Jithu Thampi

Indira Gandhi National Open University PGDM Industrial Safety Health and Environment (2010)
1. INTRODUCTION
SAFETY IN INDUSTRY
The modern safety movement started around 1912 with the First Cooperative Safety Congress
and the organisation of the national safety council in USA.From 1912 to the present time,
remarkable advance have been made in reducing the rate and severity of accidents.
The importance of industrial safety was realised because every year millions of industrial
accidents occur which results in either death or in temporary and permanent disablement of the
employees and involves a good amount of cost such as resulting from wasted man-hours
machine hours etc which results in low productivity ,profitability etc.
But the people do not give enough seriousness to it, again, In India, the world's worst industrial
catastrophe, Bhopal gas tragedy occurs. It occurred on the night of December 2-3, 1984 at the
Union Carbide India Limited (UCIL) pesticide plant in Bhopal, Madhya Pradesh. A leak of
methyl isocyanate (MIC) gas and other chemicals from the plant resulted in the exposure of
several thousands of people. The official immediate death toll was 2,259 and the government of
Madhya Pradesh has confirmed a total of 3,787 deaths related to the gas release. Other
government agencies estimate 15,000 deaths. The government's classification was criticized
after the deaths of people who were classed as having minor injuries. Chemicals (~390 tons)
abandoned at the plant continue to leak and pollute the groundwater whether the chemicals pose
a health hazard is disputed.
The costs of the above two disasters are unaccountable, the main cause of the above two are
lack in safety. These points to the need of safety in the industry.
Loss of lives and accidents cost gradually led to the formation of Factories Act,Office,Shops
and Railway premises act etc.The requirement for consideration of safety by management as
part of its responsibility arises primarily from these Acts.
Safety begins on the drawing board when in the original designs of tools of work place layout;
accident hazard may be built in or eliminated.
In an industry, safety may be considered from the mechanical side (equipment tools etc) or from
legal angles of workmen’s compensation or even as a matter of training in and motivation
towards safe work practices for workers (especially newly recruited ones).
Institute of Industrial Management for Safety Health and Environment. Page 1

Employees shall be the focus point in any industry and money, material machinery which are
the inputs of the industry can only reckoned in importance after human resource only.
Increased productivity is only possible through increased safety.
2. SAFETY MANAGEMENT

Safety Management is the implementation of a "Safety Management System" into an

organization.
Safety management system’ means the organisation and arrangements established by an

infrastructure manager to ensure the safe management of its operations;"
An effective safety management system has proved that the quality, productivity and
profitability are co-partners in business enterprises. It is very important to note that an
effective safety management system has become paramount important in industrial
activities. The effective safety management system requires an infrastructure within the
organization. Present infrastructural facilities in Medium and Small scale units are not to be
desired level. Building such an infrastructure has associated costs
In order to implement a Management System into an organization, there have to be some

procedures, processes and key documents that must be used and updated by the organization.
Key elements of a Safety Management System should contain a company policy, a safety plan,
a hazard log, internal audits and a failure reporting and corrective actions system, a risk
estimation process etc.
THE KEY DOCUMENTS

A number of documents can be considered as "key" documents in a Safety Management system
1. The System definition: Defines the system on block diagram level.
2. The Safety Plan: Describes "Who does what and when".
3. The Hazard log: Contains all known hazards and their history.
4. The Risk analysis: Contains the risk analysis performed for each hazard.
5. The Safety Requirements: The safety requirements to the system
The Safety Case: The document that proves the system is safe.

It is then up to the organization to adjust size, amount and complexity of these key elements
into a suitable and operative Safety Management System for the product and organization in
question.
SAFETY RESULTS
• From safe plant, process and operations and
• By educating and training workers and supervisors regarding safe practices on shop
floor.

3. VISION OF THE PROJECT
The vision of the project is to increase the productivity of the plant with reduced rate of accident
and to gain knowledge. In all workplaces the health and safety of employees is closely linked
with the company's profitability. Safety and productivity are the two sides of the same coin and
productivity without safety is not possible. Employees shall be the focus point in any industry
and money, material machinery which are the inputs of the industry can only reckoned in
importance after human resource only The onward march of industrialisation cannot stop
because we are in the need of greater employment opportunities and improved goods so that
there can be continuing rise in the standards of living. Thus the challenge before us today is to
operate our industrial activities in a safe manner and to achieve the desired economic growth.
Increased productivity is only possible through increased safety.Human resource strategies
for improving the health and safety of people in the workplace do not necessarily cost money -
in fact they usually save money.

4. OBJECTIVE OF THE PROJECT
Occupational accidents severely deteriorate human capital, and hence negatively affect the
productivity and competitiveness of countries. But despite this, we still observe a scarcity of
preventive practices, an unsatisfactory management commitment and an absence of safety
culture among firms. The result is evident in firms’ high accident rates. This situation is a
consequence of the general belief among firms that investing in safety is a cost, and hence has
negative repercussions for their competitiveness. The current work shows how Productivity and
Profitability gains through Health and Safety management system. It also creates awareness
among employees about the hazard and how accident effects the production of industry so that
they can go hand in hand with safety management system toward the growth of industry.

5. COMPANY PROFILE
BHARAT HEAVY ELECTRICALS LIMITED
Bharat Heavy Electricals Limited (BHEL) is one of the oldest and largest state-owned
engineering and manufacturing enterprise in India in the energy-related and infrastructure sector
which includes Power, Railways, Telecom, Transmission and Distribution, Oil and Gas sectors
and many more. It is the 12th largest power equipment manufacturer in the world. BHEL was
established more than 50 years ago, ushering in the indigenous Heavy Electrical Equipment
industry in India. The company has been earning profits continuously since 1971-72 and paying
dividends since 1976-77. 73% of the total power generated in India is produced by equipment
manufactured by BHEL. The power generating equipment including turbines, generators,
boilers and auxiliaries in the country. BHEL has already supplied thermal sets up to 500 MW
rating and has the technology to go up to 800 MW. BHEL manufactured 500/236 MW Nuclear
sets are also installed in the country.
The BHEL manufactured sets accounts for 65% of total installed capacity in India. There is
ample scope for improving the plant availability by cutting down the shut down period, by
Renovation & modernization, Rehabilitation and by timely arranging the spare parts and other
services.
BHEL has more than 35 years experience in the field of Design, manufacturing, erection and
operating experience, services in steam turbine .So that BHEL is undertaking Renovation and
modernization of BHEL & NON-BHEL Thermal Power Plants. This includes, Life assessment
studies recommendation for up-rating / up gradation, also includes retrofitting, repairs,
overhauling, with improved efficiency and heat rate and performance guarantee for a reasonable
time period. BHEL has taken lead role by providing specialized services, retrofitting renovating
and supply of even such spare parts for which complete design information and manufacturing
drawings are not available from original suppliers.
It is one of India's nine largest Public Sector Undertakings or PSUs, known as the Navratnas or
'the nine jewels’. It is India’s Largest Engineering & Manufacturing Enterprise of its kind

