1

INTRODUCTION

1.1 INTRODUCTION TO THE STUDY

Industrial health and safety today mean protecting the life and health of people
from the dangers arising during or through work. Industrial health and safety are one of
the social components of industrialization and technicalization. They are supported to
humanize not only technology and chemicals but also the whole working situation. The
Status of industrial health and safety in a country is therefore determined to a large
extent by the degree of industrialization and technicalization. The status is a good
indicator for the social, political, democratic and cultural standard of the state or society.
Health and safety is a discipline with a broad scope involving many specialized
Fields. In its broadcast sense, it should aim at:

• The promotion and maintenance of the highest degree of physical, mental and
Social well-being of workers in all occupations.
• The promotion among workers of adverse affects on health caused by their
working conditions.
• The protection of workers in their employment from risks resulting from factors
adverse to health.
• The placing and maintenance of workers in an occupational environment adapted
to physical and mental needs.
• The adaptation of work to humans.

In other words, industrial health and safety encompasses the social, mental and
physical well-being of worker, which is the “whole person”. Successful health
and safety practice requires the collaboration and participation of both employers
and workers in health and safety programmes, and involves the consideration of
issues relating to occupational medicine, industrial hygiene, toxicology,
education, Engineering safety, ergonomics, psychology, etc.,
 2

1.2 INDUSTRY PROFILE

1.2.1 An Overview of Indian Pump Industry

Pumps play a dominant role in the sectors like agriculture, production of oil and
natural gas, petroleum refining, petrochemicals, power generation, domestic and
household utilities, etc, and contribute a major part in nation’s economy.

Pump is not a new concept in the Indian industry. In fact, the ‘Pichkari’ which Lord
Krishna and his playmates used for splashing coloured water on Gopies, can be termed as
the oldest reference to a pump concept, especially of the reciprocating plunger type.
Thus, pumps must be an Indian invention, but commercial production of pumps in India,
as contemporarily understood, is quoted to be way back in the first decade of twentieth
century.
Manufacturing Scenario
Presently, the gross value of pump’s production in India is estimated to be in the
order of US$ 450 million(approx. 1.2 million No.).The scales of production and corporate
structures of manufacturers range from the small scale industries, medium to large scale
industries, both in the unorganised sectors and also public sector units.
In terms of drive ratings, the range of manufacture extends from fractional horsepower
designs to large pumps of drive rating of the order of three MW. Almost all types of
pumps, manufactured internationally, are also made in India.
Demand and Supply Situation
Indian pumps have contributed to the nation’s economy significantly. Prominent
sectors amongst them are agriculture, onshore and offshore production of oil and natural
gas, petroleum refining, petrochemicals, mining, ship-building and marine duties, power
generation, public water supply and sanitation, domestic and household utilities, process
industries producing fertilizers, insecticides, pesticides, drugs and pharmaceuticals,
textiles, soaps and detergents, cosmetic and health care products, dairies, vegetable oil
and processed and packed food products, breweries, paints, etc.
 3

Indian pump manufacturers seem to fulfil all the demands of pump-usage, since
imports are not very significant. Some special construction pumps of special materials
used for special duties like requirements of very fine vacuum are also imported. The
quantities are small although the unit cost of these pumps may be high.
Globlisation of Indian economy enthused some importers to sporadically import a few
container-loads of run-of-the mill type pumps for agriculture and domestic duties.
However, those events do not seem to have caught any fancy in the Indian markets.
Pump automatically get imported with systems, not de-packaged for items, that
can be procured indigenously. Yet,
users do seek import substitutes due to the cost-effectiveness of Indian manufacture and
for better guarantee of support with respect to after-sales service.

Technologies, Collaborations and Indigenous R&D

Most of the world-renoned technologies have been operative in India. Majority of
them seem to be European, to name a few, KSB, Sulzer, Weir, SPP, Allweiler,
Bornemann, Alsthom, Stork, Terromecanica, Godiva, Pleuger, Grundfos, ABS, Flygt,
Denver Orion, etc. Amongst them American, Japanese and Australian technologies can
be sighted in Wrthington-Dresser, Ingersoll Rand, Goulds, Durco, Ebara, Asia LMI,
Warman, etc. Indian technical skills and engineering aptitudes have shown good
capabilities of almost immediate absorption of the involved design, manufacturing and
quality control specifications and application engineering needs. That gives a good
picture of the internationally competitive field already in play in India.
The Indian craftsman often enterprises in reverse engineering at very competitive
costs. Amongst the notable achievements of indigenous development and R&D can be
cited, the primary coolant pumps and sodium coolant pumps for nuclear power, large
2250 mm delivery-size vertical turbine pumps and concrete volume pumps for cooling
water circulation in thermal power generation can also be cited.
Cavitation studies and CFD (Computational Fluid Dynamics) analysis of flow
patterns at pump suction and deriving improvements in pump and sump designs are all
becoming common practice.
 4

National and International Standards in Practice

Indian standards on agricultural pumps have been trail-blazing even in the
international context, with respect to minimum efficiency norms which were incorporated
in the standards, since 1979, and they have been reviewed and upgraded periodically.
Comparatively, only the 1994 edition of hydraulic Institute Standards gives a monogram
on estimating efficiency of centrifugal pumps. These are again, not mandatory, because
there is no certification marking system in practice for compliance with the HIS-
monogram efficiencies.
Many companies in the organized sector and some, even in the medium-scale sector,
have attained ISO-9000 certification.
Amongst process pumps, the dimensions and ratings often follow the ISO-2858
specifications, whereas API-610’s technical requirements like centre-line supports for
high temperature applications, vibrations levels, nozzle loads and moments, are also
widely popular.
In the associated field of mechanical seals, Sealol, Durametallic, Mars Cyclam,
Burgmann makes have been manufacturing for quite some time and Flexibox and John
Crane are also known to be actively interested to chip in. Alongside, magdrive and
canned motor pumps have been successfully developed indigenously.

