INTERNATIONAL GENERAL

CERTIFICATE Candidates observation

(2011 specification s!eet
IGC" # T$E $EALT$ AN%
&AFET' (RACTICAL A((LICATION
&!eet n)*ber 1 of _____
&t)dent na*e Pritesh Ramesh Bare _ &t)dent n)*ber 00196609 +
(,ace inspected Welding Consumable Manufacturing Unit _ %ate of inspection 07 09 !01"
Observations Contro, *eas)res Ti*esca,e
#a$ards and conse%uences &mmediate and longer term actions
Wear Plate Manufacturing Plant
1' ()erhead crane hoo* in loading+
unloading ba, no'1 doesn-t ha)e
safet, latch .in /hich could result in
slee. of slings from hoo* throat and
fall of the material' &t has a .otential
of se)ere head in0ur, or fatal'
&mmediate action
1he safet, latch.in should be .ut immediatel, and no
material shall be lifted /ithout the fi2ing of latch to the
crane hoo*' 3ubstitute ba,s to be use till the com.letion of
the fi2ing of safet, latch.in'
4onger term action
5nsure that ins.ection of all safet, de)ices in o)erhead
crane are .art of .eriodic maintenance schedule and
effecti)e monitoring of its com.liance'
1 #our
Monthl,
!' Plasma cutting machine no' !
o.erator /as handling hot cut .lates
/ith the hel. of cotton hand glo)es6
/hich is ineffecti)e in .rotecting
.alms of the o.erator from hot
surface of cut .late also has a
.otential to catch fire and ma, cause
burn in0ur, too'
&mmediate action
Cotton hand glo)e needs to be re.laced /ith leather
7e)lar hand glo)es
4onger term action
Ris* assessment of .lasma cutting o.eration is to be
re)ie/ and monitor that it is being use effecti)el,'
5nsure that ne/ em.lo,ee should be instructed for the use
of right PP5 for right 0ob'
8 #our
1 Month
9uring
&nduction
"' : contract /or*er /as carr,ing out
.ainting /or* of air ; /ater .i.elines
at the height of < meter b, climbing
on ladder and /ithout /earing safet,
harness' &t has .otential to fall of the
.erson from height due to sli. of
ladder or misbalance of the .erson' &t
ma, also lead to musculos*eletal
disorders due to o)erstretching /hile
tr,ing to .aint more area b, standing
of one .osition =ladder>'
&mmediate action
4adder is meant for access ; egress and should not use
for /or*ing' &t should re.lace b, mobile to/er scaffold or
scissor lift to be used' Wor*er should /ear safet, harness
/hile /or*ing on it'
4onger term action
Ris* assessment of .ainting at height /or* is to be re)ie/
and monitor that it is being use effecti)el,' 5nsure the /or*
.ermit s,stem is being follo/ed effecti)el, and monitor its
com.liance'
1 #our
1 Month
?' (ne ne/l, installed C@C /elding
machine /as not .rotected /ith
/elding =Protecti)e> screens li*e
other machines' &ts /elding
arcradiations ma, harm e,es of
other em.lo,ees6 )isitors etc'
&mmediate action
Welding screens to be .ut immediatel, around the
machine' Machine should not .ut in o.eration /ithout
.ro)iding .rotecti)e screens'
4onger term action
Ris* assessment of @e/l, installed C@C machine is to be
re)ie/ and monitor its com.liance'
1 Wee*
1 Month
<' (ne /elder /as doing manual
/elding on com.leted /ear .late as
a .art of rectification /or* inside the
/ear .late .lant /ithout using local
e2haust )entilation /hich /as
causing generation of /elding
fumes smo*e6 can harm the health
of the /elder as /ell the co+/or*ers
in the .lant'
&mmediate action
4ocal e2haust )entilation is to be .ro)ided for manual
/elding /or* area also change the direction of /elding so
/elding fumes smo*e /ill not s.read inside the .lant'
4onger term action
: se.arate /elding booth area are to be .ro)ided /ith
local e2haust )entilation s,stem for an, manual /elding
/or*' Ris* assessment for the manual /elding is to be
re)ie/ed and monitor the com.liance'
1 hour
" Months
6' 5ach /elding heads of Welding C@C
machines are connected /ith fume
e2traction s,stem follo/ed b, :ir
.ollution control de)ice /hich
absorbs generated /elding fumes' &t
get filtered through bag filters before
discharging into the en)ironment
Aood Practice obser)ed' 1he s,stem is ta*ing care of
em.lo,ees as /ell as 5n)ironment' (nl, thing is to
maintain on regular basis for better efficienc,'
:s .er the
maintenance
3chedule
7' : hea. of /ear .lates /ere *e.t on
the ground in the /al*/a, leading to
south side emergenc, e2it' &t ma,
lead to .anic due to bloc*ed
emergenc, route in case of
emergenc,
&mmediate action
: hea. of /ear .lates should be remo)ed immediatel, and
/al*/a, needs to be clear'
4onger term action
: se.arate storage rac* is to be made and as soon as
.late is unloaded from C@C machine it should go to the
