The document discusses the roles and responsibilities of various entities in ensuring industrial safety. It states that management is responsible for protecting workers from hazards, conducting safety training, and enforcing safety procedures. Supervisors must inspect work areas, report issues, and ensure safe work practices. Workers should follow safety rules and not endanger others. Trade unions educate members and negotiate safe working conditions. The government regulates workplace safety through legislation and policies. Safety officers identify and control hazards to prevent accidents.

1. MCN401 INDUSTRIAL SAFETY
ENGINERING
Mr. Joe Jeba Rajan K
Assistant Professor
Department of Mechanical Engineering
Rajadhani Institute of Engineering & Technology, Nagaroor
JOE JEBA RAJAN K , AST PROF- MECH , RIET

2. Preamble: The course is intended to give knowledge of various
• safety management principles
• various safety systems
• various machine guarding devices
• hazard identification techniques
• energy sources
• systems & applications and the need in the present context.
Learners will be able to compare different hazard identification tools and choose the
most appropriate based on the nature of industry. It aims to equip students in working
with projects and to take up research work in connected areas
JOE JEBA RAJAN K , AST PROF- MECH , RIET

3. JOE JEBA RAJAN K , AST PROF- MECH , RIET

4. JOE JEBA RAJAN K , AST PROF- MECH , RIET
Bombay Docks Explosion (1944)
April 14, 1944
• freighter SS Fort Stikine, carrying a mixed cargo of
cotton bales, gold and ammunition including tons
of explosives, caught fire and resulted in two
massive blasts in the Victoria Dock of Bombay
• 800 people died in the explosion and some 80,000
were made homeless.
Chasnala Mining Disaster (1975)
December 27, 1975
• huge explosion rocked the Chasnala Colliery in
Dhanbad (then under Bihar) killing 372 miners

5. JOE JEBA RAJAN K , AST PROF- MECH , RIET
The Union Carbide Gas Tragedy (1984)
December 3, 1984
• biggest industrial disaster of the last hundred years
in India
• 5295 people died and 5,27,894 were affected after
being exposed to some 40 tonne of methyl
isocyanate gas leaked from a pesticide plant
Korba Chimney Collapse (2009)
September 23, 2009
• 45 people lost their lives when a chimney under
construction at a power plant at the Bharat
Aluminium Company (Balco) collapsed in Korba in
Chhattisgarh

6. JOE JEBA RAJAN K , AST PROF- MECH , RIET
Visakhapatnam HPCL Refinery Blast (2013)
August 23, 2013
• blast caused due to sparks originating
from welding after a heavy build-up of
hydrocarbons in a pipeline, led to the
collapse of the cooling tower in the HPCL
refinery in Visakhapatnam.
Bhilai Steel Plant Pipeline Blast (2018)
Oct 10, 2018
• explosion in a gas pipeline connected to
the coke oven section of the Steel Plant in
Bhilai in Durg district of Chhatisgarh
• 9 dead, 12 injured

7. Introduction to Industrial safety Engineering
1.1 Need for safety. Safety and productivity. Definitions: Accident,
Injury, Unsafe act, Unsafe Condition, Dangerous Occurrence. Reportable
accidents
1.2 Theories of accident causation. Safety organization.
1.3 Role of management, supervisors, workmen, unions, government and
voluntary agencies in safety.
1.4 Safety Officer-responsibilities, authority.
1.5 Safety committee-need, types, advantages.
JOE JEBA RAJAN K , AST PROF- MECH , RIET

8. What is Industrial Safety?
The concept of industrial safety is mainly related to the
minimization of various industrial hazards.
Hazard - Any physical or chemical situation which can result in the
injury of an individual or can cause any kind of harm to the health of a
person
JOE JEBA RAJAN K , AST PROF- MECH , RIET