Exports and Share in the Global Market

Exports have been a regular feature of Indian pump industry for years. Indian
pumps have reached more than sixty countries around the world including developed
countries.
Some buy-back arrangements have also consistently been in operation for nearly twenty
in some cases, showing the strong confidence and trust, earned in the process.
But, by and large, the size and potential of the domestic market has itself been so good
that majority of manufacturers take little interest in exports to the global market is
admittedly insignificant. In contrast, the size of domestic markets of most individual
European countries has been so small that perforce of such situation. European
manufactures have developed a culture of being a global player, right from the launch of
an enterprise.
 5

Reservations or Constraints?
It is not easy to explain why manufacturing technologies, like on-line welded
sheet metal fabrication do not have an appeal for real large-scale production as the truly
appropriate technology. Such a venture is bound to be very capital-intensive and Indian
enterprises are typically shy of big
Investments. Alongside, there are natural apprehensions of being able to garner a market
position, which would give an assured and sustainable returns on such large-scale
investments. Yet conveyorised assembly lines have been there, especially, in the
production of agricultural pumps, CNC machines have also been in vogue for long. So,
Indian psyche is shy but definitely open-minded, often needing only an attitude
adaptation.

1.2.2 Future of the Industry

The resilience exhibited by the Indian economy, in the midst of the turmoil in
South Eastern economics and politically motivated economic sanctions, has underscored
the basic growth-prospective characteristics of the Indian economy. That should be a
strong enough base to reason that except for the place of the growth rate, growth by itself
will be always there. Since pumps are needed in every sector of the economy, the Indian
pump industry will always grow.
 6

1.3 COMPANY PROFILE

SAM TURBO INDUSTRY LIMITED

SAM TURBO INDUSTRY LTD., are in the field of designing, manufacturing

,supplying and servicing pumps for essential industries in India since 1971. Today, SAM
is an acknowledged leader in its industries and continues to combine innovative design
and material with most advanced manufacturing techniques to ensure unequalled quality
and reliability.
Sam’s product range includes Horizontal and Vertical Pumps with open and
closed impeller construction suitable for Chemical, Petrochemical, Paper, Fertilizers,
Refineries, Power, Sugar, Basic Metal Industries, etc. Wide range of Pumps are available
to handle all kinds of liquids in these industries.
Any pump is only as good as the material it is made from and SAM standards
could accept only castings from our own foundry. Sam have got captive steel foundry
producing castings of 450 MT/month and spectrovac and the alloying is adjusted to
stringent metallurgical specifications to ensure precise chemical composition.
Sam produces materials confirming to IS,ASTM,JIS,AFNOR, and BS Standards
like graded Cast Iron, WCB (Carbon Steel), CF8 (SS-304), CF8M (SS-316), CF3M(SS-
316L), CG8M (SS-317), CG3M (SS-317L), CD4MCU, ALLOY-20, HAST ALLOY-C,
B, Nihard-IV, Hi-Chrome (550-600 BHN) etc.
Sam pumps are approved by leading consultants/inspection agencies like
EIL,DCL, Jacob H & G, UDHE, RJ, KPG, PDIL, NTPC etc. and have executed plenty of
project orders through these consultants. Some of our important customers are Hindalco
Industries Ltd.,Reliance Industires Ltd., Grasim Industries Ltd., Birla Copper, Hindustan
Zinc Ltd, Binani Zinc Ltd., FACT., EID Parry, Ballarpur Industries Ltd., Nalco, NTPC,
SAIL, TISCO, NLC, ITC Ltd, etc. The list of projects executed thro’ various consultants
is enclosed
 7

II. ORGANISATION PROFILE: SAM TURBO INDUSTRY LIMITED

Chairman and Managing Director K. SAMPATH KUMAR
Joint Managing Director S.K. SENTHIL KUMAR
Financial Director T.SRINIVASAN
Technical Director M. ANTONISAMY

Year of Establishment and starting of 1971

Production
Present Investment 181 Million
Annual Turnover 555 Million
Installed Power a) EB2500KVA + Genset 1800 KVA
b) 67 KVA for welding
Collaboration – Technical Thyssen Ruhurpumpen GMBH - Germany
Number of Employees 600
Executives 25
Engineers 30
Inspectors 15
Supervisors 30
Skilled workers 325
Others 175
 8

1.3.2 THIRD PARTY INSPECTION AGENCIES / CONSULTANTS

1. Bharath Heavy Electricals Ltd.

2. Bax Council Bureau Ltd.
3. Chem Projects design Engineering (P) Ltd.
4. Chemtex Engineering of India Ltd.
5. Certification Engineers India Ltd.
6. Development Consultant Pvt. Ltd
7. DESEIN Pvt. Ltd
8. Dalal Consultants & Engineers Ltd.
9. Aarvi Encon.
10. Engineers India Ltd.
11. Engineering Project India Ltd.
12. FACT Engineering and Design Organisation
13. Fichtner Consulting Engineers
14. Humprey & Glasgow Consultants Pvt. Ltd
15. International Development Engineering Associates
16. Indian Register Shipping.
17. ICB Limited.
18. Kvearner Power Gas India Ltd.
19. Lloyd’s Register Industrial Services (India) Ltd.
20. Linde Process Technologies India Ltd.
21. MN Dastur & Company Pvt. Ltd
22. MK Raju consultants Pvt. Ltd
23. Metallurgical & Engineering Consutant (India) Ltd
24. National Thermal Power Corporation Ltd
25. Protech Consultants Pvt. Ltd