storage rac*'
5nsure that no material should *ee. in the /al*/a, and
emergenc, e2it is al/a,s accessible'
1 hour
6 Months
B' 1here /ere se)eral cases of melting
of safet, shoe sole of C@C /elding
machine o.erators' :fter inter)ie/ing
fe/ of them it came to *no/ after
com.letion of /elding on M3 .late
for unloading the .late from machine
o.erator ha)e to climb of a .late
/hich is hot causing the melting of
safet, shoe sole' &t might increase
the consum.tion of safet, shoes due
to fre%uent re.lacement and failure
to this can lead to a burn in0ur, to the
o.erator'
&mmediate action
PU sole safet, shoe should immediatel, re.lace /ith #eat
resistant @itrile sole safet, shoe'
4onger term action
Underta*e a Wear Plate unloading ris* assessment to see
/hether automation in the .rocess or change in the
.rocedure to eliminate direct human bod, contact to the
hot .late can be done'
5nsure that ne/ em.lo,ee should be instructed for the use
of right PP5 for right 0ob'
1 Wee*
1 Month
9uring
&nduction
INTERNATIONAL GENERAL
CERTIFICATE Candidates observation
(2011 specification s!eet
IGC" # T$E $EALT$ AN%
&AFET' (RACTICAL A((LICATION
&!eet n)*ber 1 of _____
&t)dent na*e Pritesh Ramesh Bare _ &t)dent n)*ber 00196609 +
(,ace inspected Welding Consumable Manufacturing Unit _ %ate of inspection 07 09 !01"
Observations Contro, *eas)res Ti*esca,e
#a$ards and conse%uences &mmediate and longer term actions
1eromatec =Clu2 cored /ire> manufacturing Plant
1' 3ingle #ead 9ra/ Bench machine
ha)e inade%uate fi2ed guard /hich is
ineffecti)e to .rotect a .erson from
the im.act of rotating /ire in case of
brea*age also ha)e chances to get
caught in bet/een the .inch .oints
of the rotating .arts of the
e%ui.ment' &t ma, lead to se)ere
in0ur, due to im.act of rotating /ire
and crush in0ur, due to caught in
bet/een'
&mmediate action
Prohibit the use of machine until the .ro.er cage t,.e fi2ed
guard installed' &nform the su.er)isor for .resent ha$ard
and instruct for safe o.eration'
4onger term action
5nsure that ins.ection of all machine guards is .art of the
maintenance schedule and effecti)e monitoring of its
com.liance'
Re)ie/ the ris* assessment to see /hether fi2ed guard
can be re.laced /ith &nterloc*ing guard for better
.rotection and control on .rocess'
! #ours
1 Wee*
1 Month
!' 9uring Blending of metal .o/ders b,
DE- Blender it is obser)ed that /hile
loading and remo)ing of blended
.o/der fine dust is generating and
s.read o)er nearb, floor as /ell as
in the /or*.lace en)ironment' &t ma,
lead to sli. of the .erson due to
sli..er, floor and se)er health
ha$ards li*e damage to the lungs'
&mmediate action
Cloor need to be clean on regular basis to a)oid
accumulation of dust and /or*ers /ho are handling
.o/ders should /ear ade%uate res.irator, .rotection'
4onger term action
DE- Blending o.eration should not carr, out in the
/or*.lace /ith other o.erations' &t should be done in an
isolated area /ith all necessar, .rotections li*e dust
absor.tion ; remo)al s,stem6 /or*.lace e2hausts6 anti+
sli..er, floors6 .ro)ision of regular dust remo)al ;
Personal Protecti)e 5%ui.ment-s li*e dust mas*s etc'
&mmediate
6 Months
3tic* 5lectrode Manufacturing Plant
"' #ea), oil lea*age obser)ed belo/
52trusion .ress no'" /hich ma, lead
to an in0ur, due to sli. of a .erson' &t
also has .otential of fire as it is
readil, a)ailable fuel for fire'
&mmediate action
3.illed oil should be immediatel, /i.e out /ith the hel. of
sa/ dust or cotton /aste and *ee. a tra, belo/ the
lea*age' (il soa*ed cottondust should be *e.t in
ha$ardous /aste bin to a)oid contamination'
4onger term action
Re)ie/ of maintenance schedule and monitor its
com.liance' &f re%uired increase the fre%uenc, of
.re)enti)e maintenance' 5ncourage o.erators to re.ort
such issues in future' 3u.er)isor should ins.ect the
machine .rior to use'
1 #our
1< 9a,s
?' While e2truding electrode from
h,draulic e2trusion .ress6 the
electrode is coming out /ith .ressure
and hitting the guide dis* to rest on
the belt con)e,or during this the
.arts of /et flu2 also comes out /ith
.ressure /hich ma, cause e,e in0ur,
due to fl,ing .articles foreign ob0ect'
&mmediate action
:ll the .ersons /or*ing nearb, e2trusion .resses should
/ere 1rans.arent 3afet, Aoggle'
4onger term action
: barrier screen is to be .ro)ided o..osite to e2trusion
.ress h,draulic c,linder'
Ris* assessment of 3tic* electrode e2trusion acti)it, is to
re)ie/ and monitor the im.lementation'
&mmediate
1< da,s
1 Month
<' @ear binder .re.aration area !