9. Need for Industrial Safety?
Cost Saving
Increased Productivity
Moral
Legal
JOE JEBA RAJAN K , AST PROF- MECH , RIET

10. Objectives of Industrial Safety
• To prevent any kind of incident resulting in the accidents causing loss of life and
permanent disability of the employees
• Preventing the kind of accidents resulting in the seizing of work and loss of the
production.
• Controlling the hazard to the minimum level, accidents
• Also required for having lower compensation to be paid to the employees, lesser
insurance premiums, and the accident cost.
• Aware the employees of the different safety guidelines
• Improved morale of the manpower
JOE JEBA RAJAN K , AST PROF- MECH , RIET

11. SOME IMPORTANT DEFINITIONS
• It is the state of being safe, the conditions of being protected from health and economical
losses, physical, damage accident, error, harm or other types of consequences of failure
Safety
• It is defined as policies and protections put in place to ensure plant and factory worker
protection from hazards that could cause injury.
Industrial safety
• Source, situation, substance or act with a potential for harm in terms of human injury or
ill health or a combination of these.
Hazard
1
2
3
JOE JEBA RAJAN K , AST PROF- MECH , RIET

12. SOME IMPORTANT DEFINITIONS
• Any personal injury, disease or death resulting from an occupational accident.
• An occupational injury is different from an occupational disease, which is a disease
contracted as a result of an exposure over a period of time to risk factors arising from
work activity
Injury/ Occupational Injury
• It’s a human error or person mistake by which there is a chance of accident or property
loss
Substandard Acts or Unsafe Act
4
5
• It is the condition by which there has a chance of getting accidents and property losses.
Substandard Condition or Unsafe Conditions
6
• A Near Miss is an Incident, which results in no injury, illness, damage, product loss or
harm to the company reputation.
Near Miss
6
JOE JEBA RAJAN K , AST PROF- MECH , RIET

13. Unsafe Condition vs Unsafe Act vs Near miss vs Accident
JOE JEBA RAJAN K , AST PROF- MECH , RIET

14. SOME IMPORTANT DEFINITIONS
• Dangerous occurrences are certain unintended, specified events, which may not
result in a reportable injury, but which do have the potential to cause significant
harm.
• Dangerous occurrences usually include incidents involving:
Dangerous Occurrence
7
Lifting equipment
Pressure systems
Overhead electric lines
Electrical incidents causing
explosion or fire
Explosions, biological agents
Radiation generators and
radiography
Breathing apparatus
Diving operations
Collapse of scaffolding
Train collisions
Wells
Pipelines or pipeline work
JOE JEBA RAJAN K , AST PROF- MECH , RIET

15. THEORIES OFACCIDENT CAUSATION
Industrial work place accidents
• 3/100 persons per year
• One accidental death every 51 minutes
• One injury every 19 seconds
Is there a theory that explains the causes of accidents?
Why do accidents happen?
To prevent accidents we need to know the causes.
Six widely used theories for accident causation
1.Domino theory
2.Human Factors theory
3.Accident/incident theory
4.Epidemiological theory
5.Systems theory
6.Combination theory
JOE JEBA RAJAN K , AST PROF- MECH , RIET

16. 1.Domino theory
• developed by H.W. Heinrich,
• that purports that all accidents, whether in a residence or a workplace
environment, are the result of a chain of events
Chain of events
JOE JEBA RAJAN K , AST PROF- MECH , RIET

17. 1.Domino theory
• that purports that all accidents, whether in a residence or a workplace environment,
are the result of a chain of events
Chain of
events
Heinrich’s domino theory
JOE JEBA RAJAN K , AST PROF- MECH , RIET

18. Domino 1: ancestry and the worker’s social environment, which impact the worker’s
skills, beliefs and “traits of character”,
“Recklessness, stubbornness, avariciousness, and other undesirable traits of character
may be passed along through inheritance”.
Domino 2: the worker’s carelessness or personal faults, which lead them to pay
insufficient attention to the task
Domino 3: an unsafe act or a mechanical/physical
hazard, such as a worker error (standing under
suspended loads, starting machinery without
warning…) or a technical equipment failure or
insufficiently protected machinery
Domino 4: the accident
Domino 5: injuries or loss, the consequences of the
accident
FIVE FACTORS LEADING TO AN ACCIDENT
JOE JEBA RAJAN K , AST PROF- MECH , RIET