26. Project development India Ltd

 9

27. Quality Evaluation & Systems Team Pvt. Ltd

28. Rail India Technical & Economical Service Ltd.
29. SMO ( A division of SPIC).
30. SGS India Ltd
31. Shroff & Associates Engineering (P) Ltd.
32. SPB Project Consultancy Ltd
33. Thaper Chemtex consultants Ltd
34. Tata Consulting Engineers Ltd.
35. Tata Projects Ltd.
36. Toyo Engineering India Ltd.
37. Uhde India Ltd

1.3.3QUALITY
QUALITY ASSURANCE
INTRODUCTION
Quality Assurance System and Control Programmes in the Company are applied
to manufacturing process to have, effective control methods, relevant
documentation,corrective action and provided a means for verification to assertain the
status of level of implementation of various Quality Control measures at any point of
time.
As Quality is defined as confirming to requirements to gain customer’s satisfaction
by satisfying stated and implied needs, satisfying fit form and function. In total to meet
complete expectation of the customer for satisfaction of quality throughout the contract
deal.
Various Quality Control measures are implemented to match the National and
International level of standards.

OBJECTIVE
 10

The objective of Quality Programme in our company is

(a) To achieve Quality levels required by National standards.
(b) To establish and maintain International Quality System standards
(c) To achieve consistency in the Quality of the Product manufactured.
(d) It has been decided that the company in line with its Quality Policy, would
strive to create a total Quality Environment to meet the expectation of
customers which will not only help to create an image in the world market but
also will help to achieve Price Leadership which also important in the
financial management. It is felt that continuosly striving for Quality
Leadership will bring its own economic returns.

(e) To maintain cordial vendor relation, while at the same time ensuring that
products manufactured / service rendered by them shall meet the laid-down
quality Standards.

ORGANISATION

Managers shall be responsible for implementing the Quality Assurance System in

their respective departments. The Quality Organizational set up in our company.

AUTHORITY

The General Manager – Quality Assurance shall be the final authority of all matters
pertaining to the product Quality and ensure maintaining of Quality Policy and objective
and Effect implementation of Quality Systems throughout the organisation. He reports
directly to the Joint managing Director.

RESPONSIBILITIES
 11

The Quality Control Programmes in the works include preventive and corrective
steps to control the Quality in line with the laid- down standards and approved
specifications right from the incoming raw – material stage to the finished goods stage
including after sales service to the gain customer’s satisfaction. This shall be followed in
day – to - day basis.

The General Manager - Quality Assurance Delegates responsibilities to sub –

ordinate personnel and promulgates all Quality measures and procedures necessary in the
company to ensure the end product satisfies to the laid – down approved specification.

The Quality functions include

(a) Acceptance of sub – contractors (including overseas).
(b) Review of Purchase orders.
(c) Pattern Inspection and Control.
(d) Caliberation of Inspection Equipments.
(e) Raw – material control.
(f) Control and Disposition of Non Conforming Products.
(g) Process Inspection.
(h) Final Inspection.
(i) Install Corrective Action.
(j) Identification and Application of Statistical Techniques.
(k) Identification and approval of new tools, Jigs and fixtures.
(l) Handling of customer complaints and analysis for resolution.

1.3.4 LIST OF DOCUMENTS / CERTIFICATES

 12

1. MATERIAL TEST CERTIFICATES SHOWING CHEMICAL

COMPOSTION AND PHYSICAL PROPERTIES.

2. DYNAMIC BALANCING CERTIFICATES.

3. HYDROSTATIC PRESSURE TEST CERTIFICATES
4. TESTED RECORDS SHEETS FOR PUMP PERFORMANCE
5. TESTED PERFORMANCE CURVES FOR PUMPS
6. NPSH TEST REPORTS – (OPTIONAL)
7. GUARANTEE CERTIFICATE
8. OPERATION AND INSTRUCTION MANUAL
9. GENERAL ARRANGEMENT DRAWING / FOUNDATION DETAILS
DRAWING

10. SECTIONAL DRAWING WITH BILL OF MATERIALS

11. NON DESTRUCTIVE TEST DATAS SUCH AS

A). ULTRASONIC TEST SHEET (OPTIONAL)

B). DYE PENTRATION TEST SHEET (OPTIONAL)
C). RADIOGRAPHY FILMS (OPTIONAL)

1.4 REVIEW OF LITERATURE

 13

HEALTH AND SAFETY ISSUES IN TEXTILE INDUSTRY

The major Health and safety issues can be stated as under:

1. Exposure to cotton dust.

2. Exposure to chemicals
3. Exposure to noise
4. Ergonomic issues

1. Exposure to cotton dust

The workers engaged in the processing and spinning to cotton are exposed to
significant amounts of cotton dust. Exposure to cotton dust and other particulars leads to
respiratory disorders including tightening of the chest, coughing, wheezing and shortness
of breadth among textile workers.

