MODULE 2

INDUSTRIAL SAFETY
Personal protection in work environment

• Types of PPEs, Personal protective equipment-respiratory and

non-respiratory equipment. Standards related to PPEs.
Monitoring Safety Performance: Frequency rate, severity rate,
incidence rate, activity rate.
• Housekeeping: Responsibility of management and
employees. Advantages of good housekeeping. 5 s of
housekeeping.
• Work permit system- objectives, hot work and cold work
permits. Typical industrial models and methodology. Entry
into confined spaces.
 Personal protective equipment
• Personal Protective
Equipment [PPE] are
attached to the human body
for protection against injury
or harm.
The PPE provides good defence • hot substances,
against- • radiation,
• hazards of toxic exposure, • sharp edges,
• oxygen deficiency,
• welding, cutting, grinding,
• dusting,
• striking against and stepping over objects,
• chemical splashes,
• glare,
• steam,
• water and liquids,
• flying particles,
• PPE is a second line of defence. The first line is to eliminate or
minimise the workplace hazards.
• PPE cannot eliminate the hazard, it can help eliminate an injury or
reduce its severity.
• PPE can act as a barrier
between the man and
hazard and to save from
the injury.
Factors of selection or requisite
characteristics of PPE
• It should give adequate protection against the nature, severity
and type of hazard.
• It should be of minimum weight, should give minimum
discomfort with protective efficiency.
• Attachment to the body should be flexible yet effective.
• The wearer should not be restricted in movement" or
perceptions required for the job.
• It should be durable and attractive.
• It should not cause any hazard through its material, design,
defect, use or failure.
• It should conform Indian Standards and tests required
• It should be easy to clean, repair and maintain.
• The parts, piece and service should be easily available.
Classification
Selection of Material of Construction for PPF.
NON RESPIRATORY RESPIRATORY EQUIPMENT
EQUIPMENT
Head and Hair Protection
Ear Protection
Face and Eye Protection
Body and fall protection
Feet and leg
Hand
NON RESPIRATORY EQUIPMENT
• Head and Hair Protection

• Head protectors are hard hats, caps and helmets made of aluminium,
PVC fibre glass, laminated plastic or vulcanised fibre.
• They may be fitted with brackets for fixing welding masks, protective
face screen or a lamp.
• The hats and caps are provided with replaceable harness which
provides sufficient clearance between the top of the head and shell.
Hard hat
Protects Against-Falling
objects, hitting against
obstructions such as low
ceilings, beams, scaffold
members etc.
Electrical Safety Helmet
• Protection against-Electric shock when working near live electrical
lines.
• Made of synthetic electrically non-conductive materials (PVC etc.)
Welder’s Cap
• Protection against -Falling welding spatters from above.
• Made of leather with cloth lining inside.
Crash Helmet
• Protection against Skull injuries in road accidents.
• Usually fibre / plastic material with saddle inside, without peak or rim
and with chin strap.
• Covers forehead, temples and lower portion of head (above neck)
 Ear Protection
• Unbearable sounder noise creates difficulty in communication and
causes mental and physical stress resulting in illness and accidents.

• Workers shall be required to wear hearing protectors when engaged in

work that exposes them to noise that equals or exceeds 85 dBA for 8
hrs
• PPE
• Ear plug
• Earmuff
• Helmet
Ear plug
• They are conical shaped plugs of various materials for
insertion into the ear to reduce perception of noise,
particularly impulse noise.
• They can be soft or rigid. Rigid plugs are made of rubber or
plastic materials while soft plugs are of cotton cloth or of
very fine glass cloth impregnated with oil or a waxy mastic.
Ear muffs
• Earmuffs are large pads of
rubber or similar material
attached to a band or strap
and worn about the head
for reducing the effect of
noise on factory workers
(during impact riveting,
straightening, chopping
and the like operations).
Helmet
• Head-niece or helmet is an effective
device against the effect of noise
levels exceeding 120 dB where the
above protective devices are
ineffective.
Face and Eye Protection
• Eye injuries can be caused by mechanical, chemical, thermal
and radiation hazards such as dusts, flying particles, splashes
and harmful radiation.
• Eye protectors are safety spectacles, mono goggles, impact
goggles, welding goggles, foundry goggles, chemical
goggles, gas tight goggles, face shields, welding helmets etc.
Goggles
 Goggle types

ventilated Non-ventilated
Source: OSHA.gov
Face shield
Protection of hands and arms
• Protection of hands and arms are required when workers have
to handle materials having sharp end, sharp edges, hot and
molten metals, chemicals and corrosive substances.
• The protective equipment may be gauntlet gloves, wrist
gloves, mittens, hand pads, thumb and finger guards and
sleeves.
Gloves

