) On-the- job Techniques
(A) Off-the-job training techniques :
No. Category Techniques (methods)
1. Information presentation techniques Includes Correspondence course, Films,
(less involvement of trainee). Lecture, Panel discussion, Programmed or
Computer based instruction.
2. Information processing techniques Includes Conference (APOHSO) or
(trainees are involved). discussion group, (Safety Champions), Tr.
Gr. (Initiative group)
3. Simulation techniques (experiment or Occurrence of Incident, role playing, In-
practice). basket, Vestibule, Mock-drill, Business
game.
(B) On-the job training techniques :
No. Category Techniques (methods)
1. Regular job assignment. Coaching, Job instruction training (JIT).
2. Temporary job assignment. Special assignment/recruitment on job,
committee, project etc.
job rotation in different dept of the
company
Design and Development of Training Programme :
What are the useful points in designing and developing any training programme?
1. Motivation (Proschahan)
2. Sequence of Topic (Event, Defi. Causes of Accds……)
3. Length of Tr. Topic shall fit in given period.
4. Tr. Literature shall fulfill the Objective (Zero Accd.).
5. List of Tr. Aids (Boards, Charts, Drawing, Posters, Transparencies, Overhead
Projector, TV/AV, DVDs, Handouts, Computer, LCD Projector)
6. Actual doing (F.E.) is imp. Than Hearing & Seeing.
7. Questions of trainees should be properly replied by trainer.
8. Encourage trainees by ample of opportunities.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
54
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
55
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
d) PPE
e) Fire Prevention & Fighting
f) Safety Inspection & BBS
g) On-the-Job Tr. for newcomer
h) Hazop Study , Hazan
Types of Safety Training:
a) Induction(Orientation) Tr. to new joiners
b) Safety Policy, Rules, Procedures
c) On-Site Emergency Plan for MAH Unit & Other Emergencies
d) PPE (Types, Usage & maint.)
e) Types of Accds. In his area ( B/s, Assy, Foundry, Paint shop, Forging etc.)
f) Reporting of U.A & U.C.
g) On-the-job Safety Tr. by Supervisor
h) JSA / HIRA
i) SOPs
j) Safety signs & Signals
k) Code of Standards to be followed ( for Computation of Accd. Rates, Audits etc.)
2.In case of Injury :
a) Taking Treatment & Reporting to Supervisors
b) Need for Good House-keeping
Apprentices Tr. : Since new shall be given following Tr.
a) On-the-job Tr b) Off-the-job Tr
3. On-the-job Tr. : To be given on the stage of the line
a) On the job Tr. & Job Safety Tr. By the Supervisor
b) Acquaint with Safety signs & Singles.
c) Supervisors shall be trained in HIRA to train down the line
d) Given to Apprentices, transferred employees, Trainees, FTAs who are new.
4. Off-the-job Tr. : All other Trainings other than On-the-job Training
a) It includes 10 common Tr. Methods as earlier like………
b) Lectures, Discussions, Case Study, Role playing, Bussiness games, Sending tr. Centres,
Job Instruction, Vestibule, Mock-ups.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
1. Vestibule Tr. :
a) Tr. Takes place away from actual workplace, when the job is dangerous & can harm
b) Trainee if taught on the job. It is the link between On-the-job & Of-the-job Tr.
2. Individual & Team Simulations :
a) When cost due to Human error or damage to the Equipment is too
b) high, Duplicate Equipment/ Work condition similar to original
is set up for the purpose of Tr. For safety and Economy.
3. Team Training : For Co-ordination & Co-operation amongst Team members
(Sticker applier & Driver)
4. Programmed Instructions : Safety Manual, Q-A type, Check-List, Films,
Pla-card for visitors Banners, Notices,
5. Modern Methods : Computer use for Instructions
6. Other : Technical, HRD, System Tr. ( ISO , OHSAS, EMS, ISMS etc)
7. Training to Supervisors :
a) Supervisors are in immediate contact with Shop floor workers & upper Management.
b) Being a Key Person in Accident Prevention programme, he must be trainined for Rules
c) Company's Policy, H.K., Procedures, Accd. Investigation.
d) Maintaining Safe working Condition.
e) Display MSDS for Hazardous-Materials, Signs, Accd. Reports
f) Recording, Analysis,, Safety Committee Meetings
Evaluation = It is measure of effectiveness of Tr. Prog.
Conducted Useful in Reviewing the Prog. Content,
Method, Tr. Aid as per feedback for improvement
1. Increase in Productivity
2. Increase in Competence of the job
3. Increase in job satisfaction & motivation
4. Decrease in Accd. Rate.
5. Decrease in Break-down time
6. Decrease in Absenteeism
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
58
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Training or teaching aid should be selected judiciously to make learning interesting, meaningful and
without boredom or monotony. Just after lunch interval in the afternoon, film may be more effective
than mere lecture. Where machines and equipment are used as aid, they should be safe and clean and
their safety and ergonomic aspect should also be explained.
Applications of Computers :
Computers usage is very effective for online Training Communication.
• Accident Recording & Analysis Software Programme: Feeding of Daily Accident data in the
computer received from the Dispensary of the Company, Firm is done. We can get the periodical
Analysis Report as per our requirement. i.e. weekly, fortnightly, monthly, Quarterly, Six monthly &
Yearly.
• These Analysis Reports can be sent to respective areas for information of HOD & Safety
representative of the Department for taking Action to reduce the Accidents for increasing Safety
Performance.
• Accident Investigation Report of one dept. can be sent to other depts. having similar Hazards. So
that they will take Parallel Action to avoid similar type of Accident in their location.
• Accident Investigation Report of one Plant in the Sector can be sent to other Plants of the Sector
having similar Hazards. So that they will take Parallel Action to avoid similar type of Accident at
their location.
• Video Clips of Emergency Preparedness & Response can be shooting run on the Computer at the
Entrance Gate for the knowledge of Visitors.
• In the individual Dept. Safety Instructions can be displayed on electronic digital display boards to
create awareness in individual area.
• Different types of Monthly Accident Reports can be sent to the concerned through the computers.
• Safety Training Module prepared in Computer can be displayed through LCD/LED Projector on the
front Screen to have an effective Training Programme.
• The principal coordinator of WTO contribution was Deputy Director-General Miguel
Rodríguez Mendoza with the assistance of many other coordinators.
• The WTO is based in Geneva but unlike the WHO it has no regional offices.
• It has total 560 staff headed by a Director-General, and a limited budget. By February
2002, 144 countries (Developing + Developed) were Members of the WTO. Together
they account for more than 90 per cent of world trade. Since WTO's establishment in
1995, over 40 developing countries have sought admission to the WTO with agreements
• With the entry into force of the WTO in January 1995, the Committee on Trade and
Environment was established. Its work programme builds on the work that had already
taken place in GATT since 1991 to identify the relationship between trade and
environmental measures in order to promote sustainable development, and to make
recommendations on whether any modifications to the provisions of the multilateral
trading system are required.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
One of the key Principle of WTO is (iii) The Most-favoured-nation ( MFN = means treating
other WTO Members equally ) principle and public health: Fruit from countries that do not
fulfill the sanitary requirement could, justifiably, be banned. But the same fruit with an
acceptable level of pesticide residues would be allowed in.
Structure of WTO: The WTO's top decision-making body is the Ministerial Conference
which meets at least once every two years. The General Council, which is normally attended
by ambassadors and other Geneva-based delegates, or capital-based officials (who may
include health experts), meets several times a year in the Geneva headquarters. The General
Council also meets as the Trade Policy Review Body and the Dispute Settlement Body
(DSB). Delegates at the day-to-day meetings of the WTO are government representatives of
all WTO Members and representatives of observer organizations. Both during negotiations
and in the WTO committee work, decisions are made by consensus. Voting is possible but it
has never been used in the WTO.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
61
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Chapter -3
62
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
• A representative each from the production, maintenance and purchase departments shall
be members.
• Workers representatives, of equal number, shall be elected by the workers.
• The tenure of the committee shall be 2 years.
• At least one meeting in 3 months. Minutes shall be recorded and produced before the
Factory Inspector on demand.
• The committee has right to ask or seek any information w.r.t. health & safety of workers.
Functions & duties:
• Co-operation to implement health and safety policy of Occupier.
• Dealing with all matters of health, safety and environment and arrive to the practicable
• Solutions to problems in that regard.
• Creation of safety awareness amongst workers.
• To conduct educational, training and promotional activities.
• To discuss reports on safety, health and environmental surveys, safety audits, risk
assessment, emergency plans and implementation of the recommendations of the
reports.
• To carry out health and safety surveys and identify causes of accidents.
• To look into complaints of imminent danger and suggest corrective measures.
• To review the implementation of its own recommendations.
• To form sub-committees, if necessary.
Types of Committees may be: (1) Main or Central Safety Committee (2) Plant or Shop
Safety Committee (3) Technical Safety Committee (4) Special purpose Safety Committee
etc. Technical Safety Committee is useful for specialized knowledge viz. guard design,
process and engineering revision, hazard and risk analysis, special investigation etc. It
comprises of chief engineer, safety engineer/officer, head mechanic, chief chemist and
similar expert technicians. Special Purpose Safety Committee can be setup for specific jobs
and dissolved when its purpose is accomplished. Such jobs include special accident
investigation, specific problems of worker behaviour, off-the job safety, rehabilitation or
relief problem, safety celebration or contest or award occasions etc. For a big concern
different safety committees as ' stated above are possible, but in a small factory a single
committee can carry out all functions.
63
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
64
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
• To suggests safety aspects of new design and construction of plant, machinery and
equipment and Process.
• To decide disciplinary procedures and disposal of specific safety problems.