In the year 1938 in USA, it was estimated that the disease had already affected
about 35000 people, while 100000 other people were at risk of contracting it. Hence the
Occupational safety and Health Administration i.e. OSHA made it compulsory for
employers in the textile industry to protect their workers from over exposure to cotton
dust and its evil effects.

As per those guidelines, the employer is required to inform the employees in

writing of the dust level present in the atmosphere as well as the steps that the
management is planning to take for its reduction. If the dust level cannot be reduced, it is
the duty of the management to provide respirators to the employees. The OSHA cotton
dust standard was amended in the year 2000.

A study conducted by R. Steinberg, J. Hannak and K.Balakrishnan regarding textile units

in India revealed that pulmonary function in textile workers decreased significantly with
 14

exposure to cotton dust over a long period of time. Another study conducted on textile
units in Mumbai, India indicated as 11-33% incidence of chronic Bronchitis in textile
workers.

2. Exposure to chemicals

Workers in the textile industry are also exposed to a number of chemicals,

especially those engaged in the activities of dyeing, printing and finishing. Contact of the
chemicals with skin as well as inhalation of the chemicals can lead to several serious
health effects.

3. Exposure to noise

High levels of noise have been observed in most of textile industries, particularly
those in developing countries. In the long run, exposure to high noise levels has been
known to damage the eardrum and cause hearing loss. Other problems like fatigue,
absenteeism, anxiety, reduction in efficiency, changes in pulse rate and blood pressure as
well as sleep disorders have also been noted. Lack of efficient maintenance of machinery
is one of the major reasons behind the noise pollution in a majority of the units.

A study of 77 employees in textile mills in Nagpur was conducted by Ruikar MM,

Motghare DD and Vasudeo ND. This study revealed that 76.6% of the employees were at
risk for developing noise-induced hearing loss. The study of Indian textile units by
R. Steinberg, J. Hannak and K. Balakrishnan indicated that 21.3% of the workers studied
suffered from noise-induced hearing loss.

4. Ergonomic Issues
 15

Ergonomic issues are observed in majority of the textile units in India. Most of
these units have a working environment that is unsafe and unhealthy for the workers.
Workers in these units face a number of problems such as unsuitable furniture, improper
Ventilation and lighting, and lack of efficient safety measures in case of emergencies.
The workers in such units are at risk for developing various occupational diseases like
lower back pain, neck pain, shoulder pain, and osteoarthritis of the knees.

As per a study by parimalam, Kamalamma N. and Ganguli AK in the year 2006,

there is a considerable difference in the heights of the stools and the tables used for
various operations. This led to the workers having to sit in as uncomfortable position for
entire work days. The stools were not padded and did not have backrest in most of the
units, leading to increased discomfort on the part of the workers. Also, the level of
lighting was low and improper placement of lighting fixtures led to low lighting at the
point of work, leading to eyestrain.

Apart from this, lack of efficient measures for the safety of the workers was also
observed. Lack of essential items such as first aid kits, fire extinguishers, and alarms was
noted in most of the units. This puts the workers under great risk in times of an
emergency. Protective equipments like metallic gloves were not provided to the workers
in several units for protection against potential accidents and injuries. Thus safety and
health measures play an important role in any industry. It is essential that the workers be
aware of the various occupational hazards in the industry. At the same time, it is
necessary that the management take the necessary steps to protect workers from potential
hazardous situations.

MEASURING THE IMPACT OF PSYCHOLOGICAL CONTRACT FOR

HEALTH AND SAFETY
 16

Safe behavior at work is a managerial challenge. Traditionally, research into

occupational health and safety has focused on safety culture and safety climate to explain
risk-taking and safety behaviors. Managers in high-hazard industries have therefore
concentrated on creating positive safety cultures and climates.
Recently, 1 proposed that a “Psychological contract for health and safety” may
offer an alternative explanation for individual risk-taking and safety behaviors at work.
The psychological contract is used to explain general areas of the employment
relationship and has been investigated by examining the fulfillment of promises or
obligations from both employees and employers’ perspectives. It should be noted that
different occupational groups (if not different individuals in the same group) may have
their own perceived obligations about health and safety. Therefore, organizational and
occupational contexts need to be considered carefully.
A study was conducted to develop a psychological contract measure for health
and safety. It aimed to discover whether employees with a positive psychological contract
would trust line managers more with respect to health and safety, would perceive a better
safety climate (i.e., would have more positive perceptions about what their line managers
say and do about health and safety).
The results showed participants had high expectations of what their employer had
promised with respect to health and safety. Most notably training about the risks in their
jobs, personal protective equipment and an incident reporting system. On average,
perceived obligations or promises were seen to be slightly unfulfilled, especially with
regard to investigating accidents.
The main finding was that there were significant positive relationships between
the psychological contract, trust and safety climate measures. This suggests that line
managers play a key role. To ensure that employees develop appropriate expectations,
line managers should be involved in the development of organizational health and safety
policies and procedures so they will be better able to live up to their expectations.

THE MAIN THEME OF THE PROJECT

 17

2.1 NEED FOR THE STUDY

The project work entitled “A Study on Workers’ attitude towards health and
safety measures” in Sam Turbo Industry Ltd.,Coimbatore, was undertaken with a view to
have a descriptive study of health and safety conditions prevailing in the firm.

The selection of the topic has its own importance in the present industrial
scenario. The concept of health and safety has gained importance right from the onset and
has been in transition since it began that most of the industrial accidents can be avoided
with a bit of care and better planning.

