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Study on Safety Management System of Manufacturing Industry
1.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 12 | Dec-2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 788 Study on Safety Management System of Manufacturing Industry V.Gunaseelan1, Leo A Gerald2 1P. G Scholar, Dept. of Industrial Safety Engineering, Bannari Amman Institute of Technology, Tamilnadu, India 2Professor, Dept. of Industrial Safety Engineering, Bannari Amman Institute of Technology, Tamilnadu, India ----------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - Past twenty-five years manufacturing industries have grown dramatically due to high economic development but if we look into safety aspects followed in the manufacturing sector, they are very pathetic, and it becomes threat to the employee’s life. So, safety aspects in manufacturing requires huge amount of improvement. Many companies have the policy to reduce the accident rates, but still statistics shows a high rate of accidents and injuries happening in manufacturing sector. Safety management system has various indicator to minimize the accident rates. Organizational safety culture, Behaviour safety, Safety performance are indicators of a safe workplace Key Words: Manufacturing sector, Organizational safety culture, Behavioursafety,Safetyperformance. 1. INTRODUCTION In past twenty years number of industrial accident took place in the manufacturing industries due to lack of environmental safety, unaware of industrial accidents and importance of safety. Most of small and medium level manufacturing industries do not focus on safety because of one-time investment but they don’t know about the indirect loss that occur due to accident. Management must focus on their safety improvement. According to Heinrich theory, 88% of industrial accidents were caused by human unsafe behaviour, 10% accidents were caused by the industrial unsafe environment and 2% accidents were attributed to other factors. Nowadays more number of industrial accidents occurs due to the human error. There are some methods to prevent such an industrial accident and the most effective method is to develop the human behaviour by giving particular training for the work, conducting behavioural based study to reduce the accident rates and to improve the safe environmentinindustry. From the various studies, we can clearly say that, one of thecauses for initiation of industrial accident is poor management system such as policy, safety systems etc. For improving the safety culture and behaviour of theemployee,industryneeds to provide training, education, meeting, review etc. For this purpose, the industry is in the position to spend money for the following aspects: Training, Education Meeting [1]. Communication also plays a major role in accident because the performance of communication from top level to low level management is very poor. This paper deals withcauses of accident and from these causes, we may to find out solutions and it tends to increase the performance of safety culture, safety performance and behaviour of the employee. Accident statistics in Indian industries in time period of 1988-2008. Table -1: Number of Workers and Accident Rate per Thousand Worker Year No. of workers employed No of accident Accident rate per thousand workers 1988 196156 1214 6.19 1989 233400 1030 4.69 1990 233132 839 3.56 1991 243951 489 2.00 1992 260791 549 2.11 1993 274048 533 1.94 1994 252977 490 1.94 1995 254002 437 1.72 1996 250430 323 1.28 1997 267272 114 0.42 1998 264936 74 0.28 1999 221050 75 0.28 2000 230386 55 0.24 2001 230063 55 0.24 2002 300310 34 1.12 2003 319725 23 0.071 2004 343196 19 0.05 2005 343333 50 0.14 2006 345801 64 0.18 2007 359126 52 0.14 2008 375645 61 0.16 Chart -1: Accident statistics in India from 1988 -2008
2.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 12 | Dec-2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 789 0 1 2 3 4 5 6 7 Accidentrate Year Chart -2: Accident rate in India from 1988 to 2008 2. METHODOLOGY Safety management system is an approach to reduce the accident rates and improve safety. Some of the key elements of safety management system are safety policy, safety assurance, safety risk management, safety promotion. This paper suggests some systematic approach of safety management system. Fig -1: Safety Management System 2.1 ORGANIZATIONAL SAFETY CULTURE Safety culture plays a key function in determining an organization’s success or failure and it’s a part of organizational culture. Organizationwithpoorsafetyculture which are widespread, routine procedural violations,failure to comply with the company’s own safety management system. Various steps have been used to improve the safety culture which are communicating the company values, demonstrate leadership, personalize safety outcomes, develop positive safety attitudes, engage and own safety responsibilities and accountabilities, increase the hazard awareness and preventive behaviors. Various factors in the safety climate terms have been used to measure safety culture: procedure, management commitment, visible management, safety attitudes, workmate’s influences, employee’s involvement, safety knowledge, management takes the initial work of identifying the hazard at the workplace by using various methods, HIRA (Hazard Identification Risk Assessment), JSA (Job Safety Analysis), work permit system etc. The aim of the management is to eliminate the hazard and minimize their risk at the workplace. Periodic evaluation, review of work at their workplace survey is a must. The main objective of safety culture is to focus on the working environment, welfare facilities and legal requirements. According to the factories Act 1948, Sec.11 suggests cleanliness of work environment, Sec.12 disposal of waste and effluents, Sec.13ventilationand temperature, Sec.42 