Functions of Plant Safety Committees are: (Individual Plant in the Sector)
• Percolate Safety Policy down the line
• To review accident records.
• To investigate accidents and to implement corrective actions.
• To implement directives of the Central Safety Committee.
• Enforcement of safety rules, procedures an accepted safe practices.
• To encourage and enforce the use of persona protective equipment.
• Status of CAPA on Safety inspection rounds of various shops and sections.
• To encourage safety suggestions from worker and to forward them to the Central Safety
Committee.
Plant Sub-safety Committees: Where the size of the plant is bigger, Safety Sub-Committees
are formed wherein the Safety Representative of the Area is a the Secretary, HOD is the
Chairman & equal no. of elected workmen & officers from Production, Purchase &
maintenance are the Members. Apart from the Structure the Functions are similar to that of
Plant Safety Committee,
Workers' and Union's Participation : Equal number of safety representatives from workers
(or their union) and management should constitute their joint safety committee. This may be
a central one or different in different plants. All must be sincere in their desire to co-operate
in the matters of safety. Scope of the activities and agreement should be limited to Safety.
Union representatives should be selected from the basis of their safety knowledge, interest
and experience and should be cooperative and sincere. They should not bring other union
demands like bargaining, grievance setting etc. in the meeting of safety committee. Union
must recognise management's right of leadership in a joint safety programme. Accident
prevention is an area of mutual interest and not of dispute or quarrel. Therefore the workers
or union must participate to show their abilities in this area and thus strengthening their
relationship with the management and saving their own lives from accidents.
Central Board for Workers' Education, Ministry 'of Labour, Govt. of India runs many
schemes for workers' education and training such as (1) Tripartite scheme (2) A worker to
worker training scheme (3) Voluntary scheme (4) Need based education (5) Education
Officer's training programme (6) Worker Teacher’s training programme (7) Workers'
training programme etc. In Gujarat the first workers' education I centre was established in
1967 with the co-operation of the State Govt, employers and trade unions.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
The Central Labour Institute at Bombay, Gandhi V- Labour Institute at Ahmedabad and
some trade unions also run such education and training classes for workers. All such efforts
should increase workers' participation in safety.
Supervisor's Safety Contact :By their key position between workers and management and
by their constant contact with workers they can easily and effectively promote workers'
participation in safety. The supervisor should always try to get such participation. A critical
incident technique like Tool box talk. Safety contact by safety manager, safety
engineer/officer is also useful.
Safety Suggestion Scheme : These is also a requirement of Statutory Annual Submissions
to DISH Office. This is an old practice to invite safety suggestion for improvement in
process, method, equipment, safety meetings, inspection procedure etc. Criticisms should be
replied in the plant magazine or on the notice board to provoke further suggestions and ideas.
Good suggestions should be rewarded among others to encourage them to participate. Written
suggestions are the best, but, the oral or telephonic should also be allowed. Sometimes a
contest of submitting good suggestions provides useful information and stimulates such
effort. This system is effectively accepted by Japanese management. Boxes and forms can
also be used to collect suggestions.
Safety Competitions:
• Individual comparison - Examples are safety Elocution Contest, Safety quiz, essay,
poem or slogan writing, posters or cartoons etc.
• Group comparison - Examples are department wise housekeeping competition.
Safety Incentive Schemes :
• Financial Incentive: Financial reward to the most useful suggestion or activity in
safety is the commonest method. Other financial incentives should also be given for
suggestion to solve particular safety problem of plant or process, machine or
equipment etc. Suggestion of good design for a guard or safety device should always
be rewarded by handsome amount.
• Non-Financial Incentives: Award for safety performance, trophy, memento,
certificate of merit, public honour, praise or pride, awarding special safety hat or kit
or symbol of recognition, awarding special status and duties of safety work, giving
special position such as honorary member of safety committee, raising the cadre or
post, giving extra designation for any remarkable safety contribution are all examples
of non-financial incentives.
If these incentives are properly utilised they help much in accident prevention work.
Safety performance (frequency and severity rates) of different groups can be compared for
the same period. Here groups are motivated for competition.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Winners may get shield, certificate or good prize but non-winning participants should also be
compensated for encouragement. Competition should be fair and fine and fitting to its noble
cause. Safety Quiz is one type of safety competition or contest. It can be conducted by asking
questions to participants or by giving them an objective question paper containing quiz
questions to be answered in a stipulated time. It touches wide area of safety in short time and
participation looks live.
Audio-Visual Publicity :Safety education and training by safety films on TV is the most
powerful method. Slides, filmstrips and transparencies are easily available or prepared and
therefore they should be used to die extent possible to hold the picture to discuss and
understand it in details which is not possible with a moving film.
Modern media is a closed circuit television with the control room. Such unit can be hired
also.
Other Promotional Methods :Methods for employees' participation are safety posters,
cartoons, signs and slogans, publications, booklets, bulletin boards, safety contests and
rewards, counseling of education and training, demonstration, safety meetings, safety
campaigns and stunts, first-aid training, fire brigades, safety- inventory or questionnaire,
accident investigation, inspection, job safety analysis etc.
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Subject : Industrial safety Management (23108)
CHAPTER -4
Human behavior :
• Organization Behavior and Safety Human Factor Contributing To
Accident
Human factors contributing to accident: - Human error is the major contributing factor for
occurrence of accident. Many a time an operator either forget to perform a correct thing in
right manner or performs a wrong thing such as unsafe act can be attributed to physical
deficiencies in the individual for his attitude towards the job. Any physical and the
psychological deficiency factor associated with the person can i.e. detect in the pre -
employment examination. It will avoid the miss much of specific job requirement and the
personal quality of the individual. This will help to reduce accident possibilities on the job
due to physical deficiencies of employee.
Individual Differences: - It is matter of common experience that people differ from one
another. There physical appearance and traits such as height, strength intelligence, ability of
work, memory, speed of reacting a signal, honest or emotional stability and mental traits.
Personality traits, sensory capacities, muscular co – ordination etc are some of the factor of
individual differences.
Classification of differences: -
1. Individual variable (Human Factor): - Aptitudes, personality characteristics,
physical characteristics interest & motivation age and other personal variables.
2. Work place variables: - Physical environment, work place & arrangement, design &
condition of work equipment, and method of work.
3. Organizational & social variables: - Character of the organization, type of training
& supervision, type of incentives & social environment.
4. Perception of danger and risk: - Different person have different degree of
perception of danger and risk. Due to individual differences capacity of understanding
and identifying the hazard differs while crossing highway, open person may have
correct judgment of chances of accident lowing to the distance and speed of the
vehicles coming from sides different working have difference of opinion or judgment
regarding hazard arising out of moving machinery of risk from chemicals.
In danger then important think is the response time required for quick action to protect
our self or other from the danger or risk slow response time indicates more chance of
accidents and vice – versa. Safety training can help to improve ability of good perception of
danger and risk & help to minimize accidents.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Nature of Motivation: Motivation is one of the factors that stimulates or influences job
performance. A Latin word "mover' means to move. A motive is what moves a person or
impels a person. Motivation is concerned with 'Why' and "How' of behavior.
P. T. Young defined motivation as "the process of arousing action, sustaining the activity in
progress and regularizing the pattern of activity."
Steers & Porter and Greenberg & Baron identified 3 major components of motivation:
1. Force or drive to lead to some behavior.
2. Function to guide behavior in desired direction and
3. Maintaining or sustaining behavior once it has occurred.
Herbert Moore says 'To motivate is to cause a release of energy in relation to a desired goal.
Effective motivation is determined by three factors: the goal that is to be realized, the energy
that is to be released and the tools that are to be used to direct and control that energy. The
Whole problem of motivation is the problem of the development of attitudes, loyalties and
capacities for making sacrifices toward an entity that is of greater consequence to the
individual worker than his job or •his personal welfare.'
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Motivation runs top to bottom; therefore the top management and supervisors should be
motivated first. Motivation should be self generated; otherwise it should be supplied or
induced.
NRF Maier explains motivating as a way of bringing to expression an ability, which a
person already possesses. He describes two aspects: subjective and objective. The subjective
side is a condition in the individual, which is called a need, a drive or a desire. The objective
side is an object outside the individual, which may be called the incentive or goal. When an
incentive satisfies the need (as food satisfies hunger or money satisfies economic need), the
situation is called motivating. The types of needs and incentives vary from time to time and
from person to person. It is an industrial problem to find out needs and their appropriate
incentives. This is explained below.
Theories of Motivation: Some 'psychological theories are developed to motivate people
to improve their performance. These theories are based on varieties of needs and, their
satisfaction (incentives or rewards).
Hawthorne Studies (Behavioral Approach):In an old study conducted at the Hawthorne
works of the Western Electric Company, Chicago for 15 years, beginning in 1924, concluded
that the attitudes of employees could be significantly changed by the development of a co-
operative atmosphere between workers and supervisors.
Change in temperature, humidity, lighting, rest pauses and length of workday have little
effect if the employees are well motivated with friendly, social and co-operative relations.
Thus motivation has more effect than the improvement in working conditions. If a good
confidence is generated in people, they can work hard for their company.
Success of Japanese management seems relied on this theory. Motivated soldiers have
won many battles with inferior weapons and being less in number. On power-press machines,
workers mostly injure their fingers and get demoralized if the frequency rate is not reduced.
Here a supervisor can play an important role by standing near the worker, explaining and
training him for pre-start safety •devices, guarding on machine and safe work method, thus
giving special attention, co-operation and building confidence in the worker to work accident
free. If workers receive personal touch i.e. special attention for their safety, health and
welfare by upper management, they get motivated to give more production even if working
conditions like light, space, layout etc. are not fully favorable. This is the abstract of this
oldest study.