Work plays a central role in people’s lives, since most workers spend at least
eight hours a day in the workplace, whether it is on a plantation, in an office, factory, etc.,
Therefore, work environments should be safe and healthy. Yet this is not the case for
many workers. Every day workers all over the world are faced with a multitude of health
hazards, such as:

• Dusts
• Gases
• Noise
• Vibration
• Extreme temperature

Unfortunately some employers assume little responsibility for the protection of

worker’s health and safety. In fact, some employers do not even know that they have the
moral and legal responsibility to protect workers. As a result of the hazards and a lack of
attention given to health and safety, work related accidents and diseases are common in
all parts of the world.

According to Factories Act, 1948

 18

1. Cleanliness :
(1) Every factory shall be kept clean and free from effluvia
arising from any drain, privy, or other nuisance. The floor of every work room shall be
cleaned at least once in every week.
(2) When a floor is liable to become wet in the course of any manufacturing process to
such extent as is capable of being drained, effective means of drainage shall be provided
(3) Use of disinfectants, etc., painting and varnishing, revarnishing, whitewashing or
color washing shall be resorted to.

2. Disposal of wastes and effluents : Effective arrangements shall be made in every

factory for the treatment of wastes and effluents due to the manufacturing process carried
on therein, so as to render them innocuous and for their disposal.

3. Ventilation and Temperature : Adequate ventilation shall be provided for

circulation of fresh air, and such a temperature as will secure to workers therein
reasonable conditions of comfort and prevent injury to health. The walls and roofs shall
be of such materials and so designed that the temperature shall not be exceeded and kept
low.

4. Dust and fume : Where dust or fume or impurity of such a nature as is likely to be
injurious or offensive to the workers is given off as a result of the manufacturing process
being carried on in a factory, effective measures shall be taken for prevention of
inhalation or accumulation of dust and fumes in workrooms.

5. Artificial humidification : State Government makes prescription of standards of

humidification, regarding the methods of artificially increasing the humidity of air,
methods to be adopted for securing adequate ventilation and cooling of air and such water
to be purified before use in respect of all factories in which the humidity of the air is
artificially increased

6. Overcrowding : There shall not be overcrowding in any room of the factory so as to

be injurious to the health of the workers employed therein. There shall be 9.9 cubic
 19

metres (for the factories in existence at the time of commencement of Act) and 14.2 cubic
meters (for the factories built after the commencement of Act) of space for every worker.

7. Lighting : In every part of factory where workers are working or passing there shall
be provided and maintained sufficient and suitable lighting, natural or artificial, or both.
All glazed windows and skylights used for lighting shall be kept clean. Provisions shall
also be made for preventing glare and formation of shadows.

8. Drinking water : Effective arrangements shall be made to provide sufficient supply of

drinking water and maintain at suitable points conveniently situated for all workers
employed therein. Those drinking points shall be legibly marked in a language
understood by most of the workers and shall be situated beyond 6 metres of any washing
place, urinai, latrines, spittoons. There should be cooling of water were more than 250
workers are employed.

9. Latrines and Urinals : Separate latrines and Urinals for male and female workers
shall be conveniently situated, adequately lighted and ventilated and shall be maintained
in a clean and sanitary condition. These accommodations shall be of prescribed sanitary
types. The floors and walls are to be glazed and shall be washed and cleaned at least once
in a week.

10. Fencing of Machinery : In every factory, every dangerous part of each machinery
shall be securely fenced by safeguards of substantial construction, which shall be
constantly maintained and kept in position while the parts of machinery they are in
motion or in use.

11. Pits, sumps, openings in floors, etc., : In every factory, pits, sumps, openings, fixed
vessels, tanks, openings in the ground or in the floor shall be securely covered or
securely fenced. ‘Securely fencing a pit’ means covering or fencing it in such a way that
it ceases to be a source of danger to those who have occasion to go near there.

12. Precautions in case of fire : In every factory, all practicable measures shall be taken
to prevent outbreak of fire and its spread, both internally and externally, and to provide
 20

and maintain safe means of escape for all persons in the event of fire and the necessary
equipment and facilities for extinguishing fire.
Effective measures shall be taken to ensure that all the workers are familiar with the
means of escape in case of fire and have been adequately trained in the routine to be
followed in such cases.

13. Safety of building and machinery : If any building or part of a building or

machinery or plant in a factory is in such a condition that it is dangerous to human life or
safety, the inspector may serve on the occupier or the manager or both of the factory an
order in writing specifying the measures which is in opinion shall be adopted and
requiring them to be carried our before a specified date.

2.2 SCOPE OF THE STUDY

 21

The study was done in order to know about the workers attitude towards various
health and safety measures provided in the firm. The various measures are Cleanliness,
treatment of wastes and effluents, adequate ventilation and temperature, protection from
dusts and fumes, good lighting, drinking water, latrines and urinals, maintenance of
machinery, fencing of revolving machineries, sufficient space for work, covered pits and
openings and means of escape in the event of fire.

It has been analyzed by means of survey among the workers. The study has also
helped to bring out the suggestions of employees regarding the improvement in facilities,

The scope of the study is restricted to “Sam Turbo Industry Ltd., at Coimbatore”
only.

2.3 OBJECTIVES OF THE STUDY

 22

• To find the awareness of health and Safety measures among the workers.
• To find the attitude of the workers towards industrial Health and Safety measure
provided in the firm,
• To provide suggestions regarding Health and Safety measures.

2.4 LIMITATIONS OF THE STUDY

 23

• The study has to be completed within a stipulated time period.

