Safety at TRL Krosaki

Safety At TRL Krosaki

Modern civilization is an out come of rapid growth in industrial development. Today our lives have become very fast by way of extreme mechanization with fast moving machines, fast running vehicles & so many instruments and appliances. As the operations & processes are getting mechanized day by day, the level of hazards associated with them are also getting increased.
TRL Krosaki Refractories Limited has taken various initiatives ( Management tools ) which regulates the different safety activities aiming to achieve Zero accident target.
Function of SHE Organization ( Key Issues )
  • Development of positive safety culture
  • Commitment & involvement of all
  • Prioritization of objectives
  • Technological upgradation
  • Accountability & Responsibility
Safety management executives take care the following important points for effective & successful functioning of various safety system elements.
  • Planning’s on safety Management
  • Discussion & decision making
  • Selecting the people & developing people
  • Communicating the decision
  • Motivating the people to execution
  • Constant checking over the execution
In the interest of safety & productivity, management carry out / implement the safety regulation as far as reasonable practicable to safeguard the health & safety of employees.
A. Involvement of Employees
It helps in implementing the safety management’s decisions. They give lot of suggestions and ideas because they are the people ultimately in the field. They are also involved in all the discussions to take suggestions & ideas from them thereby they feel their importance in the safety activities. This involvement of employees motivate further.
a Apex Committee
( Central Safety Committee )
This meeting is conducted once in a month and chaired by VP & Chairman of Safety Committee. This committee consists of equal number of workmen representatives & management representatives. Safety related problems are discussed in connection with accidents / incidents, Housekeeping survey & other survey status, medical check ups, statutory compliances, any improvements. The minute is circulated to all the concerned personnel in the departments, for the execution & implementation of the decision of the safety committee within a stipulated time period. This is again reviewed in the next meeting till the jobs are complied.
b SHE Mgt. Review Committee This meeting is chaired by Managing Director MD which is conducted once in every two months. This meeting is called for all HODs including incharges of all related areas to discuss the over all SHE performance of the plant. Like central safety committee meeting, here also the minute is prepared circulated to all concerned persons.
c Departmental Safety Committee This meeting is conducted once in every month at department level which is chaired by respective HOD’s involving shop floor level employees. Any unresolved points raised at department level are discussed in Apex committee meeting & the issues are solved.
d Jt. Departmental Committee This meeting is conducted once in every month at department level which is chaired by respective HOD’s involving shop floor level employees. In this platform apart from safety issues, all other issues related to Productivity, welfare, CD activities, HR etc. are discussed.
e Contractors Safety Meeting This meeting is conducted Once in every four months which is chaired by VP (HR) for HR issues & VP (Proj & SS ) for safety issues in the contractor’s working area.
B. Safety inspection / surveys / evaluation
House keeping survey Monthly Any abnormalities observed during survey of any item is immediately intimated to concerned HOD’s and also discussed in Apex committee.
Hydrant pumps, Fire Tender, Hydrant points Monthly
Emergency preparedness & response – Mock drill Monthly
Terex & Dumpers, Fork lifts Bi-Monthly
PPE, F.Aid Box, Welding M/c, Fire Hose reels Quarterly
Fire Fighting extinguishers, Crane U/L switches Half yearly
Safety Stewards Visit As & When required
Inspection by Statutory authority As & When required
C. Training, Education & Awareness on Safety, Health & Environment ( SHE )
This is a continuous process which is imparted starting from Sr. Executives to down below at grass root level including contract workers. It includes,
  • Participation in Safety seminars
  • Training by External & Internal faculties
  • Induction training to new recruits
  • On the job training & site safety instruction
  • On the spot training with practical demo on usage of PPE
Note : No gate passes are issued to contract workers unless he is undergone safety training, medical checkup & HR clearances.
D. Statutory Compliance
Safety Audit : Once in every two years
Periodical Medical Checkup : Once in a year for all employees
Colour blindness & Audiometric tests : Once in a year ( These tests are carried out for selective employees i.e crane operators / drivers, exposed to high noisy area respectively. In case any abnormalities are observed, necessary precautionary measures are taken.
Certificate of Competency : Once in a year
Testing of cranes & Lifting tools, tackles : Once in a year
Mock drill for emergency preparedness : Conducted once in six month which is witnessed by statutory authority & representatives from nearby industries. Apart from this we also conduct localized mock drills in selective areas inside plant to involve shop floor level employees to enhance their awareness & responsibilities at the time of emergencies.