19. Heinrich’s Domino Theory – Corrective Action Sequence
(The three “E”s)
• Engineering – Control hazards through product design or process change
• Education
– Train workers regarding all facets of safety
– Impose on management that attention to safety pays off
• Enforcement – Assure that internal and external rules, regulations, and
standard operating procedures are followed by workers as well as
management
JOE JEBA RAJAN K , AST PROF- MECH , RIET

20. 2. Human Factors theory
• Focus on the human errors that cause accidents.
These errors are categorized broadly as:
Ferrell’s human factors
Overload - Environmental Factors (noise, Distractions)
Internal Factors (Personal problems, stress)
Situational Factors (Instructions not clear/risk level to high)
Inappropriate Worker Response
- Know about the hazard but not doing anything about it.
- Removing safeguards
- Ignoring safety rules
Inappropriate Activities
- Lack of training and misjudgment of risk
But the structure of this theory is still a cause/effect format.
JOE JEBA RAJAN K , AST PROF- MECH , RIET

21. 2. Human Factors theory
• By providing a positive working environment, the right equipment,
policies and organization processes for staff they will work more efficiently
and safely.
Ferrell’s human factors
JOE JEBA RAJAN K , AST PROF- MECH , RIET

22. 3.Accident/incident theory
• Adapts Ferrell’s human factors of overload and also Heinrich’s domino theory
• States that causes of accident/incident are human error and/or system
failure.
These are incompatible work stations, tools or expectations
(management failure)
– Management failure (policy, training, etc.)
Ergonomic traps
Decision to err – Unconscious or conscious (personal failure)
Systems failure
JOE JEBA RAJAN K , AST PROF- MECH , RIET

23. 4. Epidemiology theory
• This field studies relationship between environmental factors and disease
• Can be used to study causal factors in a relationship
causal factors  “major unplanned, unintended contributor to an incident
(a negative event or undesirable condition),
JOE JEBA RAJAN K , AST PROF- MECH , RIET

24. 4. Epidemiology theory
• This field studies relationship between environmental factors and disease
• Can be used to study causal factors in a relationship
1. Predisposition characteristics
peer pressure, poor attitude, risk taking
Two key components:
tendencies may affect worker to certain actions
2. Situational characteristics
Together these characteristics can cause or prevent accidents that a person predisposed to a
given situation or condition may succumb to.
JOE JEBA RAJAN K , AST PROF- MECH , RIET

25. 4. Epidemiology theory
JOE JEBA RAJAN K , AST PROF- MECH , RIET

26. 5. Systems theory
• System - interacting components intended to meet a common goal
Components:
• Collect information, weigh
risks, make decisions
JOE JEBA RAJAN K , AST PROF- MECH , RIET

27. 6. Combination Theory
• avoid the tendency to try to apply one model to all accidents because
“One Model Does Not Fit All”
JOE JEBA RAJAN K , AST PROF- MECH , RIET

28. Role of Management, Supervisors,
Workmen, Unions, Government etc
ON INDUSTRIAL SAFETY
JOE JEBA RAJAN K , AST PROF- MECH , RIET

29. ROLE OF MANAGEMENT IN SAFETY
• Safety management or industrial safety is a section of management which
deals with the study of the possibilities of any disaster or danger,
correlated to the health of workers or equipment, chemicals or machines in
an industry.
• Objective - to reduce the chance of risks, accidents and harms by the
accomplishment of diverse proficiencies of risk and safety management.
• Safety management experts build up and execute various precautionary
actions to uphold safe work environments.
JOE JEBA RAJAN K , AST PROF- MECH , RIET

30. Role and responsibilities
1. Protect the company and workers from common workplace
hazards.
2. Comprise preparation and growth of workers in safety practices
3. Judgment of requirement of safety procedures
4. Regular testing and monitoring of working environs
5. Safety examinations
6. Organizing special training in case of new equipment and measures
7. Enhancement of security programmes.
ROLE OF MANAGEMENT IN SAFETY
JOE JEBA RAJAN K , AST PROF- MECH , RIET

