Working Safely with Machines

WSHC Hand Safety Forum 20th November 2014

Indirakumar Gunasekaran.,WSHO,ECO,FSM
Senior Executive
Tata Steel: A Top 15 Steel Company Globally
NatSteel is part of the Tata Steel Group

Tata Steel Europe

Tata Steel Group

Tata Steel India Tata Steel Thailand
Production Capacity:
28 million MTPA

Annual Turnover: NatSteel across

US$26.23 billion (FY12) Asia Pacific
Our Integrated Steelmaking Operations
Producing green steel from recycling metal waste

1. Radiation detection and 2. Steel production using world’s most

sorting of metal scrap energy efficient Electric Arc Furnace

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4. World’s largest Cut & Bend

Centre producing 400k tonnes
per year

3. Rolling mill benchmarked against global standards

5. Mesh Centre utilises state-of-the-
art technology to manufacture high
quality products

6. Caging Centre produces

precages and bored piles
according to customer needs

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Our Safety Journey
2003 – Certified OHSAS 18001:1999
• Converted to OHSAS18001:2007 in
2009
2006 – Certified ISO 14001:2004
2008 – Engaged DuPont as an external
consultant to embark on a rigorous
programme towards achieving our Safety
goals
Core Elements Of NatSteel’s
Safety Excellence Framework
Safety Management System
OHSAS 18001:2007
People Behavioural Controls
STOP Programme
Process Safety Management

• Reducing LTIF to Zero by 2018 Operational Discipline

2009 – bizSAFE Partner
• NatSteel made it mandatory for all
business partners to achieve at least
bizSAFE Level 3
2012 – Certified ISO 50001

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NSH Safety Statistics
FY’15
FY’08 FY’09 FY’10 FY’11 FY’12 FY’13 FY’14
(Target)

10.23 5.88 1.22 1.33 0.65 0.75 0.60 0.4

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Action Items for Preventing Hand Injuries

Develop and implement Safe Loading Guide and Hand and Finger Safety rules.

Automation to eliminate/Engineering control to reduce the exposure of man to machines.

Training and retraining employees on safe machine operation and material handling
procedures.

Build competency by attending mandatory trainings.

Conducting daily TBM and regular Comm sessions to share Incidents lesson learnt and best
practices.

To conduct Hand Safety seminar.

Improved visible signages and lighting.

Maintain high 5S standard.

Creating awareness on Operating Discipline.

Regular factory inspections and risk containment audits.

To increase STOP and Job cycle Check.

Exploring appropriate Personal Protective Equipments.

Sharing of best practices,internally,MOM,WSHC and Industry.

Safety communications through posters,banners,bulletin and pop up message in intranet.
 Safety Excellence Management System

• Full implementation on 1 April 2011

• Safety Observation and Audits (SOA)
• Incident Investigation (II)
• Process Safety Management (PSM)
• Contractor Safety Management (CSM)
• Job Cycle Check (JCC)
• Risk Containment (RC)
• Consequence Management (CM)
• Task Risk Analysis / Safe Operating
Procedure (TRA/SOP)

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Risk Control Measures

e.g. use of automation to reduce

man-machine interaction

e.g. by replacing with a safer machine

or manufacturing process

e.g. use of fixed machine guards and

presence detection devices

e.g. use of safe work procedures

and lock-out tag-out

e.g. use of safety goggles, safety

gloves and safety footwear

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Substitution to Prevent Hand Injuries
Loading/Unloading of rebar bundles using auto release hook system

Conventional Methods of Spreader beam without auto release

Loading/Unloading the rebar bundle hook attachment

Reducing
rigging
process by
50%

Removing of Chain Sling Manually

Reducing Removing of Chain Sling using remote
control
hand injury

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Substitution to Prevent Hand Injuries
Loading of Bored pile cages using quick release system
(National WSHC Innovation Award winning project)

Conventional Methods of Loading the

Bored Pile Cage Use of Extended Hook

Reducing
rigging
process by
50%

Removing of Chain Sling Manually Working Principle of the System

Reducing
hand injury

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Engineering Controls to Prevent Hand Injuries
N-Splice Threading Machine Clamp Safety Guard

Pinch point
Visual metal Protection

Butt Welding Machine Transparent Safety Guard

Hot surface
Transparent Protection

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EVG Coil machine with adjustable protective guard

Moving parts

Movable Cover

EVG coil machine, movable short segment guide

Sharp objects

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Integrated Cut and Bend Production Line with Light curtains, visual/audible alarms and
Safety rope switches

Safety rope switches

Safety rope switches

Light curtain

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Mesh Auto bender machine fixed with Light Curtains, Interlocks and Visual/Audible
alarms

Light curtains

Alarm

Interlocks

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Administrative controls to Prevent Hand Injuries

Golden Rules For Hand & Fingers Safety

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Safety Communications

Safety Messages On Intranet Table Stickers at Bulletins Safety Survey

Canteen

Posters Safety Day 2014 Safety Banners

COO safety dialogue session with supervisors, Safety Pledge by Supervisors

Hand Safety Seminar

Speaker - PPE Supplier Speaker - WSHC

Trust, Hand injuries can be prevented

Thank you for your kind attention