1.1INTRODUCTION Due to rapid industrialization, industrial workers are exposed to several types of hazardsand accidents.

Every year lakhs of workers are injured due to mechanical, chemical, electricala n d r a d i a t i o n h a z a r d s a n d i t l e a d s t o p a r t i a l o r t o t a l d i s a b l e m e n t . S o i n r e c e n t y e a r s , g r e a t e r attention is given to health and safety due to pressure from government, trade unions, labour laws and awareness of employers.The efficiency of workers depends to a great extends on the environment in which thework. Work environment consists of all the factors, which act and react on the body and mind of an employee. The primary aim is to create an environment, which ensures the greatest ease of work and removes all causes of worries.Occupational health and safety is a discipline with a broad scope involving many specializedfields. In its broadest sense, it should aim at: a) The promotion and maintenance of the highest degree of ph ysical, m e n t a l a n d s o c i a l well-being of workers in all occupations. b) The prevention among workers of adverse effects on health caused by t h e i r w o r k i n g conditions. c) The protection of workers in their employment from risks resulting from factors adverseto health. d) The placing and maintenance of workers in an occupational e n v i r o n m e n t a d a p t e d t o physical and mental needs. e) The adaptation of work to humans.S u c c e s s f u l o c c u p a t i o n a l h e a l t h a n d s a f e t y p r a c t i c e r e q u i r e s t h e c o l l a b o r a t i o n a n d participation of both employers and workers in health and safety programmes, and involves thec o n s i d e r a t i o n o f i s s u e s r e l a t i n g t o o c c u p a t i o n a l m e d i c i n e , i n d u s t r i a l h y g i e n e , t o x i c o l o g y , education, engineering safety, ergonomics, psychology, etc. 1

Occupational health issues are often given less attention than occupational safety issues because the former are generally more difficult to confront. However, when health is addressed,so is safety, because a healthy workplace is by definition also a safe workplace. The converse, though, may not be true - a so-called safe workplace is not necessarily also a healthy workplace.T h e i m p o r t a n t p o i n t i s t h a t i s s u e s of both health and safety must be addressed in e v e r y workplace.Work plays a central role in people's lives, since most workers spend at least eight hoursa day in the workplace, whether it is on a plantation, in an office, factory, etc. Therefore, work e n v i r o n m e n t s s h o u l d b e s a f e a n d healthy. Unfortunately some employers assume l i t t l e responsibility for the protection of workers' health and safety. In fact, some employers do noteven know that they have the moral and often legal responsibility to protect workers. Health of the workers: Health is a state of complete physical, mental and social wellbeing and not merely theabsence of diseases. Its a pos itive and dynamic concept which means something more than theabsence of illness.

Statutory provisions: 2

According to factories Act, 1948, the statutory provisions regarding the health of theworkers are stated in the sections 11 to 20. They are Cleanliness (sec 11): Every factory shall be kept clean by daily sweeping or washing the floors and workroomsand by using disinfectants where every necessary. Walls, doors and windows shall be repaintedor varnished at least once in every 5 years. Disposal of wastes and effluents (sec 12): The waste materials produced from the manufacturing process must b e e f f e c t i v e l y disposed of wastes. Ventilation and temperature (sec 13): There must be provision for adequate v entilation for the circulation of fresh air. Thetemperature must be kept at a comfortable level. Hot parts of machines must be separated andinsulated. The State Government may make rules for the keeping of thermometers in specified places and the adoption of methods which will keep the temperature low. Removal of Dust and fumes (sec 14): If the manufacturing process used gives off injurious or offensive dust and steps must betaken so that they are not inhaled or accumulated. The exhaust fumes of internal combustionengines must be conducted outside the factory. Artificial humidification (sec 15): The water used for this purpose must be pure. The State Government can frame rulesregarding the process of humidification etc. The water used for humidification shall be takenfrom a public supply or other source of drinking water and must be effectively purified before use. Overcrowding (sec 16): 3