•Protection from-
• Chemical solution
• Electric shocks
• Sharp object
• Hot parts
Mitten
• Mitten is a glove with a thumb but
without separately divided fingers
Mittens are preferred by some
workers in place of gloves for those
operations where finger-skill is not
required.
Finger-Cot
HAND PAD AND SLEEVES
Foot and Leg Protection
• Legs and Feet carry the weight of the body and need protection
against:
•
Falling objects
•
Sharp objects
•
Hot objects or heat
•
Chemical liquid splash
• The protective devices for legs and feet include
• Safety Shoes,
• Leg Guards
• Safety Boots
• Chaps
Safety shoes
Safety boots
• Protective boots cover the foot
and the part of the leg up to knee
of up to three fourths or full hip
height.
• Safety shoes/boots may be conductive, non conductive or spark
resistant.
• Rubber boots are useful to work in wet conditions, steel toe boots
against impact and puncture resistant soles to walk on surfaces having
nails, sharp objects etc.
METALIC FOOT
GAURD
Chaps
• Chaps. Chaps are thick trousers (pants)
without seat. Chaps are worn over ordi nary
trousers (Pants).
 Shin Guard
• Shin Guard. Generally a heavy fiber
material made to conform to the shape
of the front of the leg and strapped by
fastening behind the leg.
• It is ordinarily used by fastening
behind the legs.
• It is ordinarily used by workers in
material handling, heavy machine
operating, and meat packing job and is
designed to protect against flying
chips, heavy impact, hot sparks and
sharp objects.
Body, Skin and Fall Protection
• Body protectors are coats, waist, aprons, overalls, jackets and
complete head to toe protective suits.
• Aprons of different materials are used for protection against blows,
splashes, radiant heat, flying particles etc.
• Pads are used to protect shoulders and back from bruises.
• Impervious clothing of rubber or synthetic fabrics are used for
protection against water, moisture, dusts, vapours and liquid
chemicals.
• Complete coverage of the body and legs is not needed in many cases,
unnecessary safety clothing may hamper the efficiency of the wearer.
Apron
SAFETY JACKETS
FULL BODY SUITS
Full body harness
• Fall protection for the body
includes safety belts, lifelines
(ropes) and lanyards, harnesses
(belts & straps with buckles) and
fall-arrester devices or safety net.
Fall arrester
• Fall arrester net, if used,
should be tied firmly as
near as possible under
the working place to
minimize the fall
distance.
RESPIRATORY EQUIPMENT
• oxygen-deficient air
and harmful toxic
contaminants in the
atmosphere are the
major respiratory
hazards.
• Respiratory protective
equipment should be
considered a last resort, or
additional stand-by
protection and never a
substitute for effective
engineering control.
Classification of Respiratory Hazards
• Oxygen Deficiency
• Gaseous Contaminants
• Particulate Matter or Contaminants
• Normal ambient air contains an oxygen concentration of 20.8 percent
by volume. When the oxygen level dips below 19.5 percent, the air is
considered oxygen-deficient.
• Oxygen concentration below 16 percent is considered unsafe for
human exposure because of harmful effects on bodily function, mental
processes and co-ordination.
Classification of Respirators
• They are of two types : Air-supplying or Air-purifying.
• Air supplying respirators include air-line respirator, self breathing
(air or oxygen) apparatus, suction hose mask, pressure hose mask etc.
• Air-purifying respirators include canister, cartridge or filter
respirators which need replacement of these parts.
Airline Respirators
• Air-line respirator consists of a face-piece
(half or full mask or a loose fitting helmet or
hood) to which air is supplied through a small
diameter hose.
• It may be a continuous flow type or a demand
type.
• In a constant or continuous flow type, air is supplied continuously to
the face piece helmet or hood. air or the excess air entering the face-
piece escapes to the atmosphere.