Wor*ers /ere handling hea),
=a..ro2' 100*g> binder drum
manuall, from trolle, to /eighing
machine /hich ma, cause them
bac* in0uries6 bruises and abrasions
etc'
&mmediate action
&t is to be lifted b, for*lift /ith .ro.er drum lifting
arrangement'
4onger term action
5limination of manual handling /ith installation of re%uired
ca.acit, o)erhead crane /ith drum lifting arrangements
abo)e the /eighing machine /hich /ill lift the binder drum
from trolle, and *ee. on the /eighing machine'
1rain the su.er)isor for .ro.er manual handling and
ensure the ma2imum use of mechanical assistance'
&mmediate
6 Months
1 /ee*
6' Wor*ers /ho are /or*ing at last
.osition on a continuous stic*
electrode manufacturing lines the,
/ere lifting e2truded stic* electrodes
from con)e,or and arranging in
tra,s' 9ue to re.etiti)e mo)ement of
bod, there are chances that the,
ma, suffer from /or* related u..er
limb disorders =WRU49s>
&mmediate action
Ai)e the brea*s in bet/een the shifts' Fob rotation
amongst the e2trusion team'
4onger term action
Underta*e a 3tic* 5lectrode e2trusion ris* assessment to
see is there an, sco.e for change in /or*station design or
an, ergonomic im.ro)ement can be done
! #ours
! months
7' Aeneration of noise is %uite high in
/ire cutting machine area6 though
o.erators are /earing .ro.er 5ar
Muff Plugs long e2.osure ma,
cause hearing .roblems'
&mmediate action
3cheduled Fob rotation amongst the de.artment' Brea* in
bet/een the /or*'
4onger term action
Re)ie/ of /ire cutting o.eration ris* assessment to see
/hether an, chances of isolation of .rocess or isolation of
o.erators can be done'
1< 9a,s
! Months
INTERNATIONAL GENERAL
CERTIFICATE Candidates observation
(2011 specification s!eet
IGC" # T$E $EALT$ AN%
&AFET' (RACTICAL A((LICATION
&!eet n)*ber 1 of _____
&t)dent na*e Pritesh Ramesh Bare _ &t)dent n)*ber 00196609 +
(,ace inspected Welding Consumable Manufacturing Unit _ %ate of inspection 07 09 !01"
Observations Contro, *eas)res Ti*esca,e
#a$ards and conse%uences &mmediate and longer term actions
Aeneral (bser)ations
1' 1he damaged /eb slings /ere using
for loading 1! nos' of Wear Plate
from /ear .late .lant to truc*
standing outside .lant near main
gate no'1 /hich has .otential of
brea*ing of the slings and in0ur, due
to im.act from falling of the .lates' &1
has high .otential of accident as it is
near the main gate /here )isitor
mo)ement is ma2imum and chances
of )isitor getting e2.osed to such
ha$ard is high'
&mmediate action
9amaged /eb slings should be discarded immediatel, b,
cutting it into small .ieces and .ro.erl, tested slings /ith
DC- clam. is to be used'
4onger term action
4oading+unloading of material should be done /ith tested
lifting tools ; tac*les at loading+unloading ba, onl,6 /ith
the hel. of o)erhead crane installed in the ba, /hich /ill
isolate the acti)it, from )isitors and ris* /ill be reduced'
5nsure that ins.ection of all lifting tools ; tac*les are .art
of the maintenance schedule and effecti)e monitoring of its
com.liance'
&mmediate
B hours
1 Month
!' 5lectric cable /as laid loosel, on
ground for /or*ing on maintenance
table at ground floor near goods lift
no'1' &t has ris* to tri. and fall of the
.erson' 1he trailing cables also
.resent the ris* of electric shoc* if
mechanicall, damaged or im.ro.er
0oints'
&mmediate action
Put a co)er o)er cable or reroute it from o)erhead /hich
/ill clear the /al*/a,s in front of Aoods lift'
4onger term action
&nstall additional distribution board near maintenance table
to eliminate the need for long trailing cable'
1 #our
1< 9a,s
"' &t /as obser)ed that during re)ersing