There must be no overcrowding in a factory. In f a c t o r i e s e x i s t i n g b e f o r e t h e commencement of the Act there m u s t b e a t l e a s t 9 . 9 c u b i c m e t e r s o f s p a c e p e r w o r k e r . F o r factories built afterwards, there must be at least 4.2 cubic meters of space. The chief inspector of factories can also prescribe the maximum number of workers who can work in each work room. Lighting (sec 17): Factories must be well lighted. Effective measures must be adopted to prevent glare or formation of shadows which might cause eye strain. Drinking water (sec 18): Arrangements must be made to provide a sufficient supply of wholesome drinking water.All supply points of such water must be marked drinking water. No such points shall be within 20 ft. (or 7.5 meters) of any latrine, washing place etc. Factories employing more than 250 workers must cool the water during the hot weather. Toilet facilities (sec 19): Every factory must provide sufficient number of latrines and urinals. T h e r e m u s t b e separate provisions for male and female workers.L a t r i n e s a n d urinals must be kept in a clean and sanitary condition. In f a c t o r i e s employing more than 250 workers, they shall be of prescribed sanitary types. Spittoons (sec 20): A sufficient number of spittoons must be provided at convenient places, in a clean andhygienic condition. The State Government may take rules regarding their number, location andmaintenance. Safety of the workers: 4

Safety is a measures or techniques implemented to reduce the risk of injury, loss andd a n g e r t o p e r s o n s , p r o p e r t y o r t h e e n v i r o n m e n t i n a n y f a c i l i t y o r p l a c e i n v o l v i n g t h e manufacturing, producing and processing of goods or merchandise.

Statutory provisions: According to factories Act, 1948, the statutory provisions regarding the safety of theworkers are stated in the sections 21 to 41. They are Fencing of machinery (Sec 21): In every factory, every dangerous part of any machinery, every moving part of a primemover and every flywheel connected to prime mover the head -race and tail-race of every water wheel and water turbine, and every part of an electric generator, motor or rotary converter, every p a r t o f t r a n s m i s s i o n m a c h i n e r y , m u s t b e s e c u r e l y f e n c e d b y s a f e g u a r d s o f s u b s t a n t i a l construction. Work on or near machinery in motion (Sec 22): 5

It is necessary to examine any part of the machinery while it is motion. The examinationand lubrication of the machinery, while in motion, should be carried out only by a specially-trained adult worker wearing tight-fitting clothing. Employment of young persons on Dangerous machines (Sec 23): A young person should not be allowed to work at dangerous machines unless, has beensufficiently instructed and received sufficient training. Striking gear and devices for cutting off power (Sec 24): In every factory, suitable striking gear or other efficient mechanical appliance has to be provided, maintained and used to move driving belts. Self-acting machines (Sec 25): No travelling part of a self-acting machine in any factory and no material carried thereonshall be allowed to run on its outward or inward traverse within a distance of 18 inches from anyfixed structure which is not a part of the machine, if a person is liable to pass over the space over which it runs. Casing of new machinery (Sec 26): All machinery driven by power, every set -screw, bolt or key or any r e v o l v i n g s h a f t , spindle, wheel or pinion, spur, worm and other toothed or friction-gearing has to be properlyencased or guarded in order to prevent danger to the workmen. Prohibition of employment of women and children near cotton openers (Sec 27): Women and child workers are prohib ited to be emplo ye d in an y part o f a f a c t o r y f o r pressing cotton in which a cotton opener is at work. Hoists, lifts, lifting machines (Sec 28&29): 6

Lifting machines, chains, ropes and lifting tackles must be of g o o d m e c h a n i c a l construction, sound material and adequate strength and free from defects. They are to be properlymaintained and thoroughly examined by a competent person at least once in every 6 months. Revolving machinery (Sec 30): The maximum safe working peripheral speed of every grindstone or abrasive wheel shall be permanently affixed. Safe working peripheral speed of every revolving vessel, cage, basket,flywheel, pulley or disc has also to be ensured. Pressure plant (Sec 31): In any factory operation is carried on at a pressure above the a t m o s p h e r i c p r e s s u r e , effective arrangements shall be taken to ensure that the safe working pressure is not exceeded. Floors, stairs and means of access (Sec 32): In ever y factor y all floors, steps, stairs, passages and gangwa ys shall b e o f s o u n d construction and properly kept and maintained. Pits, sumps, openings in floors (Sec 33): Every fixed vessel, sump, tank, pit or opening in the ground or in a floor, which may be asource of danger shall be either securely covered or securely fenced. Excessive weights (Sec 34): No person is to be employed in any factory to lift, carry or move any load so heavy as islikely to cause him injury. Protection of eyes (Sec 35): The state government may require the provision of effective screens or suitable goggles if t h e r i s k o f i n j u r y t o t h e e y e s i s c a u s e d f r o m p a r t i c l e s o r f r a g m e n t s t h r o w n o f f i n t h e manufacturing process or from exposure to excessive light. Precautions against dangerous fumes (Sec 36): 7

