1) The document discusses safety training conducted at UltraTech Cement and Kirloskar Ferrous Industries. It outlines the profiles of the companies, key processes, hazards identified, and preventive measures taken. 2) Safety activities covered include toolbox talks, training, observations, and audits. Unsafe acts like improper PPE use and unsafe conditions like inadequate guarding are also described. 3) In conclusion, the training was effective in providing knowledge on industrial safety and how the companies implement systems like behavior-based safety to promote a safe work environment.

1. IN-PLANT INDUSTRIAL
SAFETY TRAINING
PART – A
PART – B
TEAM MEMBERS
RAGHU K C
SHEKAR B
SHABAZ S M D
M SREEDHAR ARUN
VISWANATH B

2. PART – A
Internal Guidance:-
Sri. THAKRA NAIK
HOD (Mech & PDIS)
Govt. Polytechnic Bellary
External Guides
Sri. Sampath Kumar. C
Sri. M.M.Nadiger
UltraTech cement Ltd & KFIL

3. •CONTENTS
 Profile of company
 Process Flow chart
 Process Hazards
 Prevention of hazards
 Standers of works Maintained
• Unsafe Act & Unsafe Condition
 Safety Activities
 Safety Observations

4. PROFILE - ULTRATECH CEMENT LIMITED
UltraTech is India's leading cement manufacturer and the 10th largest
in the world. The company has 24 cement-manufacturing units 12 of them are
Grinding units in India and along with the contribution from its overseas
locations, UltraTech Ginigera cement works capacity stands at 350 metric tones
per annum. While several factors contribute to its success, an important has
developed with pan-India builders. The brand partners with them in creating
unique product and service offerings aimed at increasing their profitability and
competitiveness
Cement :
Cement is the binding material which binds the sand, bricks and reinforcement
and constructs strong structure. Mainly the three types of cement is available in
market
OPC : Ordinary Portland Cement
PPC : Portland Pozzalanad Cement
PSC : Portland Slag Cement.

5. Process Flow Chart
Ultra tech cement ltd
RMHS MILL AREA
GRINDING
UNIT
BAG
HOUSE
16 dia & 20
dia
SILO
PACKING
PLANT
DISPATCH

6. Process Hazard
 Exposure to Dust
 Noise
 Electric hazard
 Hot work
 Work in Confined space
 Fire hazard
 Mechanical
 Vehicle movement

7. Hazards & Its Preventive Measures
Hazard s SAFETY PRECAUTIONS TAKEN
• Dust • Nose mask, breathing apparatus,
PPE’s.
• Noise • Ear plug's, Ear muff’s,
• Electrical hazard • Fire extinguishers , Fire Hydrant, Fire
bucket’s,
• Hot hazard • Fire resistant Aluminum jackets,
lather jacket
• Confined space hazard • Confined entry procedure
• Fire • Fire extinguishers, Fire Hydrants
• Mechanical hazard • Guards, Pull chords, Emergency stops.
• Vehicle movement • Safety training & education

8. Standards Of Works Maintained
 Scaffold Standard
 Work at Height
 Lock out/Tag out
 Confined Space Entry
 Excavation
 Permit to Work Procedure
 Electrical Safety
 Lifting & Shifting of Loads
 Heavy Equipment Movement
 Machine Guarding
 HOT Work Standard
 Road Safety Standard
 Rail safety

9. Unsafe Act
 Using the wrong tools
 Using the wrong material
 Using wrong method
 Failure to use PPE
 Unauthorized work
 Taking shortcuts
 Working at unsafe speed
 Operating without authority
 Failure to tag
 Failure to isolate.

10. Unsafe Condition
 Improper guarding of machines
 Improper ventilation
 Inadequate illumination
 Poor house keeping
 Absence of fencing
 Unsecured platform, floor grills etc
 Open man holes, covers
 Toxic atmosphere
 Leaky joints, vessels, valves.

