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INDUSTRIAL SAFETY
THE FACTORY AND THE WORKSHOP
• Production machinery
• Electrical connections
• Rotating parts
• Cutting equipment
• Grinding machines
• Milling machines
• Lathe machines
• Lifting vehicles
INTRODUCTION
• Accidents occur in the work place
• Result in loss of skilled man power, wasted man hours as well as
machine hours
• Supervisor is responsible for safety in the workshop
• Training should be a part of the safety program of a company
• Safety is an attitude, a form of mind of the worker. Good safety
attitude will lead to safe working habits.
• Workers need to be safety conscious as their actions may lead to
other workers being injured
OBJECTIVES OF INDUSTRIAL SAFETY
PROGRAM
1. To check all the possible chances of accidents for preventing loss of life
and permanent disability of any industrial employee, any damage to
machine and material as it leads to the loss to the whole establishment.
2. To eliminate accidents causing work stoppage and production loss.
3. To prevent accidents in industry by reducing any hazard to minimum.
4. To reduce workman’s compensation, insurance rate and all the cost of
accidents.
5. To educate all members regarding the safety principles to avoid
accidents in industry.
6. To achieve better morale of the industrial employees.
7. To increase production to a higher standard
SAFETY CONCEPTS
• Each supervisor is responsible for the safety of the workers
• The supervisor is responsible for training and ensuring safety precautions are
adhered to
• Depending on the size of the production entity, a safety department can be
created
• Sometimes the responsibility for safety rests on a safety committee formed by the
top executives of the organization
• A safety committee may consist of executives, supervisors, and shop floor
workers.
• It acts also as a policy making body on safety matters.
• Safety committee often organizes safety programs to make industrial persons
sufficiently alert for overall safety within the plant.
• A safety program tends to discover when, where and why accidents occur.
SAFETY CONCEPTS
• A safety programme should always include engineering safety at the design
and equipment installation stage, education of employees in safe practices,
concerns the attitude of employees and management.
• It should motivate all the industrial employees in accident prevention and
safety consciousness.
• It must provide all safety instructions and training essential for the
employees to think, act and work safely so that the number of accidents
can be minimized.
• Safety education must give knowledge about safe and unsafe mechanical
conditions and personal practices.
• Safety training must involve induction and orientation of new recruits to
safety rules and practices, explaining safety function, during their initial job
training through efforts made by the first level supervisors.
PLANNING FOR INDUSTRIAL SAFETY
• Careful planning for safety can help minimize accidents in the workshop
• Safety consideration includes proper layout of buildings and equipment,
such as providing adequate ventilation, sufficient working area to the
operator, clear pathways for movement of materials and parts, provision
for adequate personnel facilities- viz., canteens, lunch rooms, dispensary,
fire fighting services
• A number of important features should be considered and suitably
incorporated planning the layout of a new plant and its buildings for safety
• Sufficient lighting, ventilation, drainage, escape ways and guarding should
be provided for personnel.
• All the persons working on or around the conveyor must wear tight clothes,
gloves and safety shoes
CAUSES OF ACCIDENTS

The accidents may take place due to human causes, environmental causes and mechanical
causes.
HUMAN CAUSES
1. Accidents may occur while working on unsafe or dangerous equipment or machineries
possessing rotating, reciprocating and moving parts.
2. Accidents occur while operating machines without knowledge, without safety
precautions, without authority, without safety devices.
3. Accidents generally occur while operating or working at unsafe speed.
4. Accidents may occur while working for long duration of work, shift duty
5. Accidents commonly occur during use of improper tools.
6. Accidents may occur while working with mental worries, ignorance, carelessness,
nervousness, dreaming
7. Accidents occur because of not using personal protective devices.
ENVIRONMENTAL CAUSES

1. Accidents may occur during working at improper temperature and

humidity causes fatigue to the workers so chances of accidents
increases with workers having fatigue.
2. The presence of dust fumes and smoke in the working area may
causes accidents.
3. Poor housekeeping, congestion, blocked exits, bad plant layout etc.
may cause accidents.
4. Accidents occur due to inadequate illumination.
5. Improper ventilation in the plant may also leads to industrial
accidents.
MECHANICAL CAUSES