washing facilities, Sec.45 first-aid appliances, Sec.46 canteens, Sec.47 shelters, restrooms and lunch rooms, Sec.48 creches and Sec.49 welfare officers, the relationship between the management and workersmustbe smooth. It improves safety culture in the industries. Fig - 2: Factors of Safety Culture 2.2 BEHAVIOURAL SAFETY In everyday life, it isgenerally believed that humanerrorcan cause injuries and mostly 80-90% of accidents occur due to human error. Factors for human errors are skill-based behaviour, rule-based behaviour, knowledge based behaviour. Safety behaviour is defined as everything a person does in the observable in the working place. The presence of good safety behaviour does reflect good safety compliance. Safety behaviour is more important in manufacturing sector. It is necessary to identify all behaviour activity and then differentiatefromtheunsafeand safe behaviour. After the respective risk, all behaviour must be made and arranged in order. Safety behaviour describe the support of safety training, motivation and education
3.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 12 | Dec-2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 790 activities to be carried out by the employees [2]. There are various methods to prevent the human includes management commitment, organizational commitment, behavioural based study, safety communications, safety motivation, and safety training. Safety training is important to educate employeeson potential accidents, howtoprevent accidents and how to identify the potential hazardsinvolved in their work. Before the commencement of work new employee must attend the safety training.Behaviouralbased study is conducted by top management representative. Individual representative has been appointed for the particular work, the representative will observe the routine work of the employee at work place and will note his positive and negative points, representative will discuss the positive points with employee. Safety Motivation is an employer or top management involvement such as relationship with employees, talk on safety and advice on safety matter is related to improve safety motivation and will encourage employees’ safety behaviour. There are two types of motivation which is positive reinforcement which gives employees outcomes such as monetary rewards, bonuses and job promotion whereas others are negative reinforcement where employers may criticize, punish and threaten the employees to motivate them to perform their jobsin the safe manners [2]. Safety behavior observation and review is the most important process of correcting the unsafe behaviors in workplace to avoid human error. Fig - 3: Behaviour Change Interventions 2.3 SAFETY PERFORMANCE Periodical maintenance, inspection, audit and review will avoid the chance of creating the hazard. Safety performance will improve the quality; it eliminates all the hazards periodically to reduce the accident rate. There are many parameters that can be used to benchmark safety performance at the workplace. Safety audit, the number of safety training courses conducted, percentageofstafftrained in safety, the number of safety inspections and percentageof legal compliance. Two prominent safety performance indicators have been used worldwide for industries, factories and other workplaces. They arefrequencyrate(FR) and severity rate (SR) [5]. Safety audit is the next concern to the safety system from top level to the low level, it analyses the safety system, points out their error in their particular field and also the best safety improvement condition to the industries. Safety performance is improved by monitoring the employee. Good-quality of monitoring will identify the problems and easy way to identify the solutions. Monitoring takes lot of time and effort; only trained and knowledgeable person are required. Basic types of accident losses aredirect losses and indirect losses. Direct losses are material loss, human loss, compensation. Indirect losses are production loss, property damage, investigation cost, insurance cost. 3. CONCLUSIONS This paper suggests the need of safety behavior, organizational safety culture and performance. The study has shown that employee’s safety is more important and is highly recommended to all manufacturing industries. This will help to improve the safety aspects in all manufacturing industries. By these safety concepts a better safe work environment can be provided to the workers and the productivity will automatically get improved. This study is taken as a ground work to improve safety management on manufacturing industries. REFERENCES [1] Astri Yulia1 Mohd. Fuad Mohd Salleh, Muhd. Amieerul Noorazman and Umar Abdul Aziz Roslan, Safety Culture and its Contributing Factors in Manufacturing Workplace in Malaysia, I J A B E R, Vol. 13, No. 7 (2015): 5817-5825. [2] B. Rajarethinam and A.Elavarasi, Study on Safety Management of Small and Medium Scale Industries in Tamilnadu, International Journal of Research in Engineering and Technology, eISSN: 2319-1163|pISSN: 2321-7308. [3] Naray Venkataraman, Safety Performance Factor, International Journal of Occupational Safety and Ergonomics, 14:3, vol. 327-331. [4] Ezrin Hani Sukadarin, Nurud Suria Suhaimi and Norhidayah Abdull, Preliminary Study of the Safety Culture in a Manufacturing Industry, International Journal of Humanities and Social Science, Vol. 2 No. 4 [SpecialIssue–February2012]. [5] H Abdul Zubar, K.Visagavel, V Deepak raja and Arunmohan, Occupational health and safety management in manufacturing industry, Journal of scientific and Industrial Research, Vol.73,June 2014, pp. 381-386. [6] Naray Venkataraman, Safety Performance Factor, International Journal of Occupational Safety and Ergonomics, 14:3, vol. 327-331. [7] S.Srinivasan, 2015, The factories act, 1948(Act 63 of 1948).
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