GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER SAFETY AUDIT A KEY FOR HAZARD IDENTIFICATION TECHNIQUE

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER What is Safety Audit Verifying the existence and implementation of elements of occupational safety and health system and for verifying the system’s ability to achieve defined safety objectives ~~~IS

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER CONCERNS OF MANAGEMENT QUANTITY PