This document outlines the steps to build a safety culture at a chemical plant. It involves: 1) Surveying the plant and identifying gaps. 2) Strategic planning including establishing policies, roles and responsibilities, legal compliance, and risk management. 3) Training employees on topics like safety induction, risk assessment, PPE usage, work permits, and fire safety. 4) Documenting policies, procedures, records, and audit plans. 5) Developing a safety culture through teams, committees, communication, and events. 6) Obtaining certifications to recognize the safety management system.

1. Building Safety Culture
BY SAFETY TECH SOLUTIONS
DEMECH CHEMICAL PRODUCTS PVT. LTD.

2. Purpose Of the Visit:
Eagle Eye
Strategic
Planning And
Leadership
Train The
Trainer
Customer
Specific
Requirement
Legal
Compliance
Evaluation and
Continual
Improvement
Building
safety
Culture

3. Steps1: Plant Survey
Process
Observations
Gap Analysis Report

4. Step 2:Strategic Planning & Leadership
 Declaration of OHS Policy.
 Declaration of Strategic (Long Term) Objectives for OHSMS.
 Planning for Roles and Responsibilities for OHSMS
 Initial review of existing OHSMS with respect to the requirements of International Best Practices
 Planning of OHS Targets, Objectives and Programmes
 Planning for Legal Compliance
 Identification of Risks to OHS and Risk Management
 Planning for Emergency Management regarding Emergencies related to OHS
 Planning for Contractor/Sub Contractor management regarding matters related to OHS
 Planning for documenting the OHSMS and Documentation Structure
 Planning for the Records to be maintained
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5. Step 2:Strategic Planning & Leadership
 Implementation of OHS Policy, Programs to achieve OHS Objectives.
 Ensuring that Organizational Structures are put into place and implemented at all levels of our
Organization.
 Applying appropriate Control Measures to all the site Operations- Through SOPs.
 Identification of various Training and Providing Education and Skill development.
 On the Job Traings
 Hazard Identification and Risk Assessment, Near Miss/ Incident reporting and investigation.
 Communication and Consultation with Employees and Stake Holders.
 Implementation of Occupational Health and Safety Programs including Wellbeing and Employee
Assistance Program.
 Conducting Site Inspection, Audit, Surveys, BBS Observations, Work Place Assessment- Noise,
Ventilation, and Illumination.
 Conducting Emergency Preparedness Drills/Handling of Crises scenarios ( Loss producing situations
)
 Maintenance of Fire safety equipment , Welfare Facilities.
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6. Step 2:Strategic Planning & Leadership
 Monitoring and Measuring OHS Performance.
 Monitoring of Performance against OHS Plan.
 Monitoring of Competency and Capability including Behavior.
 OHSMS Audits – Internal and External.
 Monitoring of Inspection, Risk Assessment Review, Surveys.
 Evaluation of Compliance to Legal requirements.
 Monitoring of Compliance to Non Conformities, Corrective and Preventive Actions.
 Monitoring of Procurement, Outsourcing and Contractors.
 Monitoring of Ill Health and Loss/ Damages.
 Monitoring of Health and Safety Culture.
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7. Step 2:Strategic Planning & Leadership
 Fulfillment of Customer Specific Requirement
 Assessment of Management System effectiveness leading to Continual Improvement
 Conducting Top Management Review.
 Building Safety Culture
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8. Step 2:Trainings
 Identify The Training Needs
 Prepare a Module on the various topics, that need Focus
 Training Safety Modules Such As:
A) Safety Induction
What does safety mean
Why Safety is Important
Emergency Preparedness and Evacuation in Emergency
Safety Instructions
Information about Fire risk & Fire Extinguisher
Information about First aid box
Information about standard operating Procedures

9. Step 2:Trainings
B) Establishment of Risk Assessment – HIRA
Formation HIRA Team
Formation of HIRA Format
Identification of Work Activity
Finding Potential Hazards
Possible Accident /ill Health & Persons At Risk
Existing Risk Control Measures (if any)
Risk Evaluation
Basis of Controls ( Elimination, Substitution, Engg Control, Admin Control, PPE )

10. Step 2:Trainings
C) Importance of PPE & Its Usage
What is PPE
Types of PPEs
Identification of PPEs according to HIRA Study
Identification of PPE Matrix
Responsibilities and awareness of use of PPEs
Maintenance and Storage
Disposal

11. Step 2:Trainings
D) Work Permit
Formation of Work Permit Format
Identification of Work Activity related to work Permit
Documents Required
Work Permit Initiation and Authorization Matrix
Tool box talk
Tools and Equipment Inspection
Surprise Audit at site
Closure of Work Permit
Extension of permit & Night shift permit

12. Step 2:Trainings
E) Awareness about Fire and Fire extinguishers
Fire Triangle & Fire Classes
The company emergency evacuation plan.
Each worker's role in the plan.
Mock Drill
Assembly Point
Types of Fire extinguishers
Usage of Fire extinguishers

13. Step 2:Trainings Topics
 Near Miss, Unsafe Act, Unsafe Conditions
 Work at Height
 Job safety Analysis
 Electrical safety
 Lock Out Tag out
 Material Handling
 Management and Control of hazardous Substances
 Chemical Handling
 MSDS
 Safety Precautions in Welding process
 Precaution on Lifting Tools & tackles
 Machinery & Equipment safety
 Precautions regarding use of portable electric equipment's
 Monitoring of sub-contractor

14. Step 4:Documentaion
 Safety Policies
 Strategic Objectives
 Standard Operating Procedures – SOP’s
 Work Instructions
 Check Lists
 Records
 Plan – Do – Check – Act ( PDCA )
 Audits

15. Step 5:Culture Developments
 Formation of Various teams, First Aiders, Fire Fighters
 Safety Committee
 Safety Co - coordinators on Site
 Various Safety Events
 Safety Suggestion Scheme
 2 way Communication
 Management Review
 Health And Surveillance
 Environment Management

16. Step 6:Way Forward…….
 Certification Of ISO 45001:2018 (occupational health and safety (OH&S) management
system)
 Certification Of National Safety Council
 Certification Of British Safety Council