• In a pressure demand type respirator, air is supplied to a face-piece

when the wearer inhales and the rate is governed by his volume rate of
breathing.
• Airline respirators provide protection so long as the air supply is
maintained but the wearer‘s travel is restricted by the length of the air
supply hose.
Suction Hose Mask
• It consists of a full face piece connected to a large diameter flexible
hose. The worker draws in air by his own breathing effort, the hose is
attached to the wearer's body by a suitable safety harness with safety
line and the air inlet end of the hose is provided with a filter to arrest
particulate matter.
• Air can be drawn in by respiratory effort of the wearer upto 30 ft
length of the hose.
Pressure Hose Mask (Air supplied
hoods):
• This hose mask or hood is similar to
suction hose mask except that the air is
forced through a large diameter hose by
a hand or motor-operated blower or
compressor.
• The blower is to be operated
continuously while the mask is in use.
Air-Supplied Suits
• Air line respirators are used where normally nose and face are
exposed to hazards and not the other body parts.
• But where all body parts including nose, need protection, for
example, to do any repair or emergency work in extremely
corrosive atmosphere affecting skin and mucous membranes
or acutely toxic and immediately dangerous to life, a full
body suit of impervious clothing with respirable air supply, is
a must.
• The air line is connected to the suit 'itself and also to helmet
and distributing air evenly throughout on the body, because
without such ventilation and cooling effect, it is very difficult
and fatiguing to wear such suit for a longer time.
Air Purifying Respirators
• Air purifying respirators purify the air of gases, vapour and
particulate, but do not supply clean or fresh air.
• Therefore they must never be used in oxygen deficient
atmosphere.
• Purification of breathing air is done by mechanical filtration,
adsorption, chemical reaction or catalysis.
• The life of such respirators depends on concentration of the
contaminant, scrubbing capacity of the medium (cartridge)
and breathing demand of the wearer.
• The respirator has a face piece and a connected canister (box)
or cartridge to purify the air passing through it.
Canister Gas Mask
• This consists of a canister, containing appropriate chemical, a
full face-piece and body harness to hold the canister. Air is
drawn through the canister by the wearer and during its
passage through the chemical in the canister the contaminant
present in the incoming air is absorbed and reacted with the
neutraliser.
• The canisters are designed for specific gases and it is very
important that the appropriate type is used.
Chemical Cartridge Respirator
• This consists of a half-mask attached to one or two
cartridges.. Like canisters, the cartridges are filled with
appropriate chemicals to absorb gases or vapours drawn
through them.
• This respirator is a non-emergency gas respirator and it
should not be used in an atmosphere deficient in oxygen.
Self-rescue type Respirators
• This is designed to provide the greatest possible respiratory
protection consistent with the practicability of carrying the
device at all times so that it is always available for use during
escape.
• It consists a filter element, a mouth piece, a nose clip and
means of carrying conveniently on the body. The filter
elements are similar to chemical cartridge.
Mechanical Filter Respirators
• These remove particulate matter from the inspired air which
passes through a filter. These filters may be of the single use
or re-usable type. If these respirators are used in heavy
concentrations of particulate matter, the filling will be
clogged with dust particles too quickly and they may have to
be replaced every now and then,. Micro filters are special
filters designed to arrest ultra microscopic size of dust
particles and these are used where extremely fine dusts are
encountered.
 PPE Standards
2. 29 CFR 1910.134 Respiratory protection:
• “The employer shall provide a respirator to each employee when such equipment is
necessary to protect the health of such employee.
• The employer shall provide the respirators which are applicable and suitable for the
purpose intended.
• The employer shall be responsible for the establishment and maintenance of a
respiratory protection program

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 PPE Standards
3. 29 CFR 1910.135 Head protection
• “The employer shall ensure that each affected employee wears a protective helmet when
working in areas where there is a potential for injury to the head from falling objects.
• The employer shall ensure that a protective helmet designed to reduce electrical shock
hazard is worn by each such affected employee when near exposed electrical conductors
which could contact the head.

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 PPE Standards
4. 29 CFR 1910.136 Occupational foot protection:
• “The employer shall ensure that each affected employee uses protective footwear
when working in areas where there is a danger of foot injuries due to falling or
rolling objects, or objects piercing the sole, and where such employee's feet are
exposed to electrical hazards.”

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 PPE Standards
5. 29 CFR 1910.137 Electrical protective equipment:
• details the design requirements for specific types of electrical protective
equipment—rubber insulating blankets, rubber insulating matting, rubber insulating
covers, rubber insulating line hose, rubber insulating gloves, and rubber insulating
sleeves used for the primary insulation of employees from energized circuit parts.

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 PPE Standards
6. 29 CFR 1910.140 Hand protection:
• “Employers shall select and require employees to use appropriate hand protection
when employees' hands are exposed to hazards such as those from skin absorption of
harmful substances; severe cuts or lacerations; severe abrasions; punctures; chemical
burns; thermal burns; and harmful temperature extremes.”