E. On Site Emergency Preparedness Plan :
We have prepared our ‘On Site Emergency Preparedness plan’ which is documented and approved by Directorate of factories & Boilers, Govt. Of Orissa. This document contains the main following elements. This is practiced thru mock drills.
  • The possible disasters at TRL Krosaki
  • Inventory of hazardous substances
  • Facilities available to combat with any emergencies
  • List of key personnel & their roles & responsibility
  • Assembly point & Siren codes during emergencies
  • Dispersion model for toxic release & fire hazard
  • Emergency control room & facilities available
  • Entry & Exit points
1. Practices & Procedures : SOP, SMP, Work Permit & MSDS
Equipment wise Standard Operating Procedures & Standard Maintenance Procedures are prepared .These are well displayed near the equipments. Besides the Shut down, start up procedures, Do’s / Dont’s of different jobs are also displayed at various locations. Time to time training is imparted to concerned shop floor people.
Work Permit used at TRL Krosaki comprising Height work, Hot work, Gas safety & electrical isolation, confined space entry etc. It is a systematic procedure of documenting various steps, that should be taken in carrying out work in a safe manner along with proper authorization. There are various types of jobs in an industrial set up in which work permit is of immense practical value to ensure safety of workmen, equipments, property & environment.
MSDS ( Material Safety Data Sheet ) is available for all hazardous substances & displayed at user end.
F. Job Hazard Assessment : JSA, HAZOP & HIRA
All the above JSA, HAZOP & HIRA are all proactive approaches of accident prevention.
Job Safety Analysis of all hazardous process are prepared in consultation with the concerned department. JSA involves particularly on work method. In the analysis the operational procedures, machine guarding, protective equipments, factors affecting the health of workers are all closely examined and safety procedures & equipments to be used are specified in JSA before commencing any hazardous process.
HIRA ( Hazard Identification & Risk Assessment ) developed thru OHSAS – 18001 : 2007 requirement in which total risk identified is 191 & out of which 37 is significant based on risk index calculation as per standard.
Similarly we have also started preparing HAZOP i.e ‘Hazard & Operability’ study of some selective critical equipments involving concerned shop floor officers & workers. HAZOP is a standard hazard analysis modern technique which assess, the various types of hazard potential of mal-operation or mal-function of individual equipment or new process operation, caused because of derivation from the design intentions and their consequential effects on the process as a whole.
G. Reporting & Investigation of Accidents / incidents :
All incidents such as Near misses, F. Aid, Reportable & dangerous Occurrences are reported in a specified format followed by thorough investigation on the accident spot along with coworkers and concerned officer incharges to find out the root causes with its remedial measures which is complied thru appropriate agencies within stipulated time period. All these incidents are discussed in different forums of safety meetings & shop floor safety talks. The purpose of investigation & implementation of findings are to prevent similar one by mechanical improvement, better supervision & employee instruction. Records of all incidents are essential for efficient and successful safety work
H. Communication
It plays a very vital role & important function of any management. The communication towards safety is more effective at TRL Krosaki through Safety talks, Safety posters & leaflets, Workers participation, Display of work instructions, practical demonstration & E.mail etc.
I. Safety Promotional Activities :
In order to communicate the safety message among the employees we organise safety campaigns like National Safety Week, Fire Service day, World Environment Day, Chemical Disaster Prevention day.
Contests & other activities such as, Interdepartmental House keeping survey, Zero accident, Poster, Quiz, Essay & Slogans etc. It includes both regular & contract workers also.
J. Penalty procedures :
Like awards & recognition in the field of safety performance, we have also system for penalty / warning / caution notice / charge sheet etc. in case of any violation of safety norms. This is applicable to all level of employees including contractors & their workers.
K. Quality Assurance during procurement of PPE :
We advise the Material management department to ensure high quality of PPEs and its availability in the stock. Before approving the quality of PPEs we collect samples from different parties & take its trial at the works & feedback taken. On that basis we select quality of PPEs and approve it as sample.
L. Three years Road map on safety :
A three years road map on safety has been prepared for further improvement in safety system / procedures. Total 72 initiatives have been taken into consideration. The status of compliance is reviewed in every month by Chairman of Central safety Committee with concerned persons.
Few photographs on safety Activities / Practical demonstration at site