STOP 6 Training 1

Accident Prevention Training
“STOP 6”
What is Accident ???………
“It is unplanned & Unintended OCCURANCE which resulted in
1. Injury,
2. Property Damage
3. Or Both(1 & 2)
During the course of Employment.
No Permanent
Solution
• Human Factor/ Unsafe Act
Area of Focus
•Eqpt. Factor/ Unsafe Condition

Permanent
Solution
HEINRICH’S PRINCIPLE
“ For each major

industrial accident, there
are 29 other accidents
derived from the same
cause that result in minor
injuries, and 300 near-
accidents.”
Near Misses are

caution call/
warning to some
thing BIG which is
going to come……..
ALL ACCIDENTS ARE PREVENTABLE

WHAT IS STOP 6 ACCIDENT :-
GABRIEL IDENTIFYED POSSIBLE MAJOR ACCIDENT CAUSING

SOURCES IN AUTOMOBILE INDUSTRY
• Severity of Accident
• Frequency
• Repeated nature
Make the plan how to

eliminate & avoid
specified accidents
Methodology : -
Analysis of Accidents
Grouping accidents
A- B- C- D- E– F– Fire
Actuator Big Car Drop Electrical
Identification of areas G- H-
Gillette Health
Counter Measure for each problem

The 6+2 Designated Accidents
A: Being caught in machines

B: Coming in contact with heavy objects
C: Coming in contact with vehicles
D: Falling
E: Electrocution
F: Coming in contact with heated objects
G: Gillette – Cut Related (STOP 6+1)
H: Health related (STOP6+2)
Actuator : A
What is type A?
A means actuator i.e., Caught by machine, machine hitting member,
Press Radial drilling m/c Drilling m/c,

How to prevent
Die spotting m/c ? Die transport by crane, Lathe,
Reverting m/c Robot Milling m/c
•Spot welding m/c
Coordination between MachineCranes
& Man – Concentration Fly wheel,
any semi operated clamps,
•Hemming
Motor couplings,
Extensive m/c
training before the new Job
Punching m/c, Tapping m/c or
Type
•Not allowing other to interrupt of Injury
process : the machine
or to access Rotating tool
Upper arm bushing m/c,
•scissor
No nonlifter
standard maintenance procedures Crush Injury
while machine or system in working condition
•conveyor
Gloves notslots
allowed to use in the rotating machines
……..Actuator : A
All gear
How tomechanism,
prevent ? Conveyor Lathe
Belt drives
•Regular check for guards inCrane
the rotating machines (Locks)
Fly wheel
•No maintenance work allowed while machine in On condition
Conveyor
•Gloves not allowed
any Mechanical Powerto use
•transmission
Proper dressing
unit code & Correct usage of PPE
Blowers planning (long flexibleType
•Improper of Injury : - Crush injury
objects)
to Fatal accident
Compressors & regular check for emergency
•Installation button
Big: B
What is type B? B means Big i.e., Contact with big or heavy objects
Clamping not properly

How to prevent ? Imbalance Crane rope or sling failure due to over load
due to swing of load Crane rope or Sling failure due to defect in rope Poor
•Standing close to
Failure of handle load or below the
in bucket load while
slinging methodtransfer - Keep distance
Clamping location not right
•Use correct Jerk movements
type, capable sufficient no of slings with out defect
Failure of clamp
•Do not over load the sling
Type of Injury : - Crush, Pinching, fracture & some times fatal
•Lifting by more than one person – Positioning & load distribution
……Big: B
How to prevent
Standing close to? load Type of Injury : -
•Poor planning Standing in between load Crush & fatal
•and
Poorother
safety awareness
object
•Not following
Improper standard
slinging procedure of lifting
•System failure Handling of rope by
hand instead of tools
……Big: B
How to prevent ? Material Table

Object falling while transferring
Not placing parts properly in the fork or trolley Fork lift
Improper positioning of pallets or load in fork lift
Over stacking of material
Over stacking or improperinstacking Hand trolley
Avoid over speeding the curve roads
Inclined surface
Material falling orvehicle
from ramps during turning vehicle Tow motor
Value transfer vehicle
Car: C
What is type C?
C means Car i.e., Accident caused by vehicle
Visibility blocked for driving vehicle leads to accident Type of Injury : -