Maslow's and McGregor's Hierarchy Theory of Human Needs; (Need Satisfaction for
Safe Performance): A.H. Maslow classified the human needs and determined priorities for
them. These needs should be satisfied in the following order.
• Physiological needs: Basic or survival needs of food, water, air and rest.
• Safety needs: Protection against danger, threat and deprivation, body and position or
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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Our Indian concept is to minimize the human needs for real happiness but how to implement
it for industrial workers is a psychological problem. Self motivation and satisfaction seems to
be the best remedy.
ERG Theory: Clayton Alderson offered this theory in 1969 based on needs of Existence,
Relatedness and Growth (ERG). His theory is an improvement over Maslow's theory.
Existence needs are basic needs of food, clothing, shelter etc., and management can satisfy
them by pay, allowances, better working conditions, job security etc.
Relatedness needs are affiliation and esteem needs.
Growth needs are self- actualization need stated by Maslow.
By knowing needs of the workers if management takes necessary action to feed those needs,
the workers can be motivated for better performance.
Suppose some workers do not take part in Safety Committee because of their belief that
they know little about industrial safety. If knowing this need of knowledge, they are given
proper training for safety; they will be motivated to participate in Safety Committee.
Herzberg's and Myer's Theory (Motivation - Hygiene Theory):Frederick Herzberg and his
followers - Schwartz, Jenusaitis, Stark and Myers, carried out various studies on motivating
factors. Herzberg and his team interviewed 1500 workers for 12 types of investigation to
know what the satisfying factors were and what the dissatisfying factors with their reasons
were. From this extensive study, some more important factors are given below:
Another study points out motivation needs and maintenance needs as follows:
Motivation Needs (Intrinsic Factors) : These are the factors of growth, achievement,
responsibility and recognition such as delegation, access to information, freedom to act,
atmosphere of approval, merit increases, discretionary awards, profit sharing, company
growth, promotions, transfers and rotations, education, memberships, involvement, goal-
setting, planning, problem solving, work simplification, performance appraisal, utilised
aptitudes, work itself, invention & publication.
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Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
M
O P e rfo rm a n c e
J o b C lim a te
T
S e lf
I R e w a rd
T h e jo b its e lf
V
J o b M o tiv a tio n a l
A S a tis fa c tio n
fa c to rs
T
P e e r g ro u p (s)
I Boss
U n io n
O Peer
N U n io n
S e lf
A b ility
S e le c tio n T ra in in g
1. Here safety performance is dependent upon level of motivation and his ability to
perform.
2. Motivation depends on job climate (by boss-style, staff-climate, management-relations),
self (personality achievement), the job itself, job motivational factors, his peer group
(norms established and performed) and by the union (norms and pressures).
3. Ability depends upon selection (can he do it?) and training (does he know how?).
4. Following performance there are all kinds of rewards (positive and negative), which
influence his level of satisfaction.
5. The' rewards come from the boss, peer groups, union and self.
6. Upon receiving these rewards he then compares the reward received to what he
expected to receive and is either satisfied or dissatisfied to a degree, which influences
(feed back loop) whether or not he shall be motivated enough to perform again.
Vroom's Valance or Expectancy Theory: It is also known as 'instrumentality theory or
process theory'. Historically it goes back to Tolman (1932), Lewin '(1938) and Peak (1955)
but Vroom's version of this .theory introduced it to industrial psychology
Outcomes like salary, security, recognition etc. have different values (attractiveness) for
different people. Motivation according to this theory is a product of valance (desire),
expectancy and instrumentality.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Valance is the attractiveness of a goal or outcome. It has two propositions: (1) The desire
(Valance) for any particular objective (outcome) on the part of an individual is directly
related to the likelihood that the objective will in turn lead to other subsequent objectives of
given desirability and (2) The greater the valance of any outcome, the more quick is a person
to take action.
In Vroom's theory, money acquires valance due to its perceived instrumentality for
obtaining other desired outcomes i.e. its power of exchange or purchase.
The abstract of the theory is that the linkage between behaviour and reward should be
declared in advance, the linkage should be implemented and reward should be given every
time when a desired behaviour is achieved. This looks like a conditional motivation.
For example, if promotion or pay-rise (valance or attractiveness of the goal, outcome or
reward) is declared for certain target (desired performance) and if a worker feels it achievable
(expectancy perception), he will be motivated to engage in performing to achieve that target.
On performance, declared reward should be given to him.
By providing better comfort by ergonomic design of machines, tools, equipment,
controls etc., and reward for safety attitude and effort, management can generate desire in
workers for safe performance.
Magregor's X & Y theory: Magregor developed this theory, which has two parts - theory
'X' and theory 'Y'. Theory 'Y' is more useful to develop safety culture by motivation.
Theory X Theory Y
Normal, conventional or old views regarding Modern or correct views regarding human
human behaviour behaviour
1. An average worker has inherent dislike of 1. An average worker does not inherently
work and will avoid it if he can. dislike the work.
2. An average worker prefers direction, 2. An average worker learns not only to
wishes to avoid responsibility, has relatively accept, but also to sick responsibility under
little ambition and wants security above all. proper conditions.
3. Workers must be corrected, controlled, 3. Self-control and self-directive are
directed, threatened or punished to achieve preferred by the workers to achieve
objectives. objectives.
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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Goal-setting Theory: Rayon (1970) put more stress on 'intention' to motivate behaviour.
Locke & Latham (1990) supported this theory explaining to set goals to motivate people to
show their ability (efficiency). Research studies by Miller (1978), Latham & Locke (1979)
showed that performance could be improved by setting 'specific goals' and not the general
goal like 'do your best'.
Reward for zero accident goal, accident free month, year or department, good
housekeeping and a fixed target and guidelines motivate workers to attain them. Goals should
not be too easy or too difficult. Moderately difficult goals pose a challenge to an individual
and impose the commitment. Steady & Ka/s study (1964) showed that goals, which were
perceived as difficult but attainable, led to increased performance than goals, which were
easy or impossible to achieve.
Workers should be involved in goal setting process instead of assigning goals by
others. Workers' understanding and appreciating of goals are necessary. Latham and Saari's
study (1979) showed that it becomes easy to achieve difficult goals through supervisory
support. Chhokar and Wallin's study (1984) to improve safety performance showed that
'feedback to workers how to reach the goal' found useful and percentage of workers working
with safety precaution was raised from 65% to 95%.
Feedback improves individual as well as group performance. In Britchard, et al
(1988) study, group performance showed 75% improvement by group goal setting and
feedback. Northcraft, Lee and Litucy (1990) pointed out two types of feedback - outcome
feedback and process feedback. Outcome feedback provides information about consequences
of one's actions and process feedback about ways to improve task performance.
Zero accidents goal by NASA (USA) is the best example of this theory. In some Tata
Companies, incentives to all workers of a department where no accident occurs during a
month motivated the workers. Supervisors were giving guidance to their workers to achieve
the goal for their department.
Summary: Psychological principles discussed in all above theories suggest-various means
and ways for management (including supervisors and safety officers) to motivate people for
safety and to identify situations leading to conflict, frustration, non-co-operation etc., and
techniques to remove them. For further techniques see Chapter-6 on Safety Management.
Methods of Motivation (Incentives or Rewards) :
While discussing nature of motivation, we have seen that there are human needs,
drives or desires (explained by various theories) which- should be satisfied by necessary
incentives or rewards for the purpose of motivation. Various methods are available to apply
these incentive schemes.
Some are given below:
(A) Money as an incentive: Money, in itself has no incentive value. But it can be used to
obtain the desired incentives, because of its exchange power or value.
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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Workers have three types of relations (social system) according to Bray Field and
Crockett:
1. with fellow workers
2. within company structure and
3. Outside the company. Motivation is a function of all these systems.
Role of Safety Management in Motivation: Role of Management, Supervisors and
Safety Department in motivation is most important.
They should adopt following measures:
• Insist for adequate sensory motor abilities, appropriate muscular perceptual speed or right
perceptual style, free from accident proneness, disease and habit of intoxication,
appropriate age, sex, experience, work habits and good safety record.
• By induction training' new workers (including contract workers) should be given
necessary safety instruction and training regarding hazards and control measures in
industry. This basic knowledge will build confidence.
• Schedule for above training should be properly designed to include hazards of raw
materials and processes, safe operating procedures, safety tools and equipment to be used,
safety work permit systems, interpretation of MSDS, labels, signs & signals, rules of
transportation, loading and unloading and role of the workers in fire fighting and
operation of On-site Emergency Plan.
• Company's Safety & Health policy. Environment policy and Quality policy should be
explained with their objectives and benefits. Organizational interests should be explained.
This will bring belongingness and togetherness.
• Workers should be encouraged to participate in safety committee, safety suggestions and
all safety programmes.
• Accident case studies should be explained at all levels by analysing the different roles in
preventing such accidents. See Chapter-30.
• Motivating thoughts as given in next part 8.8 should be explained with examples. These
will help much for motivation.
• Team spirit and competitiveness should be built-up. This will induct group motivation.
• Supervisors should take sufficient rounds to them if any unsafe practice is noticed. For
good work and follow up of safely rules, they should praise the workers. Safe habits
should be cultivated.
• Proper attention should be paid for basic needs of Health, Safety and Welfare facilities
under the Factories Act and Rules for the workers.
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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
company should add more measures specific to its requirement or based on any
psychological study carried out in the industry.
Motivating Thoughts: Fig Display such Motivating Thoughts
1. It is said that 'it is not the gun that fires; it is the heart of iron which fires the gun'. After
all it is the heart (with mind) full of confidence, courage am motivation that drives a
man to achieve the goal.