Committed to Enhance Stake-holder Value, one of the Major Power Plant Equipment
Manufacturers in the World and consistent dividend paying company over three decades.
MAIN MANUFACTURING PLANTS
 Bhopal (Madhya Pradesh)

 Bharat Heavy Electrical Limited, Raipur, Haridwar (Uttarakhand)
 Hyderabad (Andhra Pradesh)
 Jhansi (Uttar Pradesh)
 Tiruchirapalli(Tamil Nadu)
 Ranipet (Tamil Nadu)
 Bangalore (Karnataka)
 Jagdishpur (Uttar Pradesh)
 Rudrapur (Uttrakhand)
 Goindwal (Punjab)
 Bharat Heavy Plates and Vessels Limited (Vizag)
Besides these manufacturing units there are four power sectors which undertake EPC contract
from various customers. The Research and Development arm of BHEL is situated in Hyderabad
and two repair shops are at HERP (Heavy Equipment Repair Plant), Varanasi and EMRP
(Electric machines repair plant) Mumbai.
PRODUCTS
• Steam Generator
• Gas Generator
• Hydro Generator
• Steam turbine
• Gas turbine
• Hydro Turbines
• Transformer
• Switchgear
• Oil field equipments
• Boiler drum
• Wind mill

BHEL BHOPAL PROFILE
Heavy Electrical Plant, Bhopal is the mother plant of Bharat Heavy Electricals Limited, the
largest engineering and manufacturing enterprise in India in the energy-related and
infrastructure sector today. With technical assistance from Associated Electricals (India) Ltd., a
UK based company; it came into existence on 29th of August, 1956. Pt. Jawaharlal Nehru, first
Prime minister of India dedicated this plant to the nation on 6th of November, 1960.
BHEL, Bhopal with state-of-the-art facilities, manufactures wide range of electrical

equipments. Its product range includes Hydro, Steam, Marine & Nuclear Turbines, Heat
Exchangers, Hydro & Turbo Generators, Transformers, and Switchgears, Control gears,
Transportation Equipment, Capacitors, Bushings, Electrical Motors, Rectifiers, Oil Drilling Rig
Equipments and Diesel Generating sets.
BHEL, Bhopal certified to ISO: 9001, ISO 14001 and OHSAS 18001, is moving towards
excellence by adopting TQM as per EFQM / CII model of Business Excellence. Heat
Exchanger Division is accredited with ASME ‘U’ Stamp.
BHEL Bhopal has its own Laboratories for material testing and instrument calibration which
are accredited with ISO 17025 by NABL. The Hydro Laboratory, Ultra High Voltage laboratory
and Centre for Electric Transportation are the only laboratories of it are in this part of the world.
BHEL Bhopal's strength is its employees. The company continuously invests in Human
Resources and pays utmost attention to their needs. The plant's Township, well known for its
greenery is spread over an area of around 20 sq kms and provides all facilities to the residents
like, parks, community halls, library, shopping centers, banks, post offices etc. Besides, free
Health services are extended to all the employees through 350 bedded (inclusive of 50 floating
beds) Kasturba Hospital and chain of dispensaries.

BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL
PRODUCTS
Power Utilization Power GenerationPower Transmission
Hydro TurbinesTransformer
AC Motors & Hydro GeneratorsSwitchgear
Alternators Heat ExchangersOn-Load Tap Changer
EXCITATION CONTROL EQUIPMENT Large Current Rectifiers
STEAM TURBINESControl & Relay Panels
Miscellaneous
Renovation &
Transportation Maintenance
Oil Rigs
Fabrication Thermal Power Stations
Transportation
Equipment

6. VISION
VISION
A world class engineering enterprise committed to enhancing stakeholder value.
MISSION
To maintain a leading position as supplier of quality equipments, systems and services to serve
the national and international markets in the field of energy generation, transmission, utilisation
and conservation for applications in the power, industrial and transportation fields. To strive for
technological excellence and market leadership in these areas
IMAGE
To build up a high degree of customer confidence by sustaining international standards of

excellence in product quality, performance and service, particularly after sales and service.
VALUES
 Zeal to excel and zest for change
 Integrity and fairness in all matters
 Respect for dignity and potential of individuals
 Strict adherence to commitments
 Ensure speed of response
 Foster learning, creativity and team work
 Loyalty and pride in the company

7. HSE POLICY OF THE COMPANY

8. SAFETY PRODUCTIVITY AND PROFITABILITY
KEY DEFINITIONS

SAFETY
Freedom from whatever exposes one to danger or from liability to cause danger or harm;
safeness; hence, the quality of making safe or secure, or of giving confidence, justifying trust,
insuring against harm or loss, etc.
Workers are considered employees under OSHA if you:
• Control the actions of the employee,
• Have the power to control the employee's actions, and
• Are able to fire the employee or modify employment conditions
PRODUCTIVITY
The amount of output per unit of input (labor, equipment, and capital). There are many different
ways of measuring productivity. For example, in a factory productivity might be measured
based on the number of hours it takes to produce a good, while in the service sector productivity
might be measured based on the revenue generated by an employee divided by his/her salary.
Productivity is directly influenced by time consuming accidents which shut down a production
line; delay deliveries incapacitate skilled operators, destroy essential equipment.Less easily
measured but just as harmful to production are the loss of efficiency and morale that develops
remain after a serious accident.
PROFITABILITY
Profitability is expressed in terms of several popular numbers that measure one of two generic
types of performance: "how much they make with what they've got" and "how much they make
from what take in. This objective refers to management desire to maximise profits or avoid
losses. Accidents and injuries cost money, thus reducing profits. Safety therefore has an impact
on profits.
PRODUCTIVITY & SAFETY

• Safety, productivity and Quality are the vital three factors in any activity.
• They are like three sides of an equilateral triangle and mutually dependent on each other.
• It is impossible to perform any of our day to day activities without influence of these
factors in one-way of other.
WHAT IS PRODUCTIVITY?
• Productivity is the arithmetical ratio between the amount produced and the amount of
any resources used in the course of production.
• In otherwords, productivity means goods and services produced in relation to the

resources utilised in producing the same.
• Productivity is not production.
• Production merely means volume of output.
• Production can be increase without consideration of cost, by increasing the input of

labour, material and equipment.
• Productivity is not merely volume of output, but output in relation to the resources
employed.
PRODUCTIVITY IMPROVEMENT MEANS
• Increasing the output for the same amount of resources.
OR