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 PPE Standards
7. 29 CFR 1910.140 Personal Fall Protection Systems:
• “Employers shall ensure that each personal fall protection system used to comply with this
part must meet all applicable requirements of this section.
• This section establishes performance, care, and use criteria for all personal fall protection
systems such as personal fall arrest systems and positioning systems.”

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 PPE Standards
7. 29 CFR 1910.132 General requirements:
• says that all PPE has to meet these minimum requirements:
1. Provide adequate protection against the particular hazards for which they are designed
2. Be of safe design and construction for the work to be performed
3. Be reasonably comfortable when worn under the designated conditions
4. Fit snugly and not unduly interfere with the movements of the wearer
5. Be durable
6. Be capable of being disinfected
7. Be easily cleanable
8. Be distinctly marked to facilitate identification only of the manufacturer

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 IS Standards related to
PPEs
HEAD PROTECTION
• IS CODE 2745 : 1983 – Specification for non-metal helmet for firemen
and civil defence personnel.
• IS CODE 2925 : 1984 – Specification Industrial safety helmet.
• IS CODE 4151 : 1993 – Specification for protective helmets for scooter
and motorcycle riders.

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 IS Standards related to
PPEs
BODY PROTECTION
• IS CODE 3521 : 1999 – Industrial safety belt and harness.
• IS CODE 4501 : 1981 – Specification for aprons.
• IS CODE 6153 : 1971 – Protective leather clothing.
• IS CODE 7352 : 1974 – X-ray lead protective aprons.
• IS CODE 8519 : 1977 – Guide for selection industrial safety equipment for the
body.
• IS CODE 8990 : 1978 – Code of practice for care and maintenance of industrial
safety clothing.

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 IS Standards related to
PPEs
EAR PROTECTION
• IS CODE 6229 : 1980 – Methods for measurement of real-ear protection of
hearing protectors and physical attenuation of ear muffs.
• IS CODE 8520 : 1977 – Guide for selection of industrial safety equipment for
eye, face and ear protection.
• IS CODE 9167 : 1779 – Specification for ear protectors

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 IS Standards related to
PPEs
EYE AND FACE PROTECTION
• IS CODE 1179 : 1967 – Equipment for eye and face protection during welding.
• IS CODE 5983 : 1980 – Eye Protector.
• IS CODE 7524 : 1980 – Method of test for eye protectors: -non optical tests.
(part -1)
• IS CODE 2521 : 1977 – Industrial safety face shield with plastic visor (part – 1)
• IS CODE 2521 : 1994 – Industrial safety face shield with wire mesh visor (part
– 2)

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 IS Standards related to
PPEs
EYE AND FACE PROTECTION (Contd…)
• IS CODE 8940 : 1978 – Code of practice for maintenance and care of industrial
safety equipment for eyes and face protection.
• IS CODE 9973 : 1981 – Specification for the visor for scooter helmets.
• IS CODE 9995 : 1981 – Specification for the visor for non-metal police and
firemen helmets.
• IS CODE 14352 : 1996 – Miner’s safety goggles – Specification.

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 IS Standards related to
PPEs
FEET AND LEG PROTECTION
• IS CODE 1989 : 1986 – Specification for leather safety boots and shoes – for
miners (part – 1).
• IS CODE 1989 : 1986 – Specification for leather safety boots and shoes -for
heavy metal industries (part – 2)
• IS CODE 3737 : 1966 – Leather safety boots for workers in heavy metal
industries.
• IS CODE 3738 : 1998 – Rubber boots – Specification.
• IS CODE 3976 : 2003 – Protective rubber canvas boots for miners –
Specification.

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 IS Standards related to
PPEs
FEET AND LEG PROTECTION (Contd…)
• IS CODE 4128 : 1980 – Specification for fireman leather boots.
• IS CODE 5557 : 1999 – Safety rubber boots.
• IS CODE 5852 : 2004 – Steel toe safety shoes.
• IS CODE 6519 : 1971 – Code of practice for selection, care, and repair of safety
footwear.

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 IS Standards related to
PPEs
HANDS PROTECTION
• IS CODE 2573 : 1986 – Specification for leather, gauntlets and mittens.
• IS CODE 4770 : 1991 – Rubber Gloves – electrical purposes – specification.
• IS CODE 6994 : 1973 – Specification for safety gloves –leather and cotton
gloves (part – 1).
• IS CODE 8807 : 1978 – Guide for selection of industrial safety equipment for
the protection of arms and hands.