2. Motivating thoughts or ideas play an important role in this regard. No motivation is
possible if human mind is not appealed by inspiring thought. This is true in case of
safety motivation also.
3. We have to motivate workers to work safely and without accident. Therefore it should
be impressively brought to their mind that any accident will cause ham to them only and
therefore any accident prevention work is in their interest. Some thoughts are given
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Subject : Industrial safety Management (23108)
below as an example. Many such thoughts may be developed based on experience and
need of time and situation .
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Subject : Industrial safety Management (23108)
1. The employer loses the benefit of an experienced (trained) person, has to pay
compensation in court and incur other expenditure including, medical and transport
charges. Time is lost in investigating the accident and repairing the machine if
damaged. Production is interrupted and no such skilled worker can be prepared in a
short time.
2. If the deceased is a social worker, society and nation both lose his services. In
totality everybody is losing and nobody is gaining by accident. Therefore friends!
Do determine from now to stop accident by all means.
2) Accident causes more Harm to the Worker: First victim of any accident is worker
himself, because he is nearer to the place of accident. Who is exposed to gas or leakage?
Worker only. Who hurt by falling, slipping or striking? Worker only. Who hurt by a falling
body? Worker only. Paying fine or compensation in court may relieve an employer, but can
an injured worker be relieved from pain and suffering? No. Can his family get his support if
he is died? No. Thus it is the worker only who loses more by accident. Therefore we have to
think of our safety first.
(3)Foolishness: To provide guard after cutting of fingers, to cause fire and then to
extinguish, to discharge gases and then to search mask, to invite emergency and then to rush
for control measures... Is it not foolishness?
Therefore, awake, arise and remove all unsafe working conditions and actions first.
(4) Worse than an Accident: Every year some 2 lakhs people die in accidents in our
country. Many more are injured. But the most serious matter is that by inhaling polluted air,
we are calling death gradually near and near.
Is it not surprising that this condition of working in polluted air is not called 'accident'
because immediate absenteeism of 48 hours is not noticed thereby?
It is always advisable to consider this condition worse than an accident and try to remove it.
(5) Five years deducted from life: Whatsoever pay-rise and facilities we may obtain, but, if
we continue to inhale polluted air, at the time of retirement, with gratuity, we will certainly
get a certificate from the nature- 'Five years are deducted from your life'.
Do you wish this? If not, awake and build a wall before the water comes. Do whatever you
can do to prevent pollution.
(6) Nothing is costlier than Life: Everybody loves own life because everything can be
experienced till the life is live. Future after life is unknown. All fruits of this world can be
enjoyed only until the eyes are open and live. .Therefore nothing is costlier than life. Then
why should we lose it by our own mistake? Therefore firmly determine not to commit and
mistake to cause an accident to oneself or others.
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Subject : Industrial safety Management (23108)
(7) Safety must be our Way of Life: Safety motivation must last lifetime. Temporary
determination due to any emotional setback or funeral asceticism (smashan-vaimgya) will not
last long. Safety attitude must become a habit or part of life. Whenever we see and wherever
we see, we must see through the safety-eyes. Our thinking, observing, working or supervising
at the workplace, home or anywhere else, must be with safety-eye, safety-outlook, safety
attitude and safe behaviour in all respects. Safety cannot be confined with any workplace or
any time limit. It has to be with us till we live and enjoy. Therefore it must be our way of life.
(8) Safety needs Active Participation: Safety begins with our selves. 'Others will practice
safety, it is their duty, why should I worry?' is an improper thinking. Safety needs our
participation too, because our mistake can contribute to an accident even if everything is all
right. And if we do not participate, how can we expect others to participate? Therefore safety
needs' our active participation first. Participate yourself in safety and let others encourage or
inspire to follow you. This is the only best way of safe behaviour.
(9)Implement, Implement & Implement: No safety slogan, safety notice or "safety
literature, including such books, will save life unless it is practiced. Therefore, implement
what you know or learn from safety literature. Don't wait till any accident takes place. Think
and prevent the possibility of accident causes. Implement all safety measures. There may be a
thin boundary between what is safe and what is unsafe, what is legal and what is not legal.
Identify this boundary and implement preventive measures to remain within a safe limit.
(10) Protect the Environment: Man is born of food, Food is of plants, Plants are of earth,
and Earth is of water, Water is of air, Air is of space and Space is of God. One, who ignores
this togetherness of life, perishes. Therefore Protect the Air, Water, Earth and Plants - all
elements of the God. They will protect you.
(11) Killing of Nature means killing of Self: By killing, polluting and distorting {he Nature
and its Vicinity, are not committing Suicide ? So, O Man, ‘Be aware and restrict such wrong
practices.
(12) Work of Safety People is Invisible: Accidents, injuries and losses that take place are
visible but those prevented are invisible. By the constant efforts of safety people, hundreds
and thousands of possibilities or events of accidents are prevented. This work is neither
visible nor measurable. Cost of such prevented accidents and losses is uncountable. Its value
is the highest. The work of safety people should be evaluated and assessed in this way.
(13) Safety pledge: "On this day, I solemnly affirm that I will rededicate myself to the cause
of safety, health, and protection of environment and will do my best to observe rules,
regulations and procedures and develop attitudes and habits conducive for achieving these
objectives. I fully realize that accidents and diseases are a drain on the national economy and
may lead to injuries, disablements, deaths, harm to health, and damage to- property, social
suffering and general degradation of environment. I will do everything possible for the
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Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
stimulation and variety in work. Environment without this motivation will suffer and
frustration may result. Change or variety in job and stimulation may reduce
frustration. In industry there are many instances creating frustration. Not providing
proper working conditions, tools, equipment and PPE despite of demand, not
providing necessary guards and safety devices on machines and not giving
promotion, increment, recognition and status as per requirement can cause
frustration. All such dissatisfying factor should be detected in time and appropriate
remedial measures including management functions should be adopted.
Some situations leading to frustration and techniques of identification and
management are given in below Table
Frustrating Situations and Remedial Measures
Situation Identification Management
1 Increasing accidents to 1 Check job or m/c 1 Remove the defect.
an individual condition. 2 Improve them.
2 Check surrounding
space, light etc. 3 Use ergonomic design,
3 Study type of tool, standard tool, equipment etc.
equipment etc. Correct it
Employ psychologist and
4 Study work method. 4 take his advice.
Study his behaviour.
2 Work quantity (goal) 1 Study results, spoilage, 1 Reduce the work reasonably
excessive. effects of workload on (make the goal attainable).
body etc. From the result, adjust the
2 Carry out time motion 2 work, machine, tool
study.
3 Work quality is not 1 Check the material. 1 Have good quality material.
obtained in spite of 2 Observe work method, 2 Give training as required.
good efforts. machine, tool etc.
4 Worker becomes 1 Discuss with him or 1 Try to remove the reasons by
irregular, inattentive or others to know the giving more pay, promotion,
reluctant etc. reasons making permanent etc.
2 Try to know family 2 Try to solve such problems
problems to the extent possible.
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Chapter -5
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Subject : Industrial safety Management (23108)
14. Indian Association of Occupational Health, C-62, Defense Colony, New Delhi-
110024.
15. Department of Industrial Health, Tata Services Ltd., Jeevan Vihar, 75, Apollo
Street, Fort, Bombay-400 023.
16. Industrial Toxicology Research Centre, P.B. No. 80, Lucknow-226001.
17. Indian Council of Medical Research, Ansarinagar, Medical Enclave, New Delhi.
18. All India Institute of Hygiene and Public Health, 110, Chittaranjan Avenue,
Calcutta-700012.
19. Safety, Health & Environment Association, 2nd Floor, Vadilonu Ghar, Kasak
Fuvara, Bharuch 392012, Gujarat.
20. Greentech Foundation, 809, Vishwadeep Tower, Distt Centre. Janakpuri, New Delhi
- 110058 (Website: www.greentech.org.)
21. Master of Industrial Hygiene and Safety Division, ISTAR Building, Vallabh
Vidyanagar - 388120, Dist- Anand, Gujarat.
22. HSE Information Services, Caerphilly Business Park, Caerphilly CF83 3GG, UK.
23. Internet, 104 websites and computer software are now available on the subjects of
industrial safety, health and environment including that of British Safety Council,
London, National Safety Council, USA, CSP (Certified Safety Professional) and CIH
(Certified Industrial Hygienist) Examinations etc. See part 13.2 also.
The publications and periodicals of above institutions and Offices of the Labour
Departments and Pollution Control Boards of various States also provide information on
safety, health and environment. NSC, USA publication 'Accident Facts' gives wide
information on accident statistics of USA every year.
Some International organizations are as under :
1. ILO: International Labour Organisation (ILO), Geneva, Switzerland (Office in
India at - 7, Sardar Patel Marg, New Delhi-110021).ILO publication "Encyclopaedia
of Occupational Health and Safety" is worth mentioning for its great service on such
information to the world.
2. World Health Organisation (WHO), Geneva, Switzerland (Office in India at World
Health House, Indraprastha Estate, Ring Road, New Delhi-110002).