• Reducing the resources for the same amount of output.
SAFETY AND PRODUCTIVITY
• Every resource has to be optimally made use of.
• There can be no two opinions that out of all the resources the human resource is the
most vital one.
• Accidents cause not only injury to the persons but also damage to the properties.
Safety assumes the greatest dimension because the losses to the human resources as well as to
the plant and machinery and the various properties assume such a huge proportion cutting a
sizeable portion of the production effort
THE REASONS FOR THE CONTINUING EFFORT TO PREVENT ACCIDENTS ARE
• Needless destruction of life and health is a moral evil
• Failure to take necessary precautions against predictable accidents -moral

responsibility for those accidents
• Accidents severely hurt efficiency and productivity
• Accidents produce far reaching social harm
• Safety movement has already demonstrated that its techniques are effective in reducing
the accident rates and promoting the efficiency
INCREASING PRODUCTIVITY AND PROFITABILITY THROUGH SAFETY ENVIRONMENT
Truly said, human resources are undoubtedly the most important assets of any industry and their
safety should be of prime concern. Adherence of safety codes and regulations ensures healthy
and safe working conditions of the workers, eventually increasing productivity and profitability
of the industry.

In all workplaces the health and safety of employees is closely linked with the company's
profitability. Safety and productivity are the two sides of the same coin and productivity without
safety is not possible. Human resource strategies for improving the health and safety of people
in the workplace do not necessarily cost money - in fact they usually save money.
For greater productivity, a healthy manpower is essential requisite. In order to ensure the health
care of the employee, the pre employment examination and pre placement examination are of
importance. To provide a congenial atmosphere, the work environment is to be monitored to
detect the symptoms of occupational health problems.
ACCIDENTS
An industrial accident may be defined as an event, detrimental to the health of man, suddenly
occurring and originating from external sources and which is associated with the performance
of a paid job, accompanied by an injury, followed by disability or even death. In every sphere of
human activity there is the possibility of an accident and the work place is no exception.
Industrial accidents are the end products of unsafe acts and unsafe conditions at work .
Many of the accidents have been attributed to human errors. As bought out by Heinrich
Pyramid one fatal injury arises out of 30 which in turn is the result of about 600 near miss
injuries. Ample scope is therefore available to mould the employees attitude by supervision,
inspection etc, to control the unsafe acts and unsafe condition.
CAUSES OF ACCIDENTS
Accidents may be caused due to
• Technical causes or unsafe conditions

• Human causes or unsafe acts
Technical causes reflects deficiencies in plant, equipment, tools, materials handling system,
general work environment etc.
Human causes by the person concerned are due to his ignorance, carelessness, day- dreaming
etc
MECHANICAL CAUSES

• Unsafe mechanical design or construction

• Hazardous arrangement
• Improper machine guarding
• Unsafe apparel
• Defective agencies or devices
• Improper material handling
• Broken safety guards
• Protruding nails
• Leaking acid valve
• Untested boilers or pressure vessels
ENVIRONMENTAL FACTORS
Environmental factors indicate improper physical and atmospheric surrounding conditions

which directly promote the occurrence of accidents. Environmental factors include
• Too low temperature cause shivering
• Too high temperature cause head ache and shivering
PERSONAL FACTORS
1. Age.
2. Health.
3. No: of dependents.
4. Financial position.
5. Home environment.
6. Lack of knowledge and skill.
7. Improper attitude towards work.
8. Incorrect machine habits.
9. Carelessness and recklessness.
10. Day dreaming and inattentiveness.
11. Fatigue.
12. Emotional instability.
13. High anxiety level.

14. Mental worriness.

15. Unnecessary exposure to risk
16. Non use of safety devices
17. Working at unsafe speed
18. Improper use of tools
ECONOMIC COST OF ACCIDENTS
• An accident can be very costly to the injured employee as well as to the employer of the
concern
• Every accident / occupational health disorder also represents loss to the organization
through various definite cost e.g.:- direct and measurable costs and indirect i.e.
somewhat intangible but nevertheless real costs.
DIRECT COSTS
Direct costs of accidents are represented by compensation payable to the worker/worker’s

dependents; cost of insurance premium; cost of treatment of worker/injured persons; cost of
repair of equipment damaged due to the accident; fines imposed by the Court for breach of law
together with cost of defense for legal recourse.
INDIRECT COSTS
Indirect costs to the organization include the cost of lost time of the injured persons,
management, first aid staff and other persons involved; cost of lost production and cost of
overtime required to be paid to meet the delivery schedules; cost of investigation of the
accidents including time involvement of management, supervisory staff and witnesses, cost of
replacement of damaged personal property and incidental cost incurred by witnesses attending
the court.
INTANGIBLE LOSS
Intangible loss to the organization includes loss of reputation to the company; impact on
motivation of fellow workers; impact on labor relation as an outcome of the accident etc.
DIRECT COSTS (Eg:-FOUNDARY ACCIDENT)

Compensation paid for injury=Rs 700/-
Medical expenses=Rs 300/-
Total compensation cost=RS 1000/-
Uncompensated wage loss=Rs 200/-
Total direct cost=Rs 1200/-
INDIRECT COST
Material spoiled =Rs X/-
Labour for cleaning it up=Rs 400/-
Injured worker’s make up pay while at home=Rs 200
Fellow workmen standing and watching at time of accident=Rs 600/-
Supervisor’s time in reporting and investigating=Rs 220/-
Down time on casting=Rs 300/-
Slowed up production rate of other employee=Rs 240/-
Total indirect cost=Rs (X+1960)
Total cost of accident(Not including over head charge which may raise the total cost of accident
by as much as 50%)=Rs(3160+X)
COST OF ACCIDENT PREVENTION
On the other hand the cost of accident prevention includes cost of protection equipment/ cost of
engineering solutions for eliminating or controlling the hazards; cost of building infrastructure
within the organization for implementation, running and monitoring of an effective safety
management system: cost of managing such infrastructure ; cost of safety training etc.