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 IS Standards related to
PPEs
RESPIRATORY PROTECTION
• IS CODE 8318 : 1977 – Colour identification markings for air purifying canisters
and cartridges.
• IS CODE 8347 : 1977 – Glossary of terms relating to respiratory protective
devices.
• IS CODE 8522 : 1977 – Respirators chemical cartridge.
• IS CODE 8523 : 1977 – Respirators canister type gas masks.
• IS CODE 9473 : 2002 – Respiratory protective devices -filtering half masks to
protect against particles – specification
• IS CODE 9563 : 1980 – Carbon monoxide filter self rescuers.
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Monitoring Safety Performance
• Frequency rate
• Severity rate
• Incidence rate
• Activity rate
 Frequency rate
• A question 'How often do injuries occur?' is replied by the frequency
rate which is defined as the disabling (lost time) injuries per
1000000 man-hours worked.

Disability Injury (Lost Time Injury) : An injury causing disablement

extending beyond the day of shift on which the accident occurred.
• Reportable Disabling Injury (Reportable Lost Time
Injury) : An injury causing death or disablement to an extent
as prescribed by the relevant statute (viz. the Factories Act
and the ESI Act).
Note that ……!
• If the injury does not cause loss of time in the period in which it
occurs but in a subsequent period, the injury should be included
in the frequency rate of the period in which the loss of time
begins.
• If an injury causes intermittent loss of time, it should only be
included in the frequency rate once, that is, when the first loss
of time occurs.

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• Since frequency rate FB is based on the lost time
injuries: reportable to the statutory authorities, it may
be used for official purposes only.
• In all other cases, frequency rate FA should be used
for comparison purposes.
• Man-hours Worked: The total number of employee-hours worked by
all employees working in the industrial premises. It includes
managerial, supervisory, professional, technical, clerical and other
workers including contractors' labour.
 What does 1000000 mean ?

• No of workers in a year = 500

• Daily Hour Worked = 8 hrs
• No. of days worked in a week = 5 days
• Total hours worked in a week = 8 x 5 = 40 hrs
• Total week in a year = 50 week
• So, In a year = 50 week x 40 hrs/week x 500 workers = 10 00 000
man hours

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Example 1
• Using the following data calculate the frequency rate of accident in an
industrial plant.

Number of workers= 500

Number of disabling injuries per year= 5.
Average number of hours worked by worker per year= 2000.

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Incidence Rate
• General incidence rate is the ratio of the number of injuries to the
number of employees during the period under review.
• It is expressed as the number of accidents or injuries, per 1000 persons
employed.
Severity Rate
• A question 'How serious are the injuries? is replied by the
severity rate which is defined as the number of days of lost
time per 1000000 man-hours worked.
Safety activity rate

• Here 'Safety activity' is the sum (during the unit period) of safety
recommendations made, unsafe practices reported, unsafe
conditions reported and the number of safety meetings held.
• Thus a safety activity rate curve can be plotted for any period - a
week, month, year etc. and the safety performance can be
compared.
• Since severity rate SR is based on the lost time injuries reportable to
the statutory authorities, it should be used for official purposes only. In
all other cases severity rate SL should be used for comparison
purposes.
Mean Duration Rate
• It is an average number of days lost per accident
Significance of Performance Rates
The injury rates are useful to -
• Measure the frequency and seriousness of accidents of a
given depar tment, branch or a factory.
• Determine from month to month or year to year whether the
condition is getting better or worse.
• Compare the experience of one operating unit with one or
more other similar units and
• Serve as a basis for an accident-prevention contest between
two or more operating units.
• A serious accident has a considerable effect on the accident
severity rate (due to increased mandays lost) but it does not
greatly affect the accident frequency rate.