1. Continued use of old, poor maintained or unsafe equipment may

result in accidents.
2. Accidents commonly occur due to use of unguarded or improper
guarded machines or equipment.
3. Unsafe processes, unsafe design and unsafe construction of
building structure may lead to accidents in the plant.
4. Accidents occur due to improper material handling system and
improper plant layout.
5. Accidents may occur due to not using safety devices such as
helmets, goggles, gloves, masks.
 COMMON SOURCES OF ACCIDENTS
1. Revolving parts, viz. pulley, flywheels, worms, worm wheel, fan, gears, gear trains, gear wheels etc.
2. Projecting fasteners of revolving parts; like bolts, screws, nuts, key heads, cotters and pins etc.
3. Intermittent feed mechanisms, viz., tool feed of planer; table feed of a shaper, ram feed of power presses
and similar other applications.
4. Revolving shafts, spindles, bars, mandrels, chucks, followers and tools like drills, taps, reamers, milling
cutters, and boring tool etc.
5. Rotating worms and spirals enclosed in casings, such as in conveyors and revolving cutting tool, like
milling cutters, circular saw blade, saw band, circular shears and grinding wheels, etc.
6. Reciprocating tools and dies of power presses, spring hammer, drop hammers, and reciprocating presses,
reciprocating knives and saw blade such bow saw, shearing and perforating machines and the cutting and
trimming machine and power hacksaws etc.
7. Moving parts of various machines, like those of printing machines, paper-cutters and trimmers, etc.
8. Revolving drums and cylinders without casing, such as concrete and other mixers, tumblers and tumbling
barrels, etc.
9. High speed rotating cages such as in hydro-extractors.
10. Revolving weights, such as in hydraulic accumulator or in slotting machines for counter-balance.
 COMMON SOURCES OF ACCIDENTS (Cont ……
11. Nips between meshing racks and pinions of machine parts
12. Nips between reciprocating parts and fixed components, such as between shaper table and the fixture
mounted on it or a planer table and table reversing stops, etc.
13. Nips between crank handles for machine controls and fixed parts.
14. Projecting nips between various links and mechanisms, like cranks, connecting rods, piston rods, rotating
wheels and discs, etc.
15. Projecting sharp edge or nips of belt and chain drives; via belt, pulleys, chains sprockets and belt fasteners,
spiked cylinders etc.
16. Nips between revolving control handles and fixed parts traverse gear handles of lathes, millers, etc.
17. Moving balance weights and dead weight, hydraulic accumulators, counter-balance weight on large slotting
machines, etc.
18. Revolving drums and cylinders uncased, tumblers in the foundry, mixers, varnish mixers etc.
19. Nips between fixed and moving parts such as buckets or hoppers of conveyors against tipping bars, stops or
parts of the framework.
20. Nips between revolving wheels or cylinders and pans or tables, sand mixers, crushing and incorporating
mills, mortar mills, leather carrying machines, etc.
21. Cutting edges of endless band cutting machines, wood working, and log cutting metal find stone-cutting
band saws, cloth-cutting band knives.
22. Nips between gears and racks strips, roller drives, presses, planning machine drives.
PREVENTIVE MEASURES
• Safe working conditions can result in savings for the company.
• Loss of life and capital investment can be prevented by following safe
working practises
• Safety clothing such as goggles, safety shoes, dust coats
• Fencing or covers on machines
• Insulation of electric cables
• Good house keeping
• Training
• Warning signs
• Fire extinguishers
 COMMON SAFTEY METHODS
1. Safety by construction or design.
2. Safety by position.
3. Safety by using fixed guards.
4. Safety by using interlock guards.
5. Safety by using automatic guards.
6. Safety by using trip guards.
7. Safety by using distance guards.
8. Safety by workplace layout and proper working conditions.
9. Safety by proper material handling.
10. Safety by using personal protective devices.
 SAFETY BY WORKPLACE LAYOUT AND
PROPER WORKING CONDITIONS
1. A suitable layout and proper working conditions play an important role in preventing
accidents which would have otherwise occurred.
2. Moving path or passage ways should be clearly marked and never be obstructed.
3. Every employee should have enough space to move and operate the machine.
4. The floor condition must be of non-skid kind. It should act as a satisfactory plane which
can be easily cleaned.
5. Height of working rooms should be adequate for proper ventilation and lighting.
6. Fire walls should be used to separate various compartments.
7. Windows should have adequate size and should be in adequate numbers.
8. Illumination should be sufficient, continuous, uniform and free from glare.
9. Proper ventilation should be there in workplace.
10. Noise level should be proper if any. If it is high, use silencers to minimize the noise
level.
SAFETY BY DESIGN
• This methods involves the implementation of safety measures in the
design of tools or machines
• This involves designing the machine or tool such that the dangerous
to the operator are covered with suitable housing or guards
• It may involve gears, belts, or drive motor being covered in the
housing of the machine. Examples include drilling machines, lathe
machines, carding machines, and milling machines.
• Lubrication points can also be located on the exterior of machines
instead of the interior,
SAFETY BY POSITION
• Also implemented in the design stage, this method ensures that the
dangerous parts are always located out of reach of the operator
• This method may also employ housing or covers
• Rollers or conveyer belts can be located in areas that are difficult for
the operator to reach as with carding wires on a carding cylinder
SAFETY BY USING FIXED GUARDS
• Such fixed guards either form an integral part of the machine or are
so tightly secured to them that they are not easily removable. In all
cases, fixed guards are developed to have a robust and rigid
construction and they should be so placed that any access to the
dangerous parts of the machine is totally prevented from all
directions particularly in the running condition of the machines.
• Fixed guards adjusted in position remain fixed and they are neither
moved nor detached. In some cases the fixed guards are provided at
a distance from the danger point. Such a provision will carry a remote
feeding arrangement and, therefore, the operator will not be
required to go near the dangerous points.
GUARDS
GUARDS
GUARDS
SAFETY BY USING TRIP GUARDS
• Trip guard in machine is comprised with tripping device which
enables quick stopping or reversal of the motion of machine as soon
as the operator approaches within the reach of dangerous parts.
• Tripping device and the trip guard works in close conjunction with
each other during problematic situations.
SAFETY BY USING INTERLOCK GUARDS
• An interlocking guard may be mechanical, electrical, pneumatic or
some sort of a combination of these.
• Such guards cannot be removed and the dangerous parts are not
exposed until and unless the machine is totally stopped. Similarly, the
machine cannot be started to work unless the guards return in
position and protects the dangerous parts.
SAFETY BY USING DISTANCE GUARDS
• Distance guard helps to fence the dangerous components of machine
such as bars or rails and position them at a suitable distance from the
machine such that even operator by chance, extends his hands over
it, his fingers, clothes or any of the body does not reach within the
area of dangerous parts.
• For additional safety, some sort of tripping device should always be
incorporated to stop the machine rapidly in case of an accident.
GUARDS
Questions
• Why is safety important?
• Which methods can be used for safety in a production factory?
• What are the causes of accidents?
• Which sources of accidents can be found in the work place
 ASSIGNMENT

• What role does NSSA play in industrial safety?

• Write notes on the Factories and Works Act.
• Write notes on accident reporting procedures.
• Handling hazardous substances.

• Relate your answer to an industry of your choice and give appropriate

examples,
• 25 Marks for each question.