While the cost of accident prevention is pre planned allowing greater flexibility and control to
the management, the cost of accident has to be borne in a totally unplanned manner. Intangible
benefits of better worker morale, higher productivity, reduced cost of production, better labor
relation also accrue to the Company. Above all it helps in safeguarding valuable human
resource hence; adoption of measures for safety of the workers is always the better option.
ACCIDENT PREVENTION
Prevention of accidents is a true humanitarian concern, it doesn’t occur by itself ;there should
be a consistent implementation of safety measures and safety programmes emphasizing the
need for
1. Safe work place lay out and working conditions.
2. Safe material handling.
3. Personal protective devices.
4. Safety activities in the organisation.
PRODUCTION MUST SAFETY FIRST
The studies on accidents during the last five years’ have well established that around 90% of
the accidents took place because of human reasons. It has also been accepted that the journey
towards excellence in safety could be made, in a nutshell, through
(a) Well laid policy, systems & procedures.
(b) Infrastructural support.
(c) Human Competency and
(d) Human attitude.
A deep insight into the failure to achieve excellence in safety from an otherwise efficient
organization revealed that the major factors responsible for the lack of success in safety are: -
(1) Lack of visible and felt leadership across all levels.
(2) Belief that safety is the function only of a particular division.
(3) Tolerance of non-conforming habits.
(4) Concern for corrective actions rather than for preventive actions.
(5) Expenditure on safety viewed as mere outflow of funds.
(6) Feeling that importance on safety affects productivity.

The root cause behind this lack of genuine interest and commitment for Safety emanates from
the perception of dichotomy between productivity and
safety – a feeling that safety is extraneous to the core operation not having positive impact on
productivity, Balance Sheet and Profit & Loss accounts.
Therefore, there is a need to explore
(i) Whether synthesis between Safety & Productivity is possible and
(ii) Whether that is really rewarding for the organization.
DICHOTOMY – HISTORICAL PERSPECTIVE
Previously, since the days of industrial revolution, the main objectives of the
Organizations were productivity & profit making. The working conditions used to be
horrible with no concern for safety & health of the workers. However, with the
pressure from the middle class intelligentsia and enactment of laws, the concept of
safety was incorporated.
As the concept of safety did not grow naturally from within and was mostly
thrust upon from outside; it was perceived as an extraneous obligation eating
away productivity & profitability. This belief compelled the organizations to frame
policies, procedures and systems separately for safety and for productivity using
different sets of resources.
DISSOLVING THE DICHOTOMY
The dichotomy can be dissolved by proper “synthesis” of the factors

influencing both productivity & safety and through “harmony” in their
manifestation.
(A) POLICY, SYSTEMS & PROCEDURES
“Well Laid Policy” for better safety has always many common elements

meant for higher productivity. “Well framed systems & procedures” for safety also
give impetus to productivity. For example, Safety requires compliance regarding
quality maintenance, testing and certification to avoid breakdown or unwarranted performances.
This also helps in higher productivity and longer life span, thereby leading to more earning &
more saving.
Excellent infrastructural support statutorily required for safe operation directly improves
productivity through uninterrupted and quicker operations. Giving human protection through
right personal protective equipments for safety also gives confidence and courage to work
efficiently on sustainable basis, thereby having direct positive impact on profit. The variables
influencing policy, systems &procedures for safety being also contributory to productivity.
(B) HUMAN ASPECTS
(I) HUMAN COMPETENCE

Competence, an essential precondition for productivity, is based on
education, experience and training. Analysis of the above components would
reveal that competence for productivity is a pre-requisite for gaining competence
in safety. Whereas, separate programmes are generally framed for improving
competence in productivity and safety, it is feasible, effective and economical to
synthesize the productivity and safety related competence developmental
programmes.
(II) ATTITUDE
The intangible yet most dominant factor for both productivity & safety is the ATTITUDE.
Attitude development has an all-encompassing effect on organization, nation and the human
civilization as a whole.
An introspection into the above behavioural pattern would reveal that they are also essential for
excellence in safety. Therefore, behavioural development through ethico-moral transformation
and creation of the organizational culture for its sustainability need not be addressed separately
for improving productivity and safety. The core values influencing both productivity and safety
being similar, the organization would reap multiple benefits through value orientation if the
apparent dichotomy between safety & productivity is ignored and be rightly integrated and
synthesized.
SOLUTION

Although all the aspects for ensuring safety are not identical to those for ensuring productivity,
they are so much similar that it is not practical and economical to treat them in disintegrated
fashion. The different components of productivity i.e. production process, maintenance, quality
control etc. having partially different domains; which were earlier treated as separate
disciplines, have long been adopted as an integrated one. The economy and the synergy thus has
been so successfully reaped, that now it is unbelievable that once some of them were
disintegrated.
Similarly, “Safety” having so many common variables with “Productivity” in the systems,
procedures, infrastructure and human components should be synthesized with “productivity” in
a holistic manner. Such integration would ensure
(i) higher productivity through safety,
(ii) eliminate separate monitoring process,
(iii) reduce overheads,
(iv) reduce expenditure and most importantly,
(v) the managers would be genuinely interested in safety while
focusing on productivity.
This will bring radical positive transformation from the “compulsive extraneous thrust” on
safety to the “inspiring empowerment coming from within” in the journey beyond excellence in
safety.
9. AREA VISITED/INSPECTED/OBSERVATIONS
I am doing my project work in Heat exchanger and condenser manufacturing division

(HCM).It is situated in bay8 of block1. There are 125 employees working in the HCM
division. Out of the total employees 92 artisans are engaged in various activities like
machining, fitting, grinding, store keeping, and material handling.
Here heat exchangers of different types and sizes are manufactured and the installed capacity
is 250MW high pressure heaters ,270-500MW low pressure heaters and 500MW surface

condensers.HCM has 30 small and large machine tools where components of heat exchangers
are machined. They are mainly lathes, drilling, horizontal boring and vertical boring
machines. To facilitate the movements of components from one work place to another, the
bay has EOT cranes of various capacities One is of 10 tons, another of 20 and 50 tons while
third is of 10 and 50 tons .In addition to that there are 8 jib cranes of various capacities at
different locations for local material handling requirements. The components are machined in
the machine shop and are then assembled in the assembly section.
The various functions in HCM are
1. Material handling
• Indenting
• Purchase order
• Receipt of material
• Production plan
2. Machining
• Drilling
• Turning
• Boring
• Lathe operations
3. Assembly and testing
• Baffle Assembly
• Tubing
• Shell Assembly
• Welding

• Grinding
• Painting
• Testing
Products of HCM division:-
 HP Heaters
 LP Heaters
 Gland Steam Condenser (GSC)
 Turbine Oil Coolers (TOC)
 Control Fluid Coolers (CFC)
 Hydro Coolers
 Transformer Coolers
 Flash Tanks & Misc. Tanks
FIG :- LAYOUT OF HCM DIVISION