31. Skills expected from a safety manager
• Outstanding interpersonal and communication skills
• Surveillance and reporting skills
• Capability to stay quiet in emergencies
• Safety awareness
• Crisis-solving and decision-making aptitude
• Good managerial and time management skills
• Capability to work separately and in a team
ROLE OF MANAGEMENT IN SAFETY
JOE JEBA RAJAN K , AST PROF- MECH , RIET

32. Responsibilities
ROLE OF SUPERVISORS IN SAFETY
• Conduct informal health and safety meetings with their employees at least
monthly
• Enforce all safe systems of work procedures that the Departmental Manager
has issued
• Report to the Departmental Manager about
• any weaknesses in the safe system of work procedures or any actions
taken to revise such procedures.
• any jobs that are not covered by safe systems of work procedures to the
Departmental Manager
• Review any unsafe acts and conditions and either eliminate them or report
them
• Instruct employees in relevant health and safety rules
• Make daily inspections of assigned work areas and take immediate steps
JOE JEBA RAJAN K , AST PROF- MECH , RIET

33. Responsibilities
• Are responsible for their health and safety
• Ensure that their actions will not jeopardize the safety or health of
other employees
• Obey any safety rules, particularly regarding the use of PPE or other
safety equipment
• Learn and follow the operating procedures and health and safety rules
and procedures
• Must correct, or report to their Supervisor, any observed unsafe
practices and conditions;
• Report any absence from the company caused by illness or an accident
Note : PPE - Personal Protective Equipment
ROLE OF SUPERVISORS IN SAFETY
JOE JEBA RAJAN K , AST PROF- MECH , RIET

34. ROLE OF TRADE UNIONS IN SAFETY
Responsibilities
• Negotiate safe working conditions for their members
• Educate shop-floor union leaders about health and safety legislation, Codes of
Practice and support their actions in ensuring members & employers compliance.
• Take active part in the formulation of health and safety legislation and policies and
monitor
• Identify, expose and report abuses of workers’ working conditions
• Organize awareness-raising campaigns through multifaceted channels to educate
members, employers, public authorities and the population at large about the
importance of improved health and safety legislation working conditions.
JOE JEBA RAJAN K , AST PROF- MECH , RIET

35. ROLE OF GOVERNMENT IN SAFETY
Responsibilities
• Government is committed to regulate all economic activities for management of
safety and health risks at workplaces and to provide measures so as to ensure safe
and healthy working conditions for every working man and woman in the nation.
JOE JEBA RAJAN K , AST PROF- MECH , RIET

36. ROLE OF GOVERNMENT IN INDUSTRTIAL SAFETY
Directive Principles
i. for securing the health and strength of employees, men and women;
ii. that the tender age of children are not abused;
iii. that citizens are not forced by economic necessity to enter jobs unsuited to their
age or strength;
iv. just and humane conditions of work and maternity relief are provided; and
v. that the Government shall take steps, by suitable legislation or in any other way,
to secure the participation of employee in the management of undertakings,
establishments or other organizations engaged in any industry.
NATIONAL POLICY ON SAFETY, HEALTH AND ENVIRONMENT AT WORK PLACE
Government of India Ministry of Labour and Employment
JOE JEBA RAJAN K , AST PROF- MECH , RIET

37. Who is a Safety Officer?
• The safety officer is an internal employee who is assigned to prevent accidents,
respond to emergencies and evaluate the effectiveness of the company’s safety
programs.
• A safety officer identifies safety hazards, investigates them thoroughly, and
controls them before someone gets hurt.
ROLE OF SAFETY OFFICERS IN SAFETY
JOE JEBA RAJAN K , AST PROF- MECH , RIET