• Decrease in frequency rate may not necessarily bring

decrease in severity rate.
Drawbacks of Performance Rates
• No rate is capable of giving complete picture of safety
performance.
• The frequency rate indicates a number of accidents per man-
hours worked only. Type, cause, severity, agency or factors of
accidents are not represented.
• The severity rate indicate a ratio of total man-days lost to
total manhours worked only. Type, cause, frequency, agency
or factors of accidents are not represented
• Many accidents and property damage or time losses not causing any
man-days lost are not properly indicated by frequency or severity
rates.
• Comparing two plants / factories based on their frequency or severity
rates is not a good practice. It does not give correct picture as the types
of hazard, working conditions/ actions, number and type of manual
handling or exposure, attitude of workers, attitude of management etc.
differ between them and these factors have definite effects on the
frequency and the severity rates.
• Denominator of both the rates (FR & SR) is 'man-hours
worked'. Mostly these figures are selected from 'Attendance
Register and there is a difference between 'Attendance in
Register' and actually working under hazard. Many
supervisors, officers and workers sit in offices or cabins or
have idle hours. Even then "such hours' are included in 'man-
hours worked'. Thus these rates do not give the absolute
correct safety picture.
• Severity rate indicates only 'absence' due to an accident. It does not
represent actual severity of pain and suffering of a worker.
Worked Examples :
• Calculate different injury rates for. a factory employing average 50
workers for the year during which 100 lost-time (disabling) injuries
(accidents) took place and totally 500 man-days lost. The workers
worked 48 hours a week and S2 weeks in the year.
 Housekeeping
• Housekeeping is not just a need-based cleaning.
• It is more than that. In addition to regular daily cleanliness, it
includes orderly arrangement of tools, equipment, materials
and process flow.
• It is an integral part of industrial activity that reduces
accidents, increases cleanliness, attractiveness and comfort,
production and improves employee's morale and public
relations.
• Up-keeping of all industrial activities in orderly manner to
minimize the accidents due to improper planning, placement,
arrangement, .handling etc., everywhere in the industrial
premises.
Indicators of poor housekeeping
• Objects & Materials on Floor
• Poor Storage Practices
• Equipment out of Place
• Dirty walls, windows, ceilings, floors etc.
• Poor waste disposal system
Keys to good housekeeping
• Cleanliness of floors, buildings & equipment.
• Proper and speedy disposal of scrap, waste and surplus
materials.
• Keeping each object in its designated place and returning
after work.
• Sufficient work' areas, exits, walkways, aisles etc.
• Orderly arrangement of material, process, machine, tools and
equipment.
• Good lighting, colour and ventilation.
• Prevention of Spillage
• Fenced platforms, and wall openings to prevent fall accidents
• Removal of possibilities of falling bodies
• Avoidance or fencing of sharp edges, corners etc
• Proper marking and identification
Benefits of Good Housekeeping
• It is an essential routine support to industrial safety and
health.
• A large number and wide range of accidents due to bad
housekeeping can be eliminated by good housekeeping.
• It aids to good maintenance and working as complementary
to it and increase overall safety and productivity.
• Clean, hygienic and safe plant environment increases
attractiveness and morals of the employees.
• Machines, tools and equipment work better in clean condition
and boost up the workmanship.
• If tools are placed in easy to find manner, job; run smoothly and give
good results.
• Much floor space or area is utilised because of proper access to
machines and equipment for cleaning and maintenance purpose.
• Time spent in locating tools and appliances and wastage of time is
controlled resulting in increase of efficiency.
 Management Policy and
Responsibility
Management must establish, declare and implements
housekeeping policy
• Dirt and disorder are always evidence of waste of materials,
time, energy and effectiveness.
• Regular cleaning of dirt and maintaining orderly things may
be a tough job, but it is the management's responsibility.
• Good housekeeping reduces accidents and increases safety,
productivity and morale.
• Working in dirt, dust and disorder increases cost and
decreases workers' comfort,
• If you can't manage to have cleanliness and order, you
can't manage your department.
Management Responsibility
• Planning and Follow up
• Overall Co-operation
• Housekeeping Contests
• Employees Assignment
Safety Officer's Role
• Suggesting the best housekeeping policy, procedure and
equipment to the top management.
• Co-operating in finalizing the policy and planning including
preplanning, space requirements and facility requirements for
good housekeeping.
• Implementing the policy, procedure and programs through
supervisors, workers and all concerned throughout the plant.
• Advising and assisting all plant people for their co-operation
in good housekeeping efforts.
• Solving the problems by appropriate design, layout, planning
and purchasing equipment for good housekeeping.
• Arranging supervision, competition, award and incentive
schemes to improve housekeeping and maintain interest.
• Designing and arranging regular and special inspections,
checklists, rating forms and records for good housekeeping.
Supervisor's Role :
• All supervisors must provide initiative
and leadership for daily attention of
the workers on cleanliness and
orderliness of workplace, machine,
equipment, tools, materials etc. in
their control.
• They have to carry out the
management policy, programme and
maintenance of good housekeeping in
their areas.
• They should take part in competition of housekeeping and try
to win awards for that. They can contribute much to boost up
workers' morale, attitude and enthusiasm towards their day to
day checking and efforts for good housekeeping.
• They have to obtain co-operation from all workers for their
success. If any award for rating standards are prescribed for
their superior performance, they should explain the workers
how to achieve them.
• They must pay constant attention on all items of removing
bad housekeeping and maintaining good housekeeping.
Workers' Role:
• Nobody else can keep their things so clean and in order as
they keep for themselves. Daily they should spare a few
moments for cleaning up.
• They have to implement the policy and checklist given to
them for good housekeeping.
• A list of items of daily and periodical checking should be
prepared, displayed and followed up accordingly.
 JAPANESE CONCEPT OF ‘FIVE-S