• The study is limited to only 100 respondents.
• The study was conducted in Salem only.
• There may be possibility of errors due to non response among the workers.
 24

2.5 RESEARCH METHODOLOGY

Research Methodology is a way to systematically solve the research problem. It

may be understood as a science of studying how the research has to be done
scientifically. From this we analyze and study the various steps that ate generally adopted
by the research and study the research problem along with the logic behind them.

RESEARCH

Research is common parlance refers to search for knowledge. One can also define
research as a scientific and systematic search for pertinent information on a specific topic.

RESEARCH DESIGN

Research Design is a framework or plan for a study that guides the collection and
analysis of the data. A research design is the arrangement of conditions for collection and
analysis of data in a manner that aims to combine relevance to the research purpose with
economy in procedure.

The research design can be broadly classified into 3 categories namely

exploratory, descriptive and experimental. The design used in the study was Descriptive
research design.

POPULATION

The entire group of people, events or things that the researcher desires to
investigate. Total number of employees in the production department of the organization
constitutes the population.
 25

SAMPLE SIZE

A subset from which data are collected and used to estimate parameters of the
total population. Here the sample size is 100.

SAMPLING TECHNIQUE

The sampling technique used was Simple Random Sampling. It is a probability

sample in which each population element has a known and equal chance of being
included in the sample and in which every combination of n population elements is a
sample possibility and it’s just as likely to occur as any other combination of n units.

DATA COLLECTION

For this study the data was collected by means of primary sources and secondary
sources.

METHODS OF DATA COLLECTION

The primary data was collected through questionnaire and the secondary data was
collected through books, journals, websites and company brochure.

STATISTICAL TOOLS USED

The statistical tools used were Percentage Analysis and Chi-Square Analysis
 26

PERCENTAGE ANALYSIS

Percentage refers to a special kind to a special kind of ratio. Percentage is used in

comparison between two or more series of data. It is used to describe relationships, to
compare relative terms and distribution of two or more series of data.

Percentage of respondents = Sample / Total respondents * 100.

CHI- SQUARE ANALYSIS

The most widely used non-parametric test of significance is the

Chi-Square test. It is particularly useful in tests involving nominal data but can be used
for higher scales. Using this technique, we test for significant differences between the
observed distribution of data among categories and the expected distribution based on
null hypothesis.

= ∑[(O-E)^2/E]
 27

2.6 ANALYSIS AND INTERPRETATION

2.6.1 PERCENTAGE ANALYSIS

Table 2.6.1.1: Awareness of general safety measures and rules

AWARENESS OF GENERAL NO. OF

SAFETYMEASURES AND RESPONSES
RULES (%)
YES 95
NO 5
TOTAL 100
Source: Primary data

Chart 2.6.1.1 Awareness of general safety measures and rules

Inference:
From the above table and chart it is shown that 95% of the employees are aware
of the general safety measures and rules and 5% of the employees are not aware.

Table 2.6.1.2: Acceptance on following the industrial safety rules

 28

INDUSTRIAL NO. OF
SAFETY RULES RESPONSES (%)
STRONGLY AGREE 30
AGREE 66
NEUTRAL 4
DISAGREE 0
STRONGLY
DISAGREE 0
TOTAL 100
Source : Primary data

Chart 2.6.1.2: Acceptance on following the industrial safety rules

Inference:
From the above table and chart it is shown that 30% of the employees strongly
agree on following the industrial safety rules, 66% agree and 4% neither agree nor
disagree.

Table 2.6.1.3: Provision of safety equipments like gloves, earplugs, boots and hard
Glasses.
 29

SAFETY EQUIPMENTS NO. OF RESPONSES(%)

STRONGLY AGREE 11
AGREE 68
NEUTRAL 20
DISAGREE 1
STRONGLY DISAGREE 0
TOTAL 100

Source: Primary Data

Chart 2.6.1.3: Provision of safety equipments like gloves, earplugs, boots and hard
glasses.

Inference:
From the above table and chart it is shown that 68% of the employees strongly agree on
provision of safety equipments, 20% agree, 11% neither agree nor disagree and 1%
disagree.
 30

Table 2.6.1.4 Acceptance on regular overhauling of machines

ACCEPTANCE ON REGULAR
OVERHAULING OF MACHINES NO. OF RESPONSES(%)
STRONGLY AGREE 1
AGREE 54
NEUTRAL 45
DISAGREE 0
STRONGLY DISAGREE 0
TOTAL 100

Source: Primary Data

Chart 2.6.1.4 Acceptance on regular overhauling of machines

 31

Inference:
From the above table and chart it is shown that 1% of the employees strongly
agree on acceptance of overhauling of machines, 54% agree, 45% neither agree nor
disagree.