In any factory, no person shall be allowed to enter any chamber, tank, vat, pipe, flue or other confined space in which dangerous fumes are likely to be present to an extent involvingrisks to persons. Explosive or inflammable dust, gas (Sec 37): All practicable measures have to be taken to prevent explosion by, effective enclosure of plant and machinery, removal or prevention of the accumulation of dust, gas etc and exclusion or effective enclosure of all possible sources of ignition. Precaution in case of fire (Sec 38): Every factory has to be provided with adequate means of escape in case of fire. Effectivea n d clearly audible means of giving warning in the case of fire have to be p r o v i d e d . A f r e e passage-way giving access to each means of escape in case of fire has to be maintained. Power to require specifications of defective parts or tests of stability (Sec 39): The factory inspector to serve on the manager of a factory to furnish specifications of defective parts or he may order the manager to carry out tests as he may specify and to inform him of the results. Safety of buildings and machinery (Sec 40): Every factory should adopt the measures to ensure the safety of the b u i l d i n g s a n d machinery. The factory must emp loy the required safety officers according to the number of workers working in the factory. Power to make rules (Sec 41): The state government has the power to make rules to supplement the provisions relatingto safety contained in the act. Occupational accidents/disease: 8

direct andi n d i r e c t e f f e c t s o n t h e l i v e s o f w o r k e r s a n d t h e i r f a m i l i e s . For workers some of the directcosts of an injury or illness are: a) the pain and suffering of the injury or illness; b) the loss of income; c) the possible loss of a job; d) Health-care costs.It has been estimated that the indirect costs of an accident or illness can be four to ten timesgreater than the direct costs, or even more. An occupational illness or accident can have so manyi n d i r e c t c o s t s t o w o r k e r s t h a t i t i s o f t e n d i f f i c u l t t o m e a s u r e t h e m . O n e o f t h e m o s t o b v i o u s indirect costs is the human suffering caused to workers' families, which cannot be compensatedwith money. Identifying hazards in the workplace: 9

a n d a f f e c t w o r k e r s i n different ways depending on the nature of the hazard, the route of exposure, the dose, etc. Some well-known occupational diseases include: a) Asbestosis (caused by asbestos, which is common in insulation, automobile brake linings,etc.) b) Silicosis (caused by silica, which is common in mining, sandblasting, etc.) c) Lead poisoning (caused by lead, which is common in battery plants, paint factories, etc.) d) Noise-induced hearing loss (caused by noise, which is common in many workplaces,including airports, and workplaces where noisy machines, such as presses or drills, etc.) Importance of management commitment on health and safety: 10

In order to develop a successful health and safety programme, it is essential that there bes t r o n g m a n a g e m e n t c o m m i t m e n t a n d s t r o n g w o r k e r p a r t i c i p a t i o n i n t h e e f f o r t t o c r e a t e a n d maintain a safe and healthy workplace. An effective management addresses all work -relatedhazards, not only those covered by government standards.A l l l e v e l s o f m a n a g e m e n t m u s t m a k e h e a l t h a n d s a f e t y a p r i o r i t y . T h e y m u s t communicate this by going out into the worksite to talk with workers about their concerns and toobserve work procedures and equipment. In each workplace, the lines of responsibility from topto bottom need to be clear, and workers should know who is responsible for different health andsafety issues. Importance of training: 11