of for*lift the re)erse horn /as not
/or*ed after inter)ie/ing the for*lift
o.erator it came to *no/ that the
re)erse horn is on s/itch /hich he
forgot to on /hile re)ersing' &t might
ha)e resulted in the se)ere in0ur, to
.edestrians due to struc* b, for*lift'
&mmediate action
(.erator is instructed to on the s/itch /ithout fail before
re)ersing the )ehicle' 3u.er)isor is made a/are of ha$ard
and as*s to monitor it .ro.erl,'
4onger term action
Re)erse horn should be lin*ed /ith the re)erse gear and it
should /or* automaticall, /ith gear' 3e.arate s/itch is to
be remo)ed'
Refresher training should be to o.erators for the safe
o.eration of Cor*lift
&mmediate
1 Month
1< 9a,s
?' Around ; Cirst Both the
manufacturing floors are e%ui..ed
/ith #G:C s,stem' &t remo)es hot
air /ith e2cess fumes6 smo*e etc'
and su..l, fresh cool air inside the
.lant /hich hel.s to *ee. .lant
tem.erature " degree less than the
outside tem.erature' &t .ro)ides
comfort and health, /or*.lace to
em.lo,ees'
Aood Practice obser)ed' 1he s,stem is ta*ing care of
em.lo,ee-s health' &t not onl, .ro)ides the comfort but
increases the .roducti)it,'
Maintenance is to be done on regular basis for better
efficienc,'
:s .er the
maintenance
3chedule
<' 4ist of trained Cirst+aiders ; Cire
fighters are not dis.la,ed in the
manufacturing .lant' &t ma, ta*e time
to a)ail hel. during the emergenc,
&mmediate action
4ist of trained first+aiders ; fire fighters to be dis.la,ed in
all .rominent locations of the .lant'
4onger term action
Ma2imum number of .ersons should be trained in first+aid
and fire fighting and /ell communicated to e)er,one in the
.lant'
&t should be .ro.erl, communicated to ne/ em.lo,ees
during 3afet, &nduction'
1 9a,
:s .er
training
Calendar
6' 9uring random Circuit brea*er
testing it /as found that t/o circuit
brea*ers at ground floor =one is
behind rolling machine and another
is near .lasma cutting machine no'1>
are not /or*ing' &t is )er, serious
and ma, lead to death of a .erson
due to electric shoc*'
&mmediate action
: .o/er su..l, is to be disconnected for both electrical
s/itched and a /arning sign should be .ut'
1hese s/itches should not be used until the re.lacement ;
testing of circuit brea*er'
4onger term action
5nsure that ins.ection of all circuit brea*ers are .art of
5lectrical maintenance schedule and effecti)e monitoring
of its com.liance'
&mmediate
! 9a,s
Monthl,
7' @o e)idence of Portable electrical
a..liances =drill machine6 grinding
machine etc'> testing /ere found' &t
ma, cause electric shoc* or fires due
to fault, e%ui.ment'
&mmediate action
5%ui.ment should be chec* for P:1 label and also )isuall,
ins.ect before use'
4onger term action
5nsure that ins.ection of all Portable electrical a..liances
is .art of 5lectrical maintenance schedule and effecti)e
monitoring of its com.liance'
Before 5)er,
use
Monthl,
B' #a$ardous chemicals substances
are stored /ith other material in the
store /hich ma, cause harm to ne/
em.lo,ee /ho is una/are of the
ha$ards related to chemicals' :lso
there are chances of reaction if t/o
incom.atible materials come in
contact'
&mmediate action
&dentif, and labelled all the ha$ardous chemicals .resent in
the store'
4onger term action
Re)ie/ of ris* assessment of ha$ardous chemical storage
and ensure its com.liance'
3e.arate arrangement to be made for storage of
ha$ardous chemicals /ith all necessar, .recautions li*e
e,e ; bod, sho/er6 Cire e2tinguishers etc'
&nformation about ha$ardous chemicals should be /ell
communicated to ne/ em.lo,ees during safet, induction'
1 /ee*
1 Month
" Months
9uring
&nduction