Sort
Set in Order
Shine
Standardize
Sustain
 Seiri- Sort
The first step of 5S, Sort, involves going through all the tools,
furniture, materials, equipment, etc. in a work area to
determine what needs to be present and what can be removed.
Some questions to ask during this phase include:
• What is the purpose of this item?
• When was this item last used?
• How frequently is it used?
• Who uses it?
• Does it need to be here?
When a group has determined that some items aren't necessary,
consider the following options:
• Give the items to a different department
• Recycle/throw away/sell the items
• Put items into storage
 Seiton- Set in Order

• This is where you apply the

principle of “there is a place
for everything.” Ensure items
are organized by function and
by frequency of use.
 Sciso-Shine
• Sciso or cleaning. Main activity of good housekeeping is
cleaning. It includes cleaning of floors, walls, ceiling, sanitary
and welfare facilities, parts of plant and machinery, PPE and
other equipment, tools, lighting fixtures, lamps, tubes etc.
 Seiketsu- Standardize
• The problem is, when 5S is new at a company, it's easy to
clean and get organized…and then slowly let things slide
back to the way they were. Standardize makes 5S different
from the typical spring-cleaning project.
• Standardize systematizes everything that just happened and
turns one-time efforts into habits. Standardize assigns regular
tasks, creates schedules, and posts instructions so these
activities become routines.
 Shitsuke- Sustain
Sustain refers to the process of keeping 5S running smoothly, but
also of keeping everyone in the organization involved. Managers
need to participate, as do employees out on the manufacturing
floor, in the warehouse, or in the office. Sustain is about making
5S a long-term program, not just an event or short-term project.
Ideally, 5S becomes a part of an organization's culture. And
when 5S is sustained over time, that's when businesses will start
to notice continuous positive results.
• Housekeeping
• Accident
• 5s

• House keeking-2
Work permit system
Work permit system
• A Permit to Work System or PTW is a standard operational
procedure used by organizations to issue documented
permission to perform tasks that are considered hazardous or
non-routine.
• A permit to work form consists of specific instructions of the
nature of the job, the time and place along with adequate
information of critical safety procedures to follow.
Permit to work document
• Sufficient authorizations from assigned personnel throughout
the permit management.
• Roles and responsibilities for a given task.
• Clearly define hazards that workers may face along with the
necessary precautionary actions to take.
• Precise description of the task along with a timeline, scope of
work and clear instructions on how to perform the given task.
• An elaborate set of risk assessment protocols including
site audit check, safety equipment check, safety training of
personnel check, and more such safety checks which varies
according to the type of job.
• A record to indicate the status of the work permit – be it
closed, cancelled, revoked, re-issued, etc.
Why Permit to Work?
• A permit to work system provides an easy way for
organizations to keep a constant eye on work-flows using a
well-documented system to streamline operations and control
safety outcomes.
• Without a work permit, you unintentionally put yourself and
those around you in danger. For example: Imagine being
stuck or asphyxiated in a confined space with no one
knowing you’re actually there or operating machinery
without enough practice or training.
What are the types of Work Permits?
• Hot Work Permit
• Cold Work Permit
• Height Work Permit
• Confined Spaces Work Permit
• Excavation Permit
• Chemical Work Permit
• Electrical Isolation Permit
Hot Work Permit
• Authorization to perform tasks in conditions that produce sparks,
flames or any other source of ignition. Examples of Hot Work
Permit include welding, soldering, flammable gases and other heat
inducing operations.
What is a Hot Work Permit?