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Subject : Industrial safety Management (23108)
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54. Chemical Emergency Preparedness, Prevention & First Aid for Extremely Hazardous
Substances U.S. Environment Protection Agency
http://yosemite.epa.gov/oswer/ceppoehs.nsf/ Alphabetical_Results?openview
55. Explosion Database of Chemicals- NIMCK- Japan
http://www.aist.go.jp/RIODB/db005/ index.html
56. Incompatibility of Chemicals http://www.pp.okstate.edu/ehs/hazmat/ labman/
Appendix-B.htm
57. Laboratory Safety Manual http: / / www. pp.okstate.edu/ ehs/hazmat/
labman/Chaplal.him
58. Hazardous Material Incident Toolkit http://www.oes.ca.gov/0perational/
OESHome.nsf/ Content/ 333G7C454B5PC40B882571070069A855?Opei->Documen
59. Hazardous Material Transport Training Module
http://hazmat.dot.gov/trainmg/mods/mod.htm
60. Data Sheets of Extremely Hazardous Chemicals by US Environmental Protection
Agency http: / / yosemite.epa. gov / oswer/ceppoehs.nsf/ Alphabetical_Results?openview
61. Fact Sheets of Hazardous Substances http:/ /web.doh.state.nj.us/rtkhsfs/ search
.aspx?lan=english
62. MSDS by Scott http://www.scottecatalog.com/msds.nsf/ AII?ReadForm
63. Environment, Health &: Safety Online http://www.ehso.com/contents.php#B
64. Poisons' Information monographs- by CCOHS Canada
http://www.inchem.org/pages/pims.html
65. Chemical Safety in Asia - Law & Practice- by ILO
http://www.ilo.org/public/english/protection/safework/papers/asiachem/index.htm
66. The Chemical Database- By Akron University http://ull.chemistry.uakron.edu/erd/
67. Recurring causes of Chemical Accidents documents http://www.plant-
maintenance.com/articles/ccps.shtml
68. Chemical Accident excellent case study by U.S. Chemical Safety and Hazard
Investigation Board http://www.csb.gov/
69. Incident Investigation Reports from Chemical Safety and Hazard Investigation Board
http://ncsp.tamu.edu/reports/CSB/csbList.htm
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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Modern Methods of Programming: Such methods use computer as basic tool and
software of required programmes. Therefore various software programmes are being
developed and used for specific purpose Programming means the process of providing a
series of instructions to the CPU to get the desired actions s.
Communicating media of the PROGRAMME :Computer, FAX, Internet, E-Mail
and V-mail system
Software: Modern software like CAMEO, EFFECT, WHAZAN, HEGADIS, SAFETI,
PHAST, BLEVE and Explosion packages -IIT, Kanpur, ALOHA, ARCHIE, CIRRUS etc.
should be utilized and updated. Safety Data Banks should be created at National and State
level. Global internet system should be utilized. MIS should be interlinked with National
SHE System at all strategic areas.
Data Storing in Programme: Above software can be used
• To store the information pertaining to day-to-day accident Recording, Accident
Investigations, Inspection Rounds, Monthly/Qtly/Yearly Accident Reports, Statutory
requirements & compliance, Training programmes, Safety meetings, future planning,
budgeting, Environmental monitoring, Work permit systems, Safety audits etc…Input
• To store various formats, tables, charts, symbols, graphs and documents to report,
analyse, reply …Output
• MIS for SMS : MIS for Safety Management System Programme should be designed by
I.T. Experts as per own need. One general model may be of the following type:
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Storing and Retrieval of Information: A floppy disk. Zip, CD and pen drive store
computer programs and data and can be read through a floppy or CD drive. Hard disk stores
permanent memory until erased .or replaced. Graphics is a display of information in picture
form. File is a collection of information stored on a disk.. The main computer functions are
input, output, storage and processing. CD writers are used to write a CD.
Computer can store, process, change and print tremendous information. Capacity of
storing is day by day increasing. Floppy, Zip, CD, VCD, Pen drive, Server etc. are the
examples of progress. Hard disk capacity is also increasing. E-mail and V-mail transforms
this stored information very fast. They connect all departments of a factory, all offices of a
State or Nation and all countries in the world. Storing and presenting of MIS has become
very fast and very easy. Laptop and palmtop are very handy. Handwriting is being replaced
by keyboard writing. Correspondence and examination through keyboard have become a part
of modern culture. Volumes of books and libraries have been reduced to small CDs.
Here 'retrieval' means taking back, finding or extracting information stored in a computer.
Any information can be directly fed to the CPU or it can be copied by inserting floppy, CD or
pen drive or through an internet. Such information stored in CPU can be recovered by a
floppy or CD drive. Such information can also be modified, corrected, altered or added. Thus
computer is useful in retrieving much information as per requirement. It saves too much time,
labour and volume of work.
Causes of MIS failure: They are of the following types:
1. Insufficient, incorrect or ambiguous information.
2. No two-way communication.
3. Confused reporting.
4. Poor exchange of information.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
10. Working hours on computer should be reduced with increasing age or difficulty.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
taxation, audit, assessment etc, good and effective integration of MIS between all
departments is essential and constantly-required.
Information on safety management system, SOP, PPE, safety work permits, statutory and
other safety provisions, forms and annexure, training subjects and schedules, safety
Suggestions, compliance etc is required by many departments from safety department.
Similarly safety department needs feedback and other information from other departments.
This is not possible without effective integration of MIS between all departments.
Therefore continuous integration between departmental MIS should be maintained and
updated.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Chapter -6
6.1 Principles of Accidents Prevention :
Incident: (Near miss + F. A. + Minor + Major + Fatal + Direct Occurrence (D.O.)+ Property
Damage + Environmental Accident)
An incident is any observable human activity sufficiently complete in itself to permit
references and predictions to be made about the persons performing the act viz. cleaning an
unguarded machine, failing to wear PPE, using compressed air on body, raising pressure or
temperature unnecessarily. It may result in accident or a near miss.
Incident for accident is defined as, 'an unplanned event or series of events that has or could
have, caused injury to people and / or damage to assets and / or damage to the environment
and / or loss of reputation.
Accident: Accident is an Unexpected, Unintended, Unforeseen, Unplanned event
interrupting orderly progress of the work in Question which may lead to an Injury or /&
property damage.
An accident is defined in different ways
Dictionary meaning of ‘accident’ is an unexpected event or mishap.
• It is defined as an event that is not expected, intended or imagined. It refers the event not
the result or effect.
• An accident is an unplanned event that interrupts the completion of an activity and that
may (or may not) cause damage to person, property or environment.
• Unintentional injury is the preferred term for accidental injury in the public health
community. It refers to the result of an accident.
• An accident is unintended, unplanned event or its sequence caused by unsafe condition(s)
or/and unsafe act(s) and may result in immediate or delayed undesirable effects.
• An accident is an unplanned and uncontrolled event in which the action or reaction of an
object, substance, person, or radiation results in personal injury or the probability thereof.
• It is also defined as an unexpected, unintended or unforeseen event that causes injury, loss
or damage.
• An accident is any unplanned, sudden event, which causes or is liable to cause or is liable
to cause an injury to man materials (including plant) or environment.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
• An accident is any occurrence that interrupts or interferes with the orderly progress of the
activity which causes or likely to cause injury with or without damage to property or
environment.
• An accident is the result of carelessness, casualness or any fault known or unknown.
• An accident is an unwanted transfer of energy beyond the threshold limits. In case of
accident to a person, physiological energy loss is an accident while in other cases it may
be an energy loss from material.
• It is an event, which is unexpected, unavoidable, unintentional act resulting from the
interaction of host (accident victim), agent (injury deliverer) and environmental factors
within situations, without involve risk taking and perception of danger – Such man.
• An accident is an unexpected, unplanned event which has a probability of causing
personal injury or property damage or both. It may result in physical harm (injury or
disease) to person(s), damage to property, loss to the company, a near miss or any
combination of these effects including delayed effect.
• An accident is an unexpected, unplanned event in a sequence of events, that occurs
through a combination of causes, it results in physical harm (injury or disease) to an
individual, damage to property, equipment, building etc., a near miss, loss to the
company, or any combination of these effects.
• An accident is an unplanned, not necessarily injurious or damaging event that interrupts
the completion of an activity. It is invariably preceded by an unsafe act or an unsafe
condition or their combination.
• An industrial (occupational) accident is also defined a san undesirable event that result in
a certain length of disability and stoppage of work and time loss due to the effect of a
production-related dangerous factor or a combination of such factors.
• An occupational accident is presently regarded as an index or a symptom of dysfunction
in a system formed by a production unit, such as a factory, a workshop, a shift or a
workplace.
• Occupational accident is also defined as “any organic or functional injury or damage to
body, limbs or health or psychic disorder due to an external, sudden or violent cause
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
occurring during work or due to work itself and resulting in death or total or partial,
permanent or temporary incapacity for work” Fata accident or death from accident is an
accident that results in one or more deaths within one year from the date of accident.
Philosophy of accident: it should be noted from above definitions of ‘accident’ that
• In accident phenomenon, which includes event and its effect, ‘event’ is more important
than its ‘event’ Event or consequence may or may not be there. For example, a person
getting chemical splash (exposure), struck by falling body, falling by striking against
object, falling from height, getting electric shock or meeting with road accident may not
get any injury or his normal activity may not be interrupted. Here event has taken place
but it has not a notable effect. Even then this is an accident for the purpose of finding the
‘cause’ of event and remedial measures to prevent its recurrence.
• Event may be one or more. One thing falls or may things fall one by one, only fire takes
place or explosion follows the fire, events of primary and secondary explosion, collision
of many vehicles, one persons die or more persons die in a sequence or due to different
injuries in one accident may constitute one accident.
• Idea of ‘accident by chance’ is not acceptable in safety philosophy. Each accident has its
‘cause’ or ‘cause’ that need inquiry, investigation and efforts to remove them.
Considering accident as chance or fate does not help to prevent the accident and may
result in another accident. Even if it is considered as chance, the ‘causes’ of that chance
occurrence are important.
• There may not be immediacy between event and effect. For example, pain or symptom
may appear after repeated actions or few hours or days after the accident, cancer may
occur after years from the exposure of a toxic substance. This delay or latency period’
hides the effect for some time. However such accident of delayed effect may prove most
serious and needs thought investigation and effective control measures viz. pesticide
poisoning and control.