Table 2.6.1.5 Display of visible signboards

DISPLAY OF SIGN NO. OF

BOARDS RESPONSES(%)
YES 84
NO 16
TOTAL 100

Source: Primary Data

Chart 2.6.1.5 Display of visible signboards

Inference:
From the above table and chart it is shown that 84% of the employees are aware
of the display of signboards and 16% of the employees are not aware.
 32

Table 2.6.1.6 Awareness about the existence and usage of fire extinguisher

USAGE OF FIRE NO. OF

EXTINGUISHER RESPONSES(%)
YES 70
NO 30
TOTAL 100
Source: Primary Data

Chart 2.6.1.6 Awareness about the existence and usage of fire extinguisher

Inference:
From the above table and chart it is shown that 70% of the employees are aware
of the existence and usage of fire extinguisher and 30% of the employees are not aware.
 33

Table 2.6.1.7 Safety is Responsibility

SAFETY IS RESPONSIBILITY NO.OF RESPONSES(%)

STRONGLY AGREE 26
AGREE 63
NEUTRAL 11
DISAGREE 0
STRONGLY DISAGREE 0
TOTAL 100
Source: primary data

Chart 2.6.1.7 Safety is Responsibility

Inference:
From the above table and chart it is shown that 26% strongly agree 63% agree
and 11% neutral about their safety at work as their responsibility.
 34

EMERGENCY ESCAPE
NO.OF RESPONSES(%)
FACILITIES
STRONGLY AGREE 5
AGREE 58
NEUTRAL 37
DISAGREE 0
STRONGLY DISAGREE 0
TOTAL 100

Table 2.6.1.8 Provision of emergency escape facilities

Source: primary data

Chart 2.6.1.8 Provision of emergency escape facilities

 35

PITS, SUMPS& OPENINGS ARE NO.OF RESPONSES(%)

DULY COVERED
STRONGLY AGREE 0
AGREE 63
NEUTRAL 37
DISAGREE 0
STRONGLY DISAGREE 0
TOTAL 100

Inference:
From the above table and chart it is shown that 5% strongly agree 58% agree and
37% neutral About the provision of escape facilities.

Table 2.6.1.9 Pits, Sumps and Openings are duly covered

Source: primary data

Chart 2.6.1.9 Pits, Sumps and Openings are duly covered

 36

Inference:
From the above table and chart it is shown that 63% agree and 37% are neutarl about the
safety of the openings.

Table 2.6.1.10 Sufficient and suitable lighting

SUFFICIENT AND SUITABLE

LIGHTING NO.OF RESPONSES(%)
STRONGLY AGREE 26
AGREE 53
NEUTRAL 21
DISAGREE 0
STRONGLY DISAGREE 0
TOTAL 100
Source : Primary data
 37

Chart 2.6.1.10 Sufficient and suitable lighting

Inference:
From the above table and chart it is shown that 26% strongly agree to the
existence of lighting facility ,53% agree and 21% are neutral.

Table 2.6.1.11 Drinking Water facility

NO.OF
DRINKING WATER RESPONSES(%)
STRONGLY AGREE 7
AGREE 39
NEUTRAL 54
DISAGREE 0
STRONGLY DISAGREE 0
TOTAL 100
Source : Primary Data

Chart 2.6.1.11 Drinking Water facility

 38

Inference:
From the above table and chart it is shown that 7% strongly agree to the existence
of drinking water facility ,39% agree and 54% are neutral.

Table 2.6.1.12 Clean Maintenance of Toilets

NO.OF
TOILET MAINTENANCE RESPONSES(%)
STRONGLY AGREE 0
AGREE 3
NEUTRAL 53
DISAGREE 44
STRONGLY DISAGREE 0
TOTAL 100
 39

Source: Primary data

Chart 2.6.1.12 Clean Maintenance of Toilets

Inference:
From the above table and chart it is shown that 3% agree to clean toilets 53%
neutral and 44% disagree.

Table 2.6.1.13 Arrangement for the disposal of wastes

DISPOSAL OF WASTES NO.OF RESPONSES(%)

STRONGLY AGREE 0
AGREE 34
NEUTRAL 53
DISAGREE 13
STRONGLY DISAGREE 0
TOTAL 100
Source: Primary data
 40

Chart 2.6.1.13 Arrangement for the disposal of wastes

Inference:
From the above table and chart it is shown that 34% agree to provision for
disposal of wastes, 53% neutral and 3% disagree.

Table 2.6.1.14 Protection against dust and fumes

PROTECTION AGAINST DUST NO.OF

& FUMES RESPONSES(%)
STRONGLY AGREE 0
AGREE 47
NEUTRAL 42
DISAGREE 11
STRONGLY DISAGREE 0
TOTAL 100
Source: Primary data

Chart 2.6.1.14 Protection against dust and fumes

 41

Inference:
From the above table and chart it is shown that 47% agree to provision for
protection against dust and fumes 42% neutral and 11% disagree.

Table 2.6.1.15 Training programs

NO.OF
TRAINING PROGRAMS RESPONSES(%)
STRONGLY AGREE 32
AGREE 68
NEUTRAL 0
DISAGREE 0
STRONGLY DISAGREE 0
TOTAL 100
Source: Primary data

Chart 2.6.1.15 Training programs

 42

Inference:
From the above table and chart it is shown that 32% strongly agree on providing
training programs which educate about the safety measures and other precautions and
68% agree to it.

2.6.2 CHI -SQUARE

2.6.2.1 Association between the age of the employees and their
awareness towards health and safety measures

H0: There is no association between the age and awareness of health and
safety measures among the workers.
H1: There is association between the age and awareness of health and
safety measures among the workers.

Age group Awareness Total

Yes No
( in years)
 43

25-35 40 4 44

36-45 35 1 36

46-55 20 0 20

Total 95 5 100

Source: Primary data

Significant value = 0.05

Degrees of freedom = 2

Chi –square tabulated value = 5.991

Chi-square calculated value=2.97714

Inference:
Since the chi-square value is less than Chi-square tabulated value, H0 is accepted
and hence inferred that there is no association between the age and awareness of health
and safety measures among the workers.