A hot work indicates any kind of work that involves a form of ignition.
It can be:
• Welding
• Soldering
• Brazing
• Grinding
• Flame cutting
• Using blow lamps, torches, hot air blowers
• A hot work permit protects the people involved in any hot work
activity from gross accidents. It is basically a Permit to Work
system with exhaustive list for all possible hot works with a step-by-
step checklist or template for safe operations.
• A hot work permit is both a preventive and an educative system to
help workers to be safe when working with ignition. Every worker
should obtain a hot work permit and follow the steps before, during
and after conducting any hot work.
A hot work permit will ensure that the workers:
• Follow all isolation practices before starting any job.
• Test for flammable substances or gases in the area of the job.
• Identify the hazardous substances and take precautions to
keep them out of the way.
• Follow all PPE instructions.
• Cordon-off the area where the hot work will be conducted.
• Be aware of various ignition sources. Eliminate any ignition
sources in the vicinity before beginning the hot work.
• Use supplementary materials like sand and blankets to protect
themselves and other surrounding areas during the job.
• Monitor the surroundings and O2 levels during the hot work.
• Have first-aid boxes and fire extinguishers handy.
• Inspect and clean up the area after completing the hot work.
• Follow protocols for incident reporting.
A hot work permit must consist of:
• The date
• The location of the job
• The duration of the job
• The exact nature of hot work
• Hazards and risks of the job
• PPE requirements
• Details of the person applying the permit and approving the
permit
• Requirements for conducting the hot work monitoring and
fire monitoring protocols
• Hot work checklist before starting the job
• Hot work protocols for jobs in confined spaces and
walls/ceilings
• Final checkup after the job
• Handover procedures and cancellation protocols
• Video
Cold Work Permit

• Authorization to operate machinery or other functions that do

not generate any form of heat in the manufacturing process.
Mechanically induced bending, shearing, squeezing and
drawing are some examples of Cold Work Permit.
What Is a Cold Work Permit?

• Any job that doesn’t require any ignition comes under cold work. Cold
work is basically a plastic deformation process caused by pressing
and/or rolling at room temperature. There are several types of cold
work jobs happening in plants:
• Rolling
• Spinning
• Drawing
• Extruding
• Pressing
• In a typical working environment, cold work activities
involve working on pipelines, adding values, spades or
blanks, erecting scaffolding, adding insulation, or involving
any mechanical or civil maintenance work without using any
flaming materials.
• In some industries, cold work can also include working with
corrosives, resins, solvents, chemical cleaning, radiation or
electrical equipment.
Here are some of the standard cold works that happen in an industry:
• Energized electrical work
• Movement of heavy equipment within a plant or a location
• Working from heights
• Underwater cold works
• Excavation activities
• Sandblasting
• Hydroblasting
What Should a Typical Cold Work Permit
Consist Of?

• The date
• The location of the job
• The duration of the job
• The exact nature of Cold Work
• Hazards and risks of the job
• PPE requirements
• Details of the person applying the permit and approving the
permit
• Requirements for conducting the Cold Work monitoring and fire
monitoring protocols
• Cold Work checklist before starting the job
• Cold Work protocols for jobs in confined spaces and walls/ceilings
• Final checkup after the job
Confined Spaces Work Permit
• Authorization to perform tasks in a narrow space which is
prone to hazards like asphyxiation, a substance that has the
ability to engulf, toxic atmosphere, etc. Confined spaces refer
to vents, shafts, sewages, tanks and much more.
• Simply putting your head into an oxygen-depleted atmosphere (for
example by looking into a nitrogen-filled tank through a manhole) can
result in loss of consciousness in as little as 15 – 20 seconds followed
by death in 2-4 minutes.
Hazards of Confined Space can be classified as-
• Poor lighting and ventilation.
• Oxygen deficiency.
• Contamination of toxic and/or flammable gases.
• Unexpected activation of machinery or flow.
• No way or no time available for exit.
• Engulfment (burying) in loose material.
• Non specific work practices.
• Other hazards are suffocation, burning, poisoning, explosion,
drowning, freezing, crushing, entrapment, scalding, stroke, heat stress,
radiation, physical trauma, injury by moving machinery, slipping or
falling etc.
The confined space entry procedure needs to accommodate the
following steps:
• Preparations to make the enclosed space safe (for example by
isolating energy sources, purging with air, maintaining oxygen
levels, testing for toxic or explosive gases).
• Informing persons involved in the work on their roles and
responsibilities and making sure they are competent for their
specific role.
• Creation and regular review of a confined space register including
relevant rescue plans and drawing.
• As far as possible, prevention and avoidance of any task
that will involve confined space work.
• Ensuring that emergency services are available and the
procedures are in place and understood for rapidly mobilizing
assistance if required.
• Issue and manage the confined space permit in line with the
companies written procedures.
• Provide all necessary protective, extraction/retrieval and
environmental monitoring equipment.
• Monitor the work taking place for additional hazards,
adjacent work, changes in the environment/conditions and the
progress/signs of physical and mental exhaustion of the
people involved.
• Testing that work has been done satisfactorily and that these
tests are also done under safe conditions.
• Proper restoration of the site after work has been completed
for the resumption of normal operations.
• Video