• Duration or span of event may be short or long Span of event should be considered from
its beginning to the end of the effect or consequence. Therefore when effect occurs just
after the event begins, duration of event is short and when effect occurs after a long time
(i.e. delayed effect) from the beginning of the event duration of the event is long.
Therefore in definition of accident, immediate or delayed, both the effects are included.
Chronic disease (effect) requires events of long duration.
• Legal definition of ‘non fatal injury accident’ or ‘dangerous occurrence’ makes it
reportable after the duration of 48 hours from the time of accident. Thus legal definition
of accident has considered 48 hours duration of event to notice any harmful effect.
Accident causing death or possibility of death is to be reported immediately (Sec. 88 &
88A, the Factories Act).
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Injury: (Injury & Accident are two different things & Injury is a consequence of the
Accident)
• To injury means 'to hurt' and an injury means harm’. In legal terms injury may be to a
person or property or both and compensation (damages) can be awarded to the injured
person for the loss he has suffered and may continue to suffer. Punitive damages can be
awarded for grave injury.
• An injury could be psychological also and not necessarily a physical condition resulting
from a mechanical, electrical, chemical or radiological accident. A heart attack resulted
from unusual mental stress from the work is injury for which compensation is payable.
But natural death or heart attack during normal activities may not be considered as an
injury from accident.
• Injuries are not considered resulting from an accident where willful death, self-inflicted
intentional injury, intoxication and undue alteration by the person injured are involved.
• There are two types of injuries. Minor injury generally means that having no permanent
effect and leading to less than three days off work. Major injury generally means that
leading to more than three days off work. The major injury may be fatal (death) or
serious. A fatal injury is a great loss to the worker, his family society and the employer.
• An injury is an external damage to the human body; disturbance or dysfunction resulted
from an accident.
• By cause, injuries may be mechanical (bruise, cuts, tissue ruptures, breakage etc.),
thermal (shock, burn, frost-bite), chemical (bum, acute intoxication and poisoning),
radiated (tissue regeneration, changes in the hematopoietic system), or combined (the
effect of more than one causative factor with various consequences). The result of
accidents (which may cause serious, minor or no injury) may be temporary or permanent
disablement or a fatality (injury).
• The term "accidental injury" denotes an injury to a workman due to an accident. It does
not include an injury to a worker's health unless it results directly from an accident, as for
example, a poisoning due to toxic chemical.
• "Serious bodily injury" as defined in section 92 of the Factories Act means "An injury
which involves, or in all probability will involve, the permanent loss of the use of, or
permanent injury to, any limb or the permanent loss of, or injury to, sight or hearing, or
the fracture of any bone, but shall not include, the fracture of bone or joint (not being
fracture of more than one bone or joint) of any phalanxes of the hand or foot".
• An injury is merely the result of an accident: An accident is controllable, but, when it
occurs, it is difficult to control the resulting injury. The severity of accident depends upon
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
the material causing injury, energy released, body part being injured and the physical or
mental condition of the person being injured. As accident precedes injury, attention
should be paid to prevent the accident.
H.W. Heinrich estimates that in a unit group of 330 accidents of the same kind and involving
the same person, considering average of averages, 300 results in no injuries, 29 in minor
injuries and I in a major lost-time injury. It indicates an ample opportunity to prevent any
injury by efforts during 300 no-injury or warning accidents. This foundation of a major injury
is shown in Fig.
Major Injury
1
Minor
29
No injury
300
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
warning, removal of safeguard, chance taking, wrong interpretation of safety rule, not
following the safety precaution, poor vision or judgement etc.
• Unsafe act is concerned with the human being and can be corrected by the action of the
human being only.
• Training plays an important role. Even if the condition is fully safe, an accident may
happen because of the unsafe act.
• At the root of creation of unsafe condition, many times the underlying cause is unsafe
act i.e. human failure somewhere, which can be detected and corrected.
• According to H.W. Heinrich, @ 88% accidents are due to unsafe acts. He considered
unsafe acts responsible for most of the unsafe conditions.
Unsafe Condition:(It is a situation which has got potential to lead to an injury unless
corrected by someone)
• It means existence of a mechanical, physical, chemical or environmental condition,
situation or state of affairs, which may cause hazard or accident.
• The unsafe condition might be the result of any unsafe act (human failure) or accidental
failure or alteration of the safe condition.
• The unsafe condition may be the sole accident cause or one of several causes. Examples
are, wrong design, no guard on dangerous part, no control of chemical process, no
provisions of safety devices, poor light, poor ventilation, confined space, high noise etc.
• Unsafe condition is concerned with the position, situation, existence or accidental
alteration of the safe condition into such position, situation, existence or state of affairs
leading to the causation of any hazard or accident.
• Such condition may be because of any unsafe act or not. Acts of God are unsafe
condition.
• Unsafe condition can be rectified, repaired or made safe mostly by engineering controls.
Hazards:
• Hazard means existing unsafe condition or action or situation or event or their
combination which has potential to cause accident.
• Thus hazard can become a cause of accident or risk and it can exist without accident or
risk.
• When due to hazard, accident happens, it is converted into accident.
• If hazard still exists, accident may happen again, viz. flammable atmosphere.
• The causes of accidents generally remain latent for some time before an accident occurs.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
• These latent or potential causes are hazards. Hazards are sometimes referred to
synonymously with accident causes, but there is a clear distinction that a hazard can exist
without an accident whereas an accident cause without an accident is an absurdity.
• Hazard recognition, diagnosis and elimination are essential to any successful safety
programme.
• Hazard is an inherent property of a substance, agent, a source of energy or situation
having the potential of causing undesirable consequences.
• Hazard means an intrinsic capacity associated with an agent or process capable of causing
harm.
• Hazard is defined as, 'any event with the potential to cause harm, ill health, injury,
damage to property, plant, products or the environment, production losses or increased
liabilities.'
• Hazard is a condition with the potential of causing injury to personnel, damage to
equipment or structures, loss of material, or lessening of the ability to perform a
prescribed function. When hazard is present, the possibility exists of these adverse effects
occurring.
• Chemical Hazard is a hazard due to chemical (including its property, storage, process,
handling, effect etc.) and it is realized by fire, explosion, toxicity, corrosion, radiation etc.
• Major Hazard is a large-scale chemical hazard, especially one, which may be realised
through an acute even.
For Major Accident Hazard (MAH) see part 3.55 following.
• Occupational hazards are the hazards arising in course of and out of occupation or
employment.
• They include physical, chemical, biological, mechanical, electrical, psychological and all
occupational health hazards, diseases and poisoning.
• Rapid ranking method is a means of classifying the hazards of separate elements of plant
within an industrial complex, to enable areas for priority attention to be quickly
established.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Error:
• Errors are of different types, viz. human error, design error; planning, production,
operation and maintenance error etc.
• Human error can be defined as a human's action, which differs from or is inconsistent
with prescribed or established behaviors or procedures. It may be of two types:
predictable or random.
• Predictable error occurs under similar conditions and can be foreseen because it has
occurred more than once.
• Random error is non-predictable and unique in nature. For example, all of a sudden a fly
or insect enters in eye due to which a worker may throw away a tool or lose his balance
and cause error. But if flies become common phenomena i.e. predictable, the error
becomes predictable one and remedial measures are required.
• Human error takes place due to omission (failure to perform a required function) or
commission (performing a function not required), failure to recognize hazard, poor
response, poor timing, wrong decision, sudden disturbance etc.
Oversight:
• Oversight means overlooking of something, error or supervision. When there are more
switches side by side and looking identical, an operator may operate a wrong switch by
oversight.
• While counting many things, by oversight, someone may make mistake. Thus oversight
denotes a state of mind by which error or mistake is possible due to lack of concentration
or attention. Result of oversight is mistake or error.
• Oversight leads to unsafe action and that may result in accident.
• The words - error, mistake and oversight - have thin difference, all leading to the
causation of hazard or accident and concern with the state of mind or human behavior.
Mistake:
• Mistake, in the sense of safety, can be defined as an act of wrong opinion, judgment about
a thing or situation which results in hazard or harm to a person, property or environment.
• It means to have wrong, perception about danger or to understand it wrongly so that it
may cause hazard.
• Like error, as explained earlier, it is an act of omission or commission resulting in hazard
or hazardous situation.
• Mistakes may be committed by men or machines and can be classified as personal
mistake, mechanical mistake, technical mistake, historical mistake etc. It may be small or
big. A gross mistake is called blunder.
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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
• Examples of mistake are wrong judgment of the speed of a vehicle, falling body or a
moving machine, to perceive blue as black, to press 'start' button instead of 'stop' button,
to press clutch or accelerator instead of brake etc.
Difference between 'error' and 'mistake' is thin and may be understood
interchangeably.
Theories of Accident Prevention: H.W. Heinrich estimates that in a unit group of 330
accidents of the same kind and involving the same person, considering average of averages,
300 result in no injuries, 29 in minor injuries and I in a major lost-time injury. It indicates an
ample opportunity to prevent any injury by efforts during 300 no-injury or warning accidents.
This foundation of a major injury is shown in Fig.
Major Injury
1
Minor
29
No injury
300
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
unsafe act (see fig. 4.2). Likewise, persons are exposed to mechanical hazards hundreds of
times before they suffer injury.
4. The severity of an injury is largely fortuitous the occurrence of the accident that results in
injury is largely preventable.
5. The four basic motives or reasons for the occurrence of unsafe acts provide a guide to the
selection of appropriate corrective measures. These are: Improper attitude. Lack of
knowledge or skill, Physical unsuitability and Improper mechanical or physical environment.