FIG :- MULTI SPINDLE CNC MACHINE FIG :- FINISHED HP HEATERS
FIG:-VERTICAL DRILLING MACHINE FIG:- INNER COIL OF H P HEATERS

HAZARD & RISK ANALYSIS
A hazard analysis is a process used to assess risk. The results of a hazard analysis are the
identification of unacceptable risks and the selection of means of controlling or eliminating
them. The term is used in several engineering specialties, including avionics, chemical process
safety, safety engineering and food safety to identification, studies and monitoring of any
hazard to determine its potential, origin, characteristics and behaviour.
Risk analysis should be performed as part of the risk management process for each project. The
data of which would be based on risk discussion workshops to identify potential issues and risks
ahead of time before these were to pose cost and/ or schedule negative impacts.
The risk workshops should be chaired by a large group ideally between 6 to 10 individuals from
the various departmental functions (e.g. project manager, construction manager, site
superintendent, and representatives from operations, procurement, [project] controls, etc.) so as
to cover every risk element from different perspectives.
The outcome of the risk analysis would be the creation or review of the risk register to identify
and quantify risk elements to the project and their potential impact.
Given that risk management is a continuous and iterative process, the risk workshop members
would regroup on at regular intervals and project milestones to review the risk register
mitigation plans, make changes to it as appropriate and following those changes re-run the risk
model. By constantly monitoring risks these can be successfully mitigated resulting in a cost
and schedule savings with a positive impact on the project.
HAZARD IDENTIFICATION RISK ASSESSMENT AND DETERMINING CONTROL

(HIRA DC)
HAZARD
Source or situation with potential for harm in terms of injury or ill health, damage to property,
damage to workplace environment, or combination of these.
(i) Safety Hazards (Injury, fatal accidents)
(ii) Health Hazards (illness, chronic diseases)

HAZARD IDENTIFICATION
Process of recognizing that a hazard exists and defining its characteristics.
RISK
Combination of the likelihood and the consequences of a specified hazardous event occurring.
RISK ASSESSMENT
Overall process of estimating the magnitude of the risk and deciding whether or not the risk is
tolerated.
DETERMINING CONTROL
Providing control measures to reduce the risk to acceptable level.
RANKING HAZARDS BY RISK.
Hazards may be categorized in several different ways. The actual method used will depend on
the safety management teams approach to the problem, what is important is that hazards are
properly and realistically assessed and priorities established. Techniques for producing a
ranking vary from very simple to complex. Here we have taken the severity of consequence,
extent of exposure to hazard and the probability of the event occurring as the measuring system.
The risk is assessed by introducing a new factor called Risk Assessing Factor
SEVERITY RATING (SR): An assessment of the worst potential consequence, defined
by the degree potential injury, illness or property damage which ultimately occur.
FREQUENCY RATING (FR): An assessment of the probability that any particular hazard will result
in an injury, an occupational illness or property damage.
The assessment is based on such factors as location and extent of exposure (ER) to the hazard in
terms of cycle or hours of operation. It also helps to calculate the immunity power of a worker
involved in a work, with particular occupational health hazard.
RISK ASSESSING FACTOR (RAF): Products of hazard rating. It helps to access the risk.
RAF=SR× FR

RESIDUAL RISK (Rr): It is the risk level after recommendations.
Rr= RAF (Acceptable or Low)

CALCULATION SHEET FOR HAZARDS AND

ASSOCIATED RISKS
SEVERITY & PROBABILITY

MATRIX
Injur Chronic Probability Ran

Ran
y Effect (Frequency) k
k
5 Dis Repeat
aster May result in edly during life 5
involving Incurable cycle of system
Multiple diseases like / at least once
fatalitie Cancer, kidney per year.
s Failure
4 Sin Sev
gle Serious illness eral time 4
fatality resulting in during life
hospitalization cycle of system
/ at least Once
in 3 years.
3 Dis Perm
abling anent losses Once in life 3
Injury ( Hearing, cycle of system
vision, / once in 8
limb/finger/toe years.
etc but not life
threatening)
2 Me Rev Unli
dical Aid ersible effects kely to occur 2
Injury but require during life
medical cycle of
monitoring system / once
in 6-16 years.
1 Mino Temporary/ Unlikely 1

r injury reversible to occur in 15
illness effects due to years.
(first aid) release of gas
etc

LEG
END
EXTREME RISK : CANNOT BE ACCEPTED, MUST

4
BE CONTROLLED TO ACCEPTABLE LEVEL
HIGH RISK : MUST IMPLEMENT EXTENSIVE

3
CONTROLS
MODERATE RISK : TO BE ANANLYSED FOR

2
ADEQUATE CONTROLS
LOW RISK : TOLERABLE, CAN BE

1
ADDRESSED BY LOWER HIERARCHY OF CONTROLS


S No LEGISLATION
1 MP Factory Rule 1962

HAZARD IDENTIFICATION RISK ASSESSMENT AND DETERMINING CONTROLS
AREA: BLOCK 1 BAY 8(HCM)
ITEM/ CONCERN IMPACT HAZARD RANKING HAZARD BY RISK CONTROL MEARURE RESIDUAL
ACTIVITY (HAZARD) (IDENTIFICATION) RISK RISK (Rr)
SF FF RAF=
SF*FF
Machining Moving Parts. Entanglement 2 3 6 Provide interlocking guards, Low
Flying Chips. Injury to Eyes, may fall avoid wearing rings, metallic
3 3 9
in to gangways watches etc
Electric shock. Burn
1 2 2
Grinding Dust Adverse Effect on 3 2 6 Use ear plug, mask, goggles etc, Acceptable
respiratory system proper wheel dressing and

Noise Damages ear and creates truing, the gap between the
2 2 4
psychological problems wheel and tool rest should be
Striking of tools to Injury 3mm
the worker or 2 3 6
nearby persons
Maintenance Spillage of oil Accident due to Slippage 2 3 6 Pour dust powder Low
Storage & Inflammable Fire & explosion, 1 4 4 Good house keeping Acceptable
handling of material
hazardous
substances
Work Lack of skill Creates accidents 2 3 6 Appointment of skilled labourer, Low

through
contract
Labourers
Crane Fall of Job during Fatal 1 3 3 Provide lock pins, inspection of Low
Operation unloading cranes.
Tube Bundle Sling Failure, Causes harm to the 3 3 9 Periodic inspection of slings, use Acceptable
insertion Failure of weld worker and damages the good quality of welds
joint casing
Material Congested space Obstruct the gang ways, 3 3 9 Provide required work space, Low
Storage lack of required

ventilation install exhaust fans
Welding Electric Arc Damages eyes due to 2 2 4 Provide a separate space for Low
Operation harmful radiation welding, use welding screens ,
gloves etc, earth cable should be
properly earthed, use skilled and
experienced operators

Fumes Adverse Effect on

Health because of
2 2 4
inhalation affects
eyes
Heat Burn 2 3 6
Electric shock Injury 1 3 3
Severity Rating of Hazard(SR)
Severity Rating of Hazard Value
Catastrophic – imminent danger exists, hazard capable of causing

1
death or loss of facilities.
Critical – hazard can result in serious occupational illness, severe

2
injury or minor property and equipment danger.
Marginal – hazard can cause minor illness, injury or equipment

3
damage, but not serious.
Negligible – Probably would not cause injury or occupational

illness, remote possibility of damage beyond minor first aid case.