11. Safety Activities
 Tool box talk
 Safety training for new members
 Safety programs
 Mock drills
 HIRA
 Safety observation
 Safety audit
 safety culture

12. Six step’s of Safety contact
 First observe, decide, stop the unsafe act,
 Comment on safe behavior,
 Discuss
* Possible consequence unsafe act
* Safety way to do job,
 Agreement to work safely,
 Discuss other safety issue,
 Thanks the Employee,

13. Safety Observation
Categories Type
 Reaction of people
 Position of people
 PPE’S
 Tools and Equipments
 Procedure
 Orderliness Standards
 Unsafe Condition
 Safe Condition
 Unsafe Act
 Safe Act

14. Safety Observations

15. PART - BPART – B

16. Contents
 Profile of company
 Process Flow chart
 Process Hazards
 Prevention of hazards
 Unsafe Act & Unsafe Condition
 Safety Activities
 Safety Observations
 Conclusion

17. Profile Of Company
PROFILE - KIRLOSKAR FERROUS INDUSTRIES LIMITED
Kirloskar Ferrous Industries Limited (KFIL),was established
in the year 1991, was born with unique advantage of having been
conceived with ideas accumulated through experience and expertise
of the Kirloskar Group in the field of Foundry business.
KFIL is having Pig Iron and Casting manufacturing facilities
at Bevinahalli, Koppal District, Karnataka and our foundry is the
first of its kind having integrated set up to serve the customer with
quality castings. KFIL has captive power generation facility
KFIL, the only foundry in Asia with backward integration to
liquid metal, has Global Capacities to meet high volumes at consistent
quality.

18. Process Flow Chart
0 RMHS SINTER PLANT MBF 1&2
MOULDING FOUNDRY
PIGIRON
CASTING
PACKING DISPATCH

19. Process Hazards
 Heat Radiation
 Fire & Toxic release
 Dust
 Electrical Hazards
 Noise
 Mechanical
 CO-Inhalation

20. Hazards & Its Preventive Measures
Hazard Precaution
• Heat radiation • Required PPEs
• Natural ventilation
• Exhaust blower system
• Fire & toxic gas
CO Monitor
• Safety relief valves provided
• BF Line provided with water seal and
isolation valves
• CO Monitor with alarm system
provided
• Gas seal pot (isolation purpose)
provided
• Shall thickness testing
• Testing & inspection yearly
• Dust • Required PPEs provided
• Electrical Hazards • Fire extinguishers , fire hydrant, fire
bucket’s,

21. Hazards & Its Preventive Measures
Hazard precaution
• Noise • Ear plug's, Ear muff’s,
• Mechanical • Guards, Pull chords, Emergency stops.
• Co – Inhalation • CO Monitor with alarm system
provided

22. Unsafe Act’s
 Using the wrong tools
 Operating without authority
 Failure to tag
 Failure to isolate.
 Using wrong method
 Failure to use PPE
 Unauthorized work
 Taking shortcuts

23. Unsafe Condition
 Improper guarding of machines
 Improper ventilation
 Inadequate illumination
 Poor house keeping
 Damaged insulation on electrical lines
 Absence of fencing
 Unsecured platform, floor grills etc
 Leaky joints, vessels, valves.

24. Safety Activities
 Tool box talk
 Shop floor training
 Safety training classes
 Safety programs
 Mock drills
 Safety observation
 Safety audit

25. Conclusion
The in plant industrial safety training undergone at the
UltraTech cement works and Kirloskar Ferrous
Industries Ltd. These industries have implemented good
safety system such as Behavior Based Safety (BBS), Tool
Box Talk, Safety training and they are following those
systems to improve the safety performance by providing
better health, good working Environment and necessary
training to all the Employees towards achieving
accidents free environment.
Finally this training was very effective and we got good
knowledge about the industrial safety

26. THANK YOU
SEEK SAFETY,
AIM SAFETY,
FOLLOW SAFETY,
ENSURE SAFETY,
TEACH SAFETY,
YIELD SAFETY,