Workers often experience work-related health problems and do not realize that the problemsare related to their work, particularly when an occupational disease, for example, is in the earlystages. Besides the other more obvious benefits of training, such as skills development, hazard recognition, etc., a comprehensive training programme in each workplace will help workers to: a) R e c o g n i z e e a r l y s i g n s / s ym p t o m s o f a n y p o t e n t i a l o c c u p a t i o n a l d i s e a s e s b e f o r e t h e y become permanent conditions. b) Assess their work environment. c) Insist that management make changes before hazardous conditions can develop. Health and safety programmes: Effective workplace health and safety programmes can help to save the lives of workers byr e d u c i n g h a z a r d s a n d t h e i r c o n s e q u e n c e s . H e a l t h a n d s a f e t y p r o g r a m m e s a l s o h a v e p o s i t i v e effects on both worker morale and productivity, which are important benefits. At the same time,effective programmes can save employers a great deal of money. For all of the reasons given below, it is crucial that employers, workers and unions are committed to health and safety. a) Workplace hazards are controlled - at the source whenever possible. b) Records of any exposure are maintained for many years. 12

c) Both workers and employers are informed about health and safety risks in the workplace. d) There is an active and effective health and safety committee that includes both workersand management. e) Worker health and safety efforts are ongoing.

1.2 COMPANY PROFILE Wheels India Limited, Padi. 13

About company: Wheels India is promoted by the TVS Group a n d w a s s t a r t e d i n t h e e a r l y 6 0 ' s t o manufacture automobile wheels. Today, Wheels India has grown as a leading manufacturer of s t e e l w h e e l s f o r passenger cars, utility vehicles, trucks, buses, agricultural t r a c t o r s a n d construction equipment in India. The company supplies 2/3 rd of the domestic market requirementand exports 18% of the turnover to North America, Europe, Asia Pacific and South Africa.The company also has a technical-financial collaboration with Titan Europe .Wheels India designs and manufactures wheels for the specific requirements of the customer.Our activities are driven by the following objectives: Maintain leadership in the domestic market and presence in export markets. Ensure customer satisfaction through timely delivery of quality products and services, atcompetitive prices. Continuously improve & innovative product design, process technology a n d w o r k environment to offer better products. Bring about involvement of all workers in achieving the above objectives.

Location: The company has strategically located plants that give it a logistical advantage and allowsflexibility in manufacturing. 14

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Capabilities:Product Development a)Design and develop wheels for a wide range of applications, backed by four decadeso f e n r i c h i n g e x p e r i e n c e f r o m f i e l d ,

16

i n t e r n a l t r i a l s , a n d E S A ( E x p e r i m e n t a l S t r e s s A n a l ys i s ) & FEM (Finite Element Method). b)Caters to OEM, after-market and niche segments.c ) C o n t i n u o u s l y e n h a n c i n g t h e v a l u e o f t h e p r o d u c t , based onf e e d b a c k f r o m c u s t o m e r s a n d o u t c o m e o f o u r i n h o u s e facilitieslisted below:d ) W h e e l s t e s t i n g l a b t o e v a l u a t e e n d u r a n c e c a p a b i l i t i e s , by conducting radial fatigue test, bending fatigue test,multiaxis fatigue test and connecting member test.e ) C A E ( C o m p u t e r A i d e d E n g i n e e r i n g ) l a b t o d o surface& s o l i d m o d e l l i n g , f i n i t e e l e m e n t a n a l y s i s , l i f e prediction, d a t a a c q u i s i t i o n & e x p e r i m e n t a l s t r e s s analysis.f ) F u l l y e q u i p p e d c h e m i c a l , m e t a l l u r g i c a l a n d p h ys i c a l lab. Process Design a) Is in final phase of development of a new process to manufacture tube type truck rim from plates. b) H a s d e v e l o p e d p r o c e s s t e c h n o l o g y t o o p t i m i z e tubeless truck rim design with lesser material input. c) Process technology development, upgradation and o p t i m i z a t i o n t o a c h i e v e p r o d u c t s w i t h t i g h t e r specifications to meet growing demands of the newer generation vehicles. d) C o n t i n u o u s r e s e a r c h o n p r o c e s s i m p r o v e m e n t s t o minimize cost of production. Tool Design & Manufacture a) Has a qualified and experienced team specialising in tool design for forming /rolling steel. b) Fully equipped in-house tool room facility with state-of-the-art machinery and 17

design tools. c) C o m p u t e r a i d e d t o o l m o d e l l i n g & m a n u f a c t u r i n g s o f t w a r e facilities, for manufacturing complicated tool profiles.

1.2.2 Table showing the Products Wheels India has the abilit y to design the complete range of steel w h e e l s t o s u i t c u s t o m e r requirements, incorporating necessary styling and performance characteristics