PROBABILITY RATING OF HAZARD(PR)
Probability Rating of Hazard Value
Probable - Probably likely to occur immediately or shortly. 1
Reasonable Probable – Probably will occur in time. 2
Remote – may occur in time. 3
Extremely Remote – Unlikely to occur. 4
EXPOSURE RATING OF HAZARD(ER)
Extent of Exposure to Hazard Value

HIGH-Exposure limit 8Hrs H
MEDIUM-Exposure limit 4Hrs M
LIGHT-Exposure limit 2Hrs L
NEGLIGIBLE-exposure limit ≤1Hrs N
RISK ASSESSING FACTOR (RAF)
Score 1(ER)≤RAF≤4(ER) 6(ER)≤RAF≤8(ER) 9(ER)≤RAF≤12(ER) 12(ER)<RAF≤16(ER)
Level of UNACCEPTABLE MODERATE ACCEPTABLE LOW

Risk

10. PRESENT SCENARIO
The turnover has doubled in last 4 years i.e. from 73 crores during year 2005-06 to Rs. 145
crores in 2009-10.
It was revealed that single bay area for carrying out activities such as material handling,
machining, hydraulic testing, painting, dispatch etc. of wide range of products was not sufficient
and hampering the productivity very badly and almost reached up to saturation level.
The turnover of Hydro coolers, Transformer and Generator coolers are also increasing at a
faster rate because of ambitious plan of expansion of Hydro turbines and Transformers. During
last 4-5 years 250 MW HP Heater and 500 MW Surface condensers have been added as a
regular product which are very large in size and numbers and are not getting accommodated in
present area and are creating serious safety hazards.

11. SITUATION OF SAFETY MANAGEMENT
SAFETY MANAGEMENT IN BHEL, BHOPAL
Concern for and action to control a safety, health and environmental for the action to control
safety, health and environmental risk to the world’s population are rapidly accelerating.
Industries have responded to the need for reliable control of these risks with a broad range of
system employing physical, operational and management control. Each system is designed to
reflect the inherent risk of operations, the structure and culture of the organisation.
Employees are assets of any industrial complex and it will remain healthy if its workmen are
healthy. The health of the workmen gets affected because of constant exposure to toxic

substances in the work environment. It has become mandatory on the part of management to
keep the work environment safe and healthy safe working conditions depend on safe plant
operation. Right from project, site and technology selection to the plant commissioning and
regular operation .Training and preparedness play an important role in maintaining safe work
environment. Above all co-operation between workers and management is required to safe-
guard the occupational safety and health of the workmen.
In BHEL, BHOPAL safety management and implementation of statutory needs are being
carried out by and independent safety engineering department with the assistant of occupational
health centre, fire fighting department and welfare department. This is established in close
liaison with directorate of industrial health and safety, Govt of M.P. Some of the salient
activities is as follows.
OCCUPATIONAL HEALTH

The statutory requirements such as cleanliness, disposal of wastes and effluents, ventilation and
temperature, dust and fumes, artificial humidification, overcrowding, lighting, drinking water,
latrines and urinals, maintained and are regularly inspected by safety representatives.
Besides, the above statutory provisions, BHEL has provided following additional health care
facilities.
OCCUPATIONAL HEALTH SERVICES, PERIPHERAL DISPENSARIES AND

HOSPITAL
• First aid & emergency services.
• Man maintenance programme.
• Preventive health care programme.
• Pathology and Bio-chemistry Analysis.
• Psychological guidance and counselling.
• Industrial Hygiene & toxicology lab.
• Audiology monitoring.
• Health Education Programme.
• Ergonomics.
Safety activities as per statutory requirements are regularly inspected and records are kept ready
for verification by the directorate of industrial Health &Safety, Govt of M.P.
Provision of latest electronic machine guards, radio remote control cranes, exhaust systems for
dust/gas collections, automatic fire-fighting systems have been installed at accident and health
prone areas.

SAFETY PROMOTIONAL ACTIVITIES
TRAINING
1. Industrial employees are exposed to industrial safety training.
2. Employees are also nominated to attend external training/seminars arranged by

NSC/RLI/CLI/LPA/DMI and other organisations to have latest knowledge about the safety
developments.
3. All the daily rated workers/contracted labours are given one day safety awareness safety
training which has resulted in reduction of accidents.
4. With the faculty member of RLI Kanpur all the lady employees and lady workers of BHEL
were given safety awareness training.
5. Every department has got trained persons for first-aid and for fire extinguisher operation.
SAFETY AWARD SCHEME
Awards are given on the following grounds:
Departments of Zero-Accident
Department of Best- Housekeeping
Best safety Steward
SAFETY COMPETITIONS
SUGGESTION SCHEME
Safety suggestions are invited from the employees and after due consideration by
suggestion committee the good suggestions are implemented and suggestees are
awarded with cash as well as certificates.
SAFETY COMMITTEES
Central Safety Committee meets once in three months.