2.6.2.2 Association between the total years of experience and their

awareness towards health and safety measures

H0: There is no association between the years of experience and awareness of

health and safety measures among the workers.
H1: There is association between the years of experience and awareness of health
and safety measures among the workers

Years of Awareness Total

Yes No
experience
0-10 52 2 54
 44

11-20 36 2 38

21-30 7 1 8

Total 95 5 100

Source: Primary data

Significant value = 0.05

Degrees of freedom = 2

Chi –square tabulated value = 5.991

Chi-square calculated value=1.143942

Inference:
Since the chi-square value is less than Chi-square tabulated value, H0 is accepted
and hence inferred that there is no association between the years of experience and
awareness of health and safety measures among the workers.

2.6.3 FINDINGS

 95% of the employees are aware of the general safety measures and rules and
5% of the employees are not aware.

 30% of the employees strongly agree on following the industrial safety rules, 66%
agree and 4% neither agree nor disagree

 68% of the employees strongly agree on provision of safety equipments, 20%

agree, 11% neither agree nor disagree and 1% disagree.
 45

 1% of the employees strongly agree on overhauling of machines, 54% agree,

45% neither agree nor disagree.

 84% of the employees are aware of the display of signboards and 16% of the
employees are not aware.

 70% of the employees are aware of the existence and usage of fire extinguisher
and 30% of the employees are not aware.

 5% strongly agree 58% agree and 37% neutral About the provision of escape
facilities

 63% agree and 37% are neutral about the safety of the openings.

 26% strongly agree to the existence of lighting facility ,53% agree and 21% are
neutral.

 7% strongly agree to the existence of drinking water facility ,39% agree and 54%
are neutral.

 3% agree to clean toilets 53% neutral and 44% disagree.

 34% agree to provision for disposal of wastes, 53% neutral and 3% disagree.
 46

 47% agree to provision for protection against dust and fumes 42% neutral and
11% disagree.

 32% strongly agree on providing training programs which educate about the
safety measures and other precautions and 68% agree to it.

 From the Chi-Square calculation it is inferred that there is no association between

the age and awareness of health and safety measures among the workers.

 From the Chi-Square calculation it is inferred that there is no association between

the years of experience and awareness of health and safety measures among the
workers.

3.1 SUGGESTIONS

Based on the study “Workers’ attitude towards health and safety Measures at Sam Turbo
Industry Ltd., it is understood that the company is providing good health and safety
measures and the required precautions.
 47

However the awareness about safety measures is less among the helper category of
employees. Hence the organization should take care and ensure that proper training and
awareness is provided to them.

The study also indicated a few areas where improvements can be made and some
corrective measures can provide much more satisfaction to the employees.

The following recommendations made are purely the opinion of the workers and they
are:

To provide good and clean drinking water facility

To maintain clean toilets

To bring in more mechanization of work to ease the work of production so that idle time
of the workers can be reduced.

To increase the space of work area.

3.2 CONCLUSION

From the present study, it is concluded that most of the employees are aware of
the health and safety measures of the firm. Also the employees have an overall positive
attitude on health and safety measures provided by the firm and the study provides a
 48

suggestion that the attitude of the employees can be increased by improving some of the
measures as mentioned in the suggestions above.

BIBLIOGRAPHY

References

1.C.R. Kothari, Research Methodology, New age International (p) ltd.,

 49

Publishers, New Delhi, 2004,”Types of research”

2.R.S.Sivaraman, E.Vijayageetha (2005), “Statistics for management”,
Sona Versity,”Chi-square test”
3.John. V.Grimaldi, 2006,” Management and Industrial Safety Achievement”
Professional safety,
4.M.H. Jeeves, 2007,”Measuring the impact of a Psychological contract for health and
safety” people Management
5.Paramananda Nayak and Avijit Nandal, 2006,”sensitive Analysis of Textiles and
clothing Industry”, business perspectives.

Website

www.citehr.com
www.managementparadise.com

QUESTIONNAIRE
Hi,
You are the life blood of our organization!! Below are certain questions related to health
& safety measures .Post your opinions to make our campus a safer one.
 50

NAME:
(optional)

AGE: SEX : MALE/ FEMALE

MARITAL STATUS: MARRIED / UNMARRIED

DEPARTMENT:

DESIGNATION:

YEARS OF EXPERIENCE: @ SAM TURBO:

@ OTHERS:

Please put a tick mark against your choice of preference.

1. I am aware of the general safety measures and rules.
a. Yes b. No

SA-strongly agree; A- Agree; N-neutral; DA-disagree; SDA-strongly

disagree
No. Statement SA A N DA SDA
2. I follow the industrial safety rules to protect
from uncertainties
3. Safety equipments like gloves, earplugs, boots,
hard glasses are being provided.

4. Overhauling of machines are done regularly

5. Visible sign boards indicating the precautions are displayed.

a. Yes b. No

6. I am aware of the existence and usage of fire extinguisher

a. Yes b. No

SA-strongly agree; A- Agree; N-neutral; DA-disagree; SDA-strongly

disagree
No. Statement SA A N DA SDA
7. My safety at work is my responsibility.
 51

8. Emergency escape facilities are provided in

the factory.
9. Pits, Sumps, and Openings in the factory are
securely covered and fenced.
10. There is sufficient and suitable lighting in
every part of the factory.
11. There are sufficient supply points for
drinking water.
12. Toilets are maintained periodically and are
dirt free.
13. Effective arrangements are made for disposal
of wastes.
14. We ared provided with suitable protection
from inhalation of dust and fumes inside the
factory.
15. Training programs educating first aid,safety
precautions and health measures are being
conducted.