6. Four basic methods are available for preventing accidents. These are Engineering revision,
Persuasion and appeal. Personnel adjustment and Discipline.
7. Methods of most value in accident prevention are analogous with the methods required for
the control of the 'quality, cost and quantity of production.
8. Management has the best opportunity and ability to initiate the work of prevention,
therefore it should assume the responsibility.
9. The supervisor or foreman is the key man in individual accident prevention. His
application of the art of supervision for the control of work performance is the factor of
greatest influence in successful accident prevention. It can be expressed and taught as a
simple four step formula - Identify the problem, find and verify the reason for the existence
of the problem, select the appropriate remedy and apply the remedy.
The humanitarian incentive for preventing accidental injury is supplemented by two powerful
economic factors: (1) The safe establishment is efficiently productive and the unsafe
establishment is inefficient (2) The These axioms were the first set of principles or guidelines
ever set before in industrial safety and it has guided all safety activity till today. During the
passage of 75 years, some of his axioms are questioned and disbelieved as truths, but, most of
them are still true and deal with the important areas of safety, viz. accident causation and
prevention, reasons of unsafe acts and conditions, management control functions,
responsibility of organization, costs of accident, safety and productivity etc.
H. W. Heinrich’s Accident Sequence:
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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
The five factors .in accident occurrence series in chronological order are:
a) Ancestry and social environment.
b) Fault of person.
c) Unsafe act and/or mechanical or physical hazard.
d) Accident and
e) Injury
One factor is dependent on another and one follows because of another, thus
constituting a sequence that may be compared with a row of dominoes placed on end and in
such alignment in relation to one another that the fall of the first domino precipitates the fall
of the entire row. An accident is merely one factor in the sequence. If this series is interrupted
by the elimination or withdrawal of even one of the five factors that comprise it, the injury
can possibly be prevented. See Fig.
1 2 3 4 5
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Subject : Industrial safety Management (23108)
• Accident is caused because of unsafe act or condition both. Injury is the result of
accident.
This suggests the steps of management controls as under:
Unsafe Mechanical, Chemical, Physical
Unsafe Acts of Persons (88%) Conditions (10%)
1. Operating without authority or clearance, 1. Unguarded, absence of required guards.
failure to secure or warn. 2. Inadequate support or guards, guards of
2. Operating or working at unsafe speed. improper height, strength, mesh etc.
3. Making Safety devices inoperative. 3. Defective, rough, sharp, slippery, decayed,
4. Using unsafe or defective equipment or cracked surfaces etc.
equipment unsafely or improperly. 4. Unsafe design of machines, tools, plant,
5. Unsafe loading, placing, mixing, equipment or supplies.
combining, etc. 5. Unsafely arranged, poor housekeeping,
6. Taking unsafe position or posture. congestion, blocked exists, etc.
7. Working on moving or dangerous 6. Inadequately lighted, sources of glare etc.
equipment. 7. Inadequately ventilated, impure air source
8. Distracting, teasing, abusing, startling etc.
horseplay etc. 8. Unsafely clothed, no goggles, gloves or
9. Failure to use safe affair or personal masks, wearing high heels etc.
protective equipment or devices. 9. Unsafe processes, mechanical, chemical,
10. Failure to warn co-workers or to secure electrical, nuclear hazards etc.
equipment. 10. Inadequate warning systems.
11. Improper lifting. 11. Fire & Explosion hazards.
12. Servicing equipment in motion. 12. High noise or vibration.
13. Use of drugs or alcohol. 13.Hazardous dusts, gases, fumes vapours
etc.
This supports Heinrich's conclusion that human failure is the predominant cause of accidents.
However, this is not necessarily applicable to all or majority of the industrial accidents as per
other theories.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Criticism of Heinrich's Theory and His Reply:H.W. Heinrich's ratio theory (fact finding
from a study of 75000 accident cases) that 88% accidents are due to unsafe acts, 10% due to
unsafe conditions and 2% unpreventable is criticised as follows:
Heinrich made his analysis from reports submitted to insurers by the managers of the
companies at which the accidents happened. No manager would want to indicate to the
insurer or to the safety authority or agency that the company had been at fault and that
hazards existed in the workplace under his control. Such a statement may sound harsh but is
borne by known practices, which also distort statistical data.
This ratio idea is fallacious because it rests on a false assumption that accidents are
result of either unsafe acts or unsafe conditions. Actually there are multiple (combined)
factors as supported by the results stated below.
A study conducted by the National Safety Council (USA) yielded the following conclusions:
18% injuries due to mechanical causes.
19% injuries due to personal causes.
63% due to a combination of both causes.
A study by the Department of Labour and Industry of the State of Pennsylvania yielded the
following:
3% "due to mechanical causes.
2% due to unsafe acts.
95% due to a combination of both causes.
The ratio idea had done much harm and many employers still say, 'Why should first of all we
spend a lot of money on only 10% mechanical causes? We will start after 88% personal
causes are removed by the employees'.. Such concept is damaging. There are two essentials
in every case of injury - there must be some degree, of hazard and there must also b~ faulty
behaviour by someone. If the factor of hazard is properly detected and eliminated, there could
be no injury. Similarly, if behaviour could be made and kept perfect, the result would be the
same. Both these are the duties of every management It must try collectively to combat the
combined causes of accident and should not separate the unsafe acts as employee's
responsibility only. Law always stresses for employer's responsibility first. Why? Because the
primary duty, money and ultimate control lie with the management to detect and remove
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
unsafe conditions actions and to give necessary training to the workers. This is the only safe
and healthy approach.
Heinrich is aware about the public debate and criticism of his 88-10-2% ratio in accident
causation stated above and its wide spread that may influence people to ignore the machine
guarding and to take the assumedly easier path of issuing instructions. In reply, he states his
belief that the accident-prevention fraternity, like almost all professional groups, want all the
pertinent facts and he has more faith in-their good judgement than to fear that they will ignore
the very first common-sense step of safeguarding mechanical environment. The machine is
dangerous as man makes it so. It's man's use of the machine - more correctly, his abuse of it -
that creates danger.
He points out that judgement must be used in selecting the major cause when a mechanical
hazard and an unsafe act both contribute to accident occurrence. Personal judgement may
lead to error, but it is defensible and in the majority of cases results in fair conclusions.
The 300-29-1 Ratio (Foundation of lost-time accident - Explaining the foundation of
a major injury, Heinrich estimates that in a unit group of 330 accidents of the same kind and
involving the same person, 300 result in no injuries, 29 in minor injuries and I in a major lost-
time injury. See Fig. 4.2. He explains this 300-29-1 ratio as an aid in accident prevention,
because, it vividly emphasises preventive opportunity, when an employee, either because of
his repeated unsafe action or repeated exposure to an unsafe mechanical condition, suffers
300 no-injury accidents (actual events such as slips and falls but fortunately not causing
injury) surely there can be no lack of opportunity in preventive effort.
Replying misunderstanding and misquotation of this ratio, he states that this ratio is an
average. Sometimes a major or serious injury occurs the very first time a person acts unsafely
or is exposed to mechanical hazard – in other cases he is so endangered hundreds or
thousands of times and may slip or fall many times before injury is sustained. In industry,
where, employees are under supervision, these unsafe practices, conditions and the resulting
narrow escapes from actual injury (events-accidents) are tangible and visible. They can and
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
should be controlled long before one of the 300 no-injury accidents ultimately causes an
injury.
In above ratio - cases, a major injury is any case that is reported to insurance office or to the
State Compensation Commissioner. A minor injury is a scratch, bruise, or laceration such as
is commonly termed a first-aid case. A no-injury accident is an unplanned event involving the
movement of a person or an object, ray, or substance (slip, fall, flying object, inhalation etc.),
having the probability of causing personal injury or property damage but not resulted in
injury (near miss).
Hepburn's Theory
H.A. Hepburn amplified the above Heinrich's theory and arrived at the principle that an injury
accident is the result of the convergence at the same point of time of 4 factors (1) Unsafe
actionable (2) Unsafe conditional (3) Proximate casual and (4) Personal.
Unsafe Actionable
Here unsafe actionable and conditional factors are as usual Personal factor means person
injured or likely to be injured by an accident and die person causing the accident. The
proximate factor is that immediate causative factor such as failure of a brake, sudden
exposure to gas etc., which by its reaction causes a sudden closing together or convenience of
all the four factors to cause an injury accident He emphasises that lie four factors are
complementary to one another m causation of any injury-accident such that, if any one or
more can be withdrawn by any means during or just before convergence, an injury accident
can be prevented. The event of an accident will not be prevented by efforts to control any one
of the factors to the exclusion of the others. Remedial measures must be adopted for each of
the factors. Like Heinrich he also suggested planning and organizing to prevent unsafe
actions and remove unsafe mechanical or physical conditions.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
MANAGEMENT
MAN MACHINE
MEDIA
In this theory
1. Man includes- workers, public etc.
2. Machine includes- equipment, vehicle etc.
3. Media includes- environment, weather, roadways etc.
4. Management means within which above three parameters operate i.e. to be controlled by
the management.
Characteristics of –
1. Man includes- age, sex, height, skill level, training, motivation etc.
2. Machine includes- size, weight, speed, shape, material of constriction, energy etc.
3. Media includes- pressure, temperature, content, contaminants, obstruction on road etc.
4. Management includes- structure, style, policy,
5. procedure, communication etc.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Simple example of this theory is a man slipping due to walking on a banana skin lying on .the
road. Here main contributing factors are as under:
Man - A man walking on the road.
Machine or object or vehicle - Slippery banana skin.
Media - Hard road.