38. ROLE OF SAFETY OFFICERS IN SAFETY
Roles
Planning
• Must create a safe environment by making sure they have all the necessary equipment
for their team.
• Also have to ensure that they have all the required things for their team.
Organizing
• Responsible for organizing their workload so that no harm will come
• Make sure that employees can complete the tasks without causing any damage to the
workplace or anyone else.
Supervising
• Responsible for supervising everyone who works under them to ensure that they are
doing their work safely.
In general, safety officers have three main roles:
JOE JEBA RAJAN K , AST PROF- MECH , RIET

39. ROLE OF SAFETY OFFICERS IN SAFETY
Responsibilities
• Plan and implement OSH policies and programs
• Advise and lead employees on various safety-related topics
• Prepare educational seminars and webinars on a regular basis
• Review existing policies and procedures
• Adhere to all the rules and regulations
• Work with HR to set up a new employee on-boarding process for safety
• Conduct risk assessment
• Enforce preventative measures
• Check if all the employees are acting in adherence with rules and regulations
• Prepare and present reports on accidents and violations and determine causes
OSH -Occupational safety and health
JOE JEBA RAJAN K , AST PROF- MECH , RIET

40. JOE JEBA RAJAN K , AST PROF- MECH , RIET

41. SAFETY COMMITTEE
Elements of a safety committee
1. Rules and regulations: To create a safe work environment, safety committees
consider national, state and company policies when creating operation rules and
regulation for their workplace.
2. Scheduled walkthroughs: Safety committees inspect their operations
frequently to assess the adherence to safety rules.
3. Regular meetings: Safety committees meet regularly to discuss safety topics.
A safety committee is a group of individuals that focuses on ensuring that their
workplace is safe for everyone.
JOE JEBA RAJAN K , AST PROF- MECH , RIET

42. SAFETY COMMITTEE
Elements of a safety committee
4. Incident report reviews: When accidents and incidents occur in the workplace,
the safety committee reviews them and determines what could be done
differently to increase safety in the incident situation.
5. Safety assessments: Members of the safety committee may conduct monthly or
quarterly safety assessments of all procedures.
6. Employee education: Providing safety literature for all staff members to
consume is an important part of the safety committee's work.
A safety committee is a group of individuals that focuses on ensuring that their
workplace is safe for everyone.
JOE JEBA RAJAN K , AST PROF- MECH , RIET

43. Chairman: This general manager or who seconded in command. He must be the
top operating official of the company.
Members: Department managers or supervisors, five workers representatives, if
company is unionized, it is much easier to pick who will represent the workers.
Secretary: a safety officer or who delegated to perform the task of overseeing the
safety of workers could be a secretary.
If the committee covers the health aspect, the company doctor and nurse shall also
be included in the committee. In some committee setup at least half of the workers
are members. Example on SC
If the company has more than a hundred workers, the following shall compose the safety
committee:
COMPOSITION/ STRUCTURE of SAFETY COMMITTEE
JOE JEBA RAJAN K , AST PROF- MECH , RIET

44. COMPOSITION/ STRUCTURE of SAFETY COMMITTEE
• Workers should have equal representation as employers
• Workers’ representatives should be elected by their co-workers freely through a
direct and secret vote.
• Employers’ representatives are designated directly by management.
• Technician responsible for OSH matters or the OSH management system are
part of the committee, and the medical service can also be represented
• Number of representatives varies depending on several parameters:
• the size of the workplace
• the number of workers, departments and worksites;
• its geographical location;
• the type of activity and the associated risks;
• the number of trade unions present at the workplace;
JOE JEBA RAJAN K , AST PROF- MECH , RIET

45. FUNCTION OF SAFETY COMMITTEE
• Being a liaison/relationship group between employees and management
• Increasing awareness of safety at the facility
• Identifying workplace risks and creating a plan (or making
recommendations) to reduce risks
• Integrating safety and health priorities into corporate culture
• Encouraging safety training for employees and management
• Conducting and evaluating audits
• Performing routine safety inspections
OSH -Occupational safety and health
JOE JEBA RAJAN K , AST PROF- MECH , RIET