Sharp corners
Contusion Many
Loading material above the visible zone times fracture &
Over taking vehicles Fatal accident
Too many dolly connected to vehicle
Improper lay out
……Car: C
While Unloading & stacking materials – Material falling & leads accident
Fork hitting near by stacked material
Rude way of loading material
How to Prevent
Sufficient gap between stockings
Operating vehicles only by licensed operator
No urgency while loading or unloading
……Car: C
Lifting too many part at a time

Improper placing and stacking parts in the forks
Jerk movement & sudden brake
Over speeding in corners
With out pallet lifting some parts
Drop : D
What is type D?
D means Drop i.e., TM falling from height or elevated position
How
Equipment
to prevent
failure
? ( Not maintained properly or tested properly)
Proper planning of any activity
Defective Tools
Use correct tools & equipments
Ensure
ImproperQuality of construction
construction or poor of critical
quality of equipment
materials or warning system
& facility
Regular Maintenance check for equipment or tool
– Preventive maintenance
…….Drop : D
Carelessness during work

Not using proper PPE’s for height work
No warning boards – Openings
Type of Injury : -
Fracture & Fatal accident
Electrical : E
What is type E?
E means Electrical Shock or hazard by equipment or other electrical installations
How to tools
Portable prevent
– Not?double insulated or metallic body Type of Injury : -
Always
Equipment use Double
is not insulated
grounded toolproperly
or earthing
Ensure work area free from water Burn injury & Fatal
Floor condition not safe – Wed condition
Not to work in the raining time (In open Atm)accident
Regular
Not using check for equipments or tools for any damage
proper PPE
Working background – During drilling – Cables in the walls
…….Electrical : E
•Too Manysupervision
Proper joints in the cable
before starting & during work by leader
No insulation for the joints
•Keeping in safe distance – Working near HV or open live cables
Damage to the insulation in the cable
•Working nearwork
Electrical live electrical
by only cable or HV line
qualified person only
Open joints or electrical joints in the open condition – Rain
Fire : F
What is type F?
F means Any fire incident causing injury to person or damage to property
•Gas leak in the flammable gas cylinder or pipe lines or storage

•Failure of valve, joints or any other accessory ( Pr Gauge )
•Back fire, Storing cylinder near hot area(Welding, Furnace etc)
•Source of ignition in the flammable storage, Paint booth, Storage area etc
•Mal function of equipment in the flammable area
Guillotine : G
What is type G ?
G means Cut injury by any means
How to prevent?
Not Using the safety wear Type of Injury : -
1.Sharp
Keeping sufficient
object falling distance
or touching (Standardization)
the Team members Cut injury or
2.Failure
Following standard
of Warning device orprocedure
Guards working procedure
amputation of limps
3. Using correct PPE
Panels slip from Hand
4. Correct usage of PPE
5.While unloading
Storage Panel hitting
– Proper stock,other member & Method
Quantity
Carelessness while using the sharp tools
Health : H
What is type H ?
H means Health related by any means
How to prevent?
Not Using the safety wear Type of Injury : -
1.Sharp
Hygienic workoratmosphere
object falling (Freemembers
touching the Team from fumes, dust,
Cut noise…)
injury or
2. Following standard procedure working procedure amputation of limps
Failure of Warning device or Guards
3. Using correct PPE
4.Panels slip from
Correct Hand
usage of PPE
5.While
Adopting
unloadingengineering
Panel hittingmethods to provide safe
other member
work area.
Carelessness while using the sharp tools
How to Reduce or eliminate Stop 6 Accidents from Work place ?
• Under stand what is Stop 6 type accidents

• Divide your work area & equipments in to multiple area
• Analyze possible accidents in process or equipments
• Take counter Measure
• Educate the Members & maintain ensure Members following the
counter measure
• Educate the members and training members on Stop 6 Accidents
• Taking idea from Members and implement the Counter measure
Let’s run thro’ some
slides on STOP 6+2
situations we come
across and the
countermeasure
development.
Thank you

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Accident Prevention Training

•Eqpt. Factor/ Unsafe Condition

“ For each major

Near Misses are

ALL ACCIDENTS ARE PREVENTABLE

GABRIEL IDENTIFYED POSSIBLE MAJOR ACCIDENT CAUSING

Make the plan how to

Counter Measure for each problem

A: Being caught in machines

Press Radial drilling m/c Drilling m/c,

Clamping not properly

How to prevent ? Material Table

Visibility blocked for driving vehicle leads to accident Type of Injury : -

Lifting too many part at a time

Carelessness during work

•Gas leak in the flammable gas cylinder or pipe lines or storage

• Under stand what is Stop 6 type accidents

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