As per the multiple causation theory some of the contributing factors surrounding this
accident can be found out by asking :
1. Why was the defect in ladder not found in normal (past) inspections?
2. Why did the supervisor allow its use? Why did he not get it repaired urgently?
3. Didn't the injured worker know he shouldn't use it?
4. Was he properly trained or not?
5. Was he reminded or cautioned?
6. Did and do the supervisor examine the job first?
The answers to these and similar questions would suggest the following measures:
Systems Model Theory :Similar to V.L. Grose's multiple causation theory, Bob Firenze
developed a system model theory as under:
Here interaction between man, machine and environment (basic pre-elements for any
accident) leads to an accident if the information available to the important element of the
system is inadequate. If the risk is high and the decisions based on information are illogical
and unsound, an accident occurs resulting into incompletion of the task.
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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Accident
Overload Human
(load, capacity, state) error
Incompatibility
Improper activities Initiating
incidents
Accidents
Outcomes
Casual Chain
This theory states that accidents are the result of a casual chain (as in multiple causation
theory), one or more of the causes being human error, which is in turn caused by three
situations - overload, incompatibility and improper activities.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Epidemiological Theory:
Suchman stated definition of accident as "An unexpected; unavoidable, unintentional act
resulting from the interaction of host (accident victim), agent (injury deliverer) and
environmental factors within situations which involve risk taking and perception of danger".
His model is shown below:
This originated from the study of epidemics. Casual association between diseases or other
biological processes (accidents) and specific environment are studied. A classic example of
epidemiological method was given by Snow who discovered that persons using a particular
water supply had a higher death rate from cholera than others. Gordon and McFarland
supported that accidental injuries could be studied with the same techniques.
Surry’s Decision Theory:
Jean Surry developed this theory stemming from .the epidemiological model of Suchman. It
assumes that by a person's action or inaction, danger occurs to the person. If any negative
responses to the question are shown during the danger build-up cycle, the danger becomes
imminent. If all replies' are positive, the danger diminishes. A negative response to one of the
questions will lead to inevitable injury. An accident can be the result of many different routes
through the model (20 routes). There are fewer routes leading to no-injury situations.
Energy (Release) Theory :
Dr. Leslie Ball, former Director of Safety for NASA, introduced a causation theory. His
thesis is that all accidents are caused by hazard, and all hazards involve energy, either due to
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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
involvement with destructive energy sources or due to a lack of critical energy needs. This
model is most useful to identify hazards and to understand system safety.
Gibson noted that injury to a living organism can be only by some energy
interchange. Hence it was suggested that the energy exchange should be considered as the
injury agent. The energy exchange resulting in an injury could be mechanical, chemical,
thermal, electrical etc. This concept is useful in understanding the way injury is caused and
examining the solutions. When a grinding wheel is in stop-position it does not make
accident, but if it runs and fingers trapped, it makes accident because of its kinetic energy.
William Hadden, m 1970, explained 'energy transfer or release' as the main factor for
accident causation and said that accidents and injuries are caused because of transfer or
release of energy between objects, events or environment interacting with people.
1. Prevent the transfer or origin of energy, e.g. safe substitution - using toluene instead of
benzene, not keeping the car running, dipping instead of spraying, shot blasting instead of
sand blasting.
2. Reduce the amount of energy trailer, i.e. drive vehicle or machine at slow speed, reduce
quantity or concentration 'of hazardous chemicals.
3. Prevent release of energy, e.g. flameproof electric fitting in flammable area, fall arrester
device, dyke to stop spread of .chemical, safe overflow pipe or level cut off device.
4. Change the rate of release or distribution of released energy, e.g. reduce the road slope,
use inhibitor to reduce rate of reaction, sprinkler to reduce rate of burning, scrubber to scrub
toxic gas, condenser to liquefy organic vapour.
5. Divert (separate) the energy released in time or space, e.g. separate paths for vehicles and
pedestrian traffic, keep electric wiring or pesticide out of reach, discharge gases at height
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
6. Provide barrier between the energy released and a structure or a person likely to be
affected, eg. guards on machines, radiation shield, filter, safety goggles, earplugs, insulation
on hot surface, blast wall against explosion energy.
7. Make the surfaces of structure safe. e.g. rounded corners, blunt objects, big handles of
tools and no sharp edges.
8. Strengthen the structure or person susceptible to damage, e.g. fire resistant wall, training
to workers and vaccination for disease.
9. Early detection ,of damage and actuate counter effect, e.g. fire detectors with sprinklers,
high level alarm and tripping of feed pump, temperature alarm and starting of cooling system.
10. Speedy measures to restore normal condition, e.g. rehabilitation of injured worker,
repairing of a damaged machine or vehicle.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
consequence or effect may not be needed. Thus accident control is a vital factor in
every industry, which if ignored or practised unskillfully, leads to needless human
suffering and business bankruptcy.
The accident-prevention task requires both, the short term approach (direct control of
personal performance and environment) and the long-term approach of instruction, training
and education. This task must be performed before an accident and injury occur. Subsequent
efforts after accidents are also necessary.
Thus accident prevention may be defined as an integrated programme, a series of co-
ordinated activities, directed to the control of unsafe acts and unsafe conditions and based on
knowledge, attitude and ability for safety. It aims to serve industry, country and humanity.
Five basic or fundamental steps for accident prevention (safe and efficient production),
suggested by H.W. Heinrich, are:
1. Organization. (Policy & Safety Structure)
2. Fact finding.(Investigation)
3. Analysis of the facts found (for immediate cause & Root cause)
4. Selection of remedy and (Corrective & Preventive action)
5. Application of the remedy (Actual Implementation for closure)
Sixth step of 'Monitoring' (i.e. measurement o: result, assessment i.e. comparison with legal
criteria or standard, feedback and further improvement) is also suggested. Such review is
necessary after all safety progrmmes.
SAFETY
5 Application of remedy
4 Selection of remedy
3 Analysis
2 Fact finding
1 Organisation
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
Direct costs are easy to calculate as their money value is directly available. Workers' legal
compensation or accident insurance premiums (net premiums after deducting refund if any),
medical expenses of doctors' bills, medicine bills, hospital/ dispensary charges etc., extra
compensation paid to the injured worker or his family and all other direct
expenses/expenditures paid, by the employer due to the accident, constitute direct costs.
If hospital charges' doctor's bill, medicine bill or other expenditure is paid by insurance
company, only premium cost should be considered. Direct cost includes insured expenditure
and direct payment only.
Indirect Costs Uninsured or Intangible (hidden):Indirect costs are of many types
and need careful consideration to determine their 'equivalent money value'. Use of cost data
sheets and other methods have been developed to calculate indirect costs. They include
following
1. Cost of wages paid for working time lost by insured workers, other than workers'
compensation payments.
2. Cost of wages paid for working time lost by workers, other than the injured worker(s).
3. The net cost to repair, or replace material or equipment that was damaged in accident.
4. Extra cost due to overtime work necessitated by accident.
5. Cost of wages paid to supervisors for their time required for activities necessitated by
accident.
6. Wage cost due to decreased output of injured worker after return to work.
7. Cost of learning period and preparation of new worker(s).
8. Uninsured medical cost borne by the company.
9. Cost of time spent by higher officers, outsiders and clerical workers on investigations
or in restarting the production or in processing compensation application, procedure
and other administration.
10. Cost of work interruption due to idle machine, work stoppage or spoilage.
11. Cost of property (including material and equipment) damage due to accident.
12. Uninsured other costs and the miscellaneous unusual costs.
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
The ratio 4 to 1 : In 1927, H. W. Heinrich presented a paper at the National Safety Congress
(USA), and placed the indirect cost as an average 4 times the direct cost. This was the origin
of much discussed and controversial 4 to I ratio.
Bird and Germain, however consider this revised concept, an ineffective tool in safety
motivation and they suggested, a ledger-costs concept that appear on department ledgers. The
main factors considered in accident cost-accounting are -
1. Workers:
(a) Total cost of workers' compensation benefits.
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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
(b) Wages and medical costs paid during disability in addition to (a) above.
(c) Cost of time lost on day of accident and on subsequent days.
(d) Cost of time spent on light work or reduced output.
4. Cost of time spent on the case by first-aid attendant and hospital department staff, when
not paid for by the insurance carrier.
5. Cost due to damage to the machine, tools, or. other property or to the spoilage of material.
6. Incidental cost due to interference with production, failure to fulfill orders in time, loss of
bonuses, payment of forfeits and other similar causes.
7. Cost to employer under employee welfare and benefit systems.
8. Cost to employer in continuing the wages of the injured employee in full, after his return -
even though the services of the employee (who is not yet fully recovered) may for a time l)e
worth only about half of their normal value.
9. Cost due to the loss of profit on the injured employee's productivity and on idle machines.
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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
10. Cost that occurs in consequence of the excitement or weakened morale due to the
accident. (Stoppage or slawing down of work)
11. Overhead cost per injured employee - the expense of light, heat, rent, and other such
items, which continues while the injured employee is a non-producer.
This list is not exhaustive and many points can be added to it, though it is sufficient to point
out one
Example :Let us consider an example of a worker drawing Rs. 900/- p.m. and meeting with
an accident at his age of 40 (completed) and losing three fingers of one hand (i.e. 30%
permanent partial disablement).
Direct Cost (Rs.)
1. Compensation under Workmen's Compensation Act.
From Sr. No. 8 of Part II of Schedule I,
30% of (60% of 900 x the age factor)
= 0.30 (540 x 184.17)
= 0.30 x 99451.8 = 29835
2. Medical & Hospital charges
including fees, medicines, milk, fruits etc. = 02137
3. Transportation charges = 00200
Total direct cost Rs. 32172
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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)
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