46. EMPLOYERS’ RESPONSIBILITIES/ DUTIES SAFETY
COMMITTEE
• Give adequate information on preventive measures taken and appropriate training on
OSH
• Ensure that the workplaces, machinery, equipment and processes, as well as chemical,
physical and biological substances and agents under their control are safe and without
risk to health when the appropriate preventive and protective measures are taken
• Provide adequate protective clothing and personal protective equipment (PPE) to
prevent risk of accidents or of adverse effects on health;
• Provide for measures to deal with emergencies and accidents, including adequate
first-aid arrangements.
JOE JEBA RAJAN K , AST PROF- MECH , RIET

47. BENEFITS FROM SAFETY COMMITTEE
For the employer
• Decreasing employee accidents and loss costs, which will significantly impact the cost
of Worker’s Compensation insurance.
• Medical/ lost wage costs — along with accident frequency — directly drive a
company’s annual experience modification premium factor, resulting in premium
impact.
For the committee members
• Employee committee participation builds an increased awareness of the company’s
viewpoint and commitment to the safety of its employees.
• Employee representatives will develop more engagement with the company by having
a meaningful voice.
• The employee members will also broaden their knowledge and understanding of the
operational impact workplace accidents and how to identify a hazards and develop
solutions.
JOE JEBA RAJAN K , AST PROF- MECH , RIET

48. For the employees:
• Employee will enjoy a much safer work environment with a company that cares for the
wellbeing of all of its people.
• Having the opportunity to serve on safety committees employees feel more connected
to the company by having a voice.
BENEFITS FROM SAFETY COMMITTEE
JOE JEBA RAJAN K , AST PROF- MECH , RIET

49. JOE JEBA RAJAN K , AST PROF- MECH , RIET
PART A (Each carry 3 marks)
1. Differentiate Unsafe act and Unsafe conditions with suitable examples
2. Define Industrial Hazard in Industrial safety.
3. Write the suggestion made by Ferrell’s to overcome human error
4. Define Dangerous occurrences in Industrial safety.
5. Write short note on Combination Theory
6. List the various incidents that results in Dangerous occurrences
7. List the various theories of accident causation
8. Write short note on Systems theory
9. Write the key components of Epidemiology theory
10. Define “Decision to err” of 3.Accident/incident theory
11. Write how Ferrell’s categorize human errors
12. What are the three “E”s suggested by Heinrich’s as corrective action sequence
13. Discuss the significance of a safety committee in improving the safety performance
of an industry

50. JOE JEBA RAJAN K , AST PROF- MECH , RIET
Part A
14. Write any few Role and responsibilities of Management on industrial safety
15. Write any few Skills expected from a safety manager
16. Write any few responsibilities of supervisors in industrial safety
17. Write any few responsibilities of trade unions in industrial safety
18. Write any few responsibilities of government in industrial safety
19. List out few Directive Principles of policies by Indian Ministry of Labor and Employment
20. Write the various roles of safety officers in industrial safety
21. List any four Elements of a industrial safety committee
22. Write the different composition of a safety committee
23. Write any few functions of a safety committee
24. Write the benefits from safety committee for an employer
25. Write the benefits from safety committee for the employees

51. JOE JEBA RAJAN K , AST PROF- MECH , RIET
PART B
List the various accident causation theories and explain any one in details. (14 Marks)
a) Discuss the significance of safety policy in reducing the accidents. (4 Marks)
b) Safety and productivity are the two sides of a coin’. Are you agreeing with this statement?
Explain with your arguments. (10 Marks)
a) Safety at Work Increase Productivity of Industry: Justify (07 Marks)
b) Explain role of Safety Education and training in Industry (07 Marks)
c) Discuss the Risk Associated with Industrial Work (07 Marks)
d) b) Explain the responsibilities of Management & Supervisors on industrial safety
(07 Marks)
a) Explain the skills required from safety manager and responsibilities trade unions on
industrial safety (07 Marks)
Explain in detail about the roles & responsibilities of safety officers in industrial safety
(07 Marks)