Central Safety Sub-Committee.
Stewards Safety Committee once sin a month.
Departmental Safety Committee meets once in a month and implement the safety suggestions.
DAILY SAFETY INSPECTION OF SHOP FLOORS
The safety representative visit daily to shop floor and with the help of safety stewards, brings in
notice the unsafe acts and unsafe conditions prevailing and suggests remedial action to the shop
in charges. A sample checklist used for the departmental safety inspection card is given below.
BHARAT HEAVY ELECTRICALS LIMITED. Bhopal
SAFETY & ENVIRONMENT ENGINEERING DEPARTMENT
Block Safety Inspection Report

Card Ref No: Date: Dept:
Block No: HOD: HSE Officer:
Sl Bay Section Position/ Safety Problem Noticed Recommendations

No
Machine
IMPLEMENTATION OF OHSAS 18001
As a part of implementing OHSAS guidelines in an organization, BHEL have to create health

and safety systems manual in which all the guidelines of the OHSAS requirements applicable to
the particular organization will be covered and it will be communicated all the agencies of the
company according to which they have to comply with.
While developing the systems manual, BHEL have to describe about the company’s profile
which includes what are all the products of the company, manufacturing facilities that are
available in the company and the various initiatives they have taken towards environmental
friendly activities.
Firstly, evaluate the Health and Safety needs of the staff and visitors in the industry. Then
identify the boundaries of the Health and Safety system and document the procedures for
meeting the requirements of OHSAS 18001. Ensure these procedures are fully implemented,
then audit and review them.
Once developed, internal audits are needed to ensure the system continues to be effective.
Always bear in mind the need to conform to legislative requirements.
Having chosen a third party certification body for the audit, it will review your documentation
to ascertain that it meets all the requirements of OHSAS 18001. This is followed at a later date

by an audit to check that records are being kept and documented working practices are being
followed.
After a successful audit, a certificate of registration to OHSAS 18001 will be issued. There will
then be continual surveillance visits (usually once a year) to ensure that the system is
maintained and continues to be effective
IMPLEMENTATION OF ISO 14001
ISO (the International Organization for Standardization) is a worldwide federation of national

standards bodies (ISO) member bodies. The work of preparing International Standards is
normally carried out through ISO technical committees. Each member body interested in a
subject for whom a technical committee has been established has the right to be represented on
that committee. International organizations, governmental and non-governmental, in liaison
with ISO, also take part in the work. ISO collaborates closely with the International Electro
technical Commission (IEC) on all matters of electro technical standardization.
As a part of implementing the ISO standards a MR (Management Representative) (HSE) will be

appointed and he will be given full authority and organizational freedom to approve, revise,
manage and implement this manual consistent with Company’s policies and objectives related
to HSE.
All the other concerned departments are responsible for complying with this manual. Each
section head identified in this manual is responsible for implementing the requirement and
resolves any non-conformity within his department/section.
The organisation shall ensure that interning audit of the ems are conducted period of intervals to
1. Comfier med to planned arrangements for environment management system

including the requirements this international standard
2. Hs been properly implemented and is maintained
a. Provide information on the results of audit to management
After a successful audit, a certificate of registration to ISO 14001 will be issued. There
will then be continual surveillance visits (usually once a year) to ensure that the system
is maintained and continues to be effective

Environmental Aspects Feasibility Analysis
Sl Activity/ Significant Associat Eliminatio

No Product/ Aspect ed n/
Services Impact Reductio
n/ Control
1 Machining Disposal Water Control of
of various of coolant Pollution coolant
Componen
t
2 Preparatio Over Depletio Control
n of Consumpti n of
Coolant/ on of Oil Natural
water resource
s
3 Generation Disposal Land Control
of Non of Non Nuisanc
Saleable Salable e
Solid Solid
Waste Waste
4 Use of Disposal Land Control
Coolant/ of Drums Nuisanc
Lubricant e
5 Generation Disposal Land Control
of Non of Solid Nuisanc
Saleable Scrap e
Solid Scrap
CELEBERATION OF NATIONAL EVENTS
1. Road Safety Week - 1st week of January
2. National Safety Day - 4th March

3. Fire Fighting Day - 14th April
4. World Environment Day - 5th June
5. Industrial Safety Day - 3rd December
NATIONAL SAFETY COUNCIL, M.P. CHAPTER
BHEL, Bhopal is Head Quarter of National Safety Council, M.P. Chapter and takes leading role
in propagating safety awareness programme in the whole of Madhya Pradesh through five
action-centres situated at Vijaipur, Jabalpur, Korba, Bhilai and Indore. The chapter arranges
safety audit programmes, safety seminars and helps in celebration of national events and also
publishes quarterly “Suraksha Pradeepika” in Hindi highlighting the safety needs and
achievements.
SAFETY DISPLAY ROOM
Safety has been equipped with:-
Overhead projector with the screen
Sitting arrangement for 50 persons
Display of latest magazines
Display of safety appliances
Display of fire-fighting equipments
Display of safety awards and safety certifications received
ACCIDENTS
With implementation of statutory as well as mandatory regulations the accidents in BHEL are
substantially reduced and management is aiming to achieve Zero-accident
ENVIRONMENT

Massive plantation in BHEL and in Township.Water and air quality regularly monitored by
industrial hygienist, Technical Services department of BHEL and by the scientist of Pollution
Control Board of Govt. of (M.P.)
1. Workplace monitoring regularly carried out to keep the water, air and airborne dust particles
within the Threshold Limit Value.
2. Noise level, lighting, vibration, heat stress are regularly monitored and corrective actions are
taken, if needed.
3. At Berkhera Sewage Treatment Plant bio-gas is generated for making chapattis, and for
hospital use, water treated and used for orchards and solid waste is converted into manure.
4. All the solid and liquid wastes generated are fully neutralised before their disposal.
5. All the water used in BHEL is re-cycled and used and not allowed to go outside for general
public or for public cultivation.
FIRE FIGHTING SERVICES
BHEL, Bhopal has its own fully fledged fire fighting services department to control the fire
hazards. Complete BHEL factory is connected by fire hydrant system and hazardous areas are
installed with automatic fire control systems.

12. STRENGTH, WEAKNESS, OPPURTUNITIES & THREATS
STRENGTH
 Sound engineering base and ability to assimilate
 Relatively stable industrial relationship
 Access to contemporary technologies with the support from renowned
Collaborators.
 Ability to manufacture or procure to supply spares.
 Largest source of domestic business leading to major presence and influence in the
market.
 Low labour cost.
WEAKNESS
 Larger delivery cycles in comparison with international suppliers of similar equipment.
 Inability to provide supplier’s credit, soft loans and financing of projects.
 Due to poor financial position of state electricity boards, which are the major customers
of BHEL in India, liquidity position of BHEL is not satisfactory.
 Being a public sector company BHEL is suffering from sub optimality of control due to:

 Displacement of social objectives by political objectives, which may lead to

redundant costs and also rising costs
 Direct political intervention in managerial decision over an arm length relationship that
would restrict government’s task of setting appropriate managerial incentive structure.
 Internal inefficiencies in bureaucratic activity.
OPPORTUNITIES
 Demand for power and hence plant equipment is expected to grow.
 Private sector power plants to offer expanded market as utilities suffers resource crunch.
 Ageing power plants would give rise to more spares and services
business.
 Life expansion program for old power stations.
 Easy processing of joint ventures/ collaboration/import/ acquisition of

new technology.
 Financial and operational autonomy for profit making public sector enterprises. To make
the public sector more efficient government has decided to grant enhanced autonomy
and delegation of powers to the profit making public sector enterprises
THREATS
 Increased competition both national and international
 Multilateral agencies reluctant to lend to power sector because of poor financial

management of S.E.Bs
 More concessions to private sector and not to government owned utilities like NTPC or
S.E.Bs, so future power projects would be opened up in private sector

 Level playing ground not available, foreign companies spending much more on business
promotion tactics.
13. TANGIBLE AND INTANGIBLE BENEFITS
TANGIBLE BENEFITS
1. Increased productivity and profitability.
2. Accident prevention.
3. Hygienic work area.
4. Less material loss.
6. Involvement of everyone in safety.
7. Make a safe working environment.
INTANGIBLE BENEFITS
1. Certification of ISO-9001, ISO-14001, OHSAS-18001.
2. Improvement of employee morale.
3. Employee welfare programmes
4. Helps to maintain continual improvement.
5. Bonus and incentives.

6. Enhancement of employee/employer relations.
14. RECOMMENDATIONS
1. Only items required for recent production requirement be available on the shop floor, no
unnecessary items, materials, components etc.
2. Gangways must free from obstrucles.
3. Clear identification of machines as critical.
4. The noise zone should be categorized.
5. Sign boards are to be provided inside the site. The speed limit should be 15-20kmph
inside the factory and in the plant it should be 2-5kmph.
6. The damaged welding cables should not be used for long time and it should be replaced
frequently and earth cable should be properly clamped to the work piece and near to the
welding spot.
7. Additional responsibilities of safety officer should be removed.
8. Wire rope shall be taken out of services when in any length of 8 times the diameter; the
total number of visible broken wires exceeds 10% of the total wire construction of the wire
rope. (A 6x7 constructed 1 inch diameter rope has 42 wires. 10% of 42 = 4 wires. 1 inch
diameter X 8 = 8 inches. Thus if the wire rope has 4 visible wire broken in any 8 inch
section, it must be replaced.)
9. Regularly lubricate the Wire ropes.

10. All openings in floors and other similar areas are to be covered in a manner that prevent
falls. .
11. Safe access to reach platform must be provided.
12. Provide a separate area for welding.
13. Fire extinguishers availability near welding and cutting operations.
14. Flame arrestors provided on gas cylinders
15. Acetylene and Oxygen hoses non-inter changeable, easily identified and inspected daily.
16. Cylinders must be kept erect during gas cutting operation.
17. Proper eye protection and protective apparel must be worn during all welding/gas cutting
operations.
18. Provide inter-locking guard for ARBOG CNC machine.
15. CONCLUSION
The need to improve working conditions is a collective concern, prompted by both

humanitarian and economic considerations. Creating more jobs and of better quality is one
of the main objectives of the social policy which in turn creates chances for industrial
accidents affecting the productivity and profitability of an organization. A safe and healthy
working environment is thus an essential element for accident prevention. Accident
prevention can only be attained through safety. It represents control of man performance,
machine performance and physical environment. Organisations must strive at to
institutionalize accident prevention programs in their respective units on a scientific
footing ,keeping liaison between their business interest and employees safety and welfare
thus we can conclude that safety plays a vital role in the productivity of the company which
in turn the profitability.

16. BIBLIOGRAPHY
• Safety management in industries by Dr. S. A. Pillai.

• www.bhel.com.
• Journals of National Safety Council.
• Industrial Engineering and Management by O.P. Khanna.
• Indian Factories Act 1948.


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Indira Gandhi National Open University PGDM Industrial Safety Health and Environment (2010)

Institute of Industrial Management for Safety Health and Environment. Page 1

Institute of Industrial Management for Safety Health and Environment. Page 2

Safety Management is the implementation of a "Safety Management System" into an

Safety management system’ means the organisation and arrangements established by an

In order to implement a Management System into an organization, there have to be some

THE KEY DOCUMENTS

1. The System definition: Defines the system on block diagram level.

2. The Safety Plan: Describes "Who does what and when".

5. The Safety Requirements: The safety requirements to the system

Institute of Industrial Management for Safety Health and Environment. Page 3

• From safe plant, process and operations and

Institute of Industrial Management for Safety Health and Environment. Page 4

3. VISION OF THE PROJECT

Institute of Industrial Management for Safety Health and Environment. Page 5

4. OBJECTIVE OF THE PROJECT

Institute of Industrial Management for Safety Health and Environment. Page 6

BHARAT HEAVY ELECTRICALS LIMITED

Institute of Industrial Management for Safety Health and Environment. Page 7

MAIN MANUFACTURING PLANTS

 Bhopal (Madhya Pradesh)

Institute of Industrial Management for Safety Health and Environment. Page 8

BHEL BHOPAL PROFILE

BHEL, Bhopal with state-of-the-art facilities, manufactures wide range of electrical

Institute of Industrial Management for Safety Health and Environment. Page 9

BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL

Power Utilization Power GenerationPower Transmission

Institute of Industrial Management for Safety Health and Environment. Page 10

A world class engineering enterprise committed to enhancing stakeholder value.

To build up a high degree of customer confidence by sustaining international standards of

 Zeal to excel and zest for change

 Integrity and fairness in all matters

 Respect for dignity and potential of individuals

 Strict adherence to commitments

 Ensure speed of response

 Foster learning, creativity and team work

 Loyalty and pride in the company

Institute of Industrial Management for Safety Health and Environment. Page 11

7. HSE POLICY OF THE COMPANY

Institute of Industrial Management for Safety Health and Environment. Page 12

8. SAFETY PRODUCTIVITY AND PROFITABILITY

Institute of Industrial Management for Safety Health and Environment. Page 13

Workers are considered employees under OSHA if you:

• Control the actions of the employee,

• Have the power to control the employee's actions, and

• Are able to fire the employee or modify employment conditions

PRODUCTIVITY & SAFETY

Institute of Industrial Management for Safety Health and Environment. Page 14

• In otherwords, productivity means goods and services produced in relation to the

• Productivity is not production.

• Production merely means volume of output.

• Production can be increase without consideration of cost, by increasing the input of

PRODUCTIVITY IMPROVEMENT MEANS

• Increasing the output for the same amount of resources.

Institute of Industrial Management for Safety Health and Environment. Page 15

• Reducing the resources for the same amount of output.

SAFETY AND PRODUCTIVITY

• Every resource has to be optimally made use of.

THE REASONS FOR THE CONTINUING EFFORT TO PREVENT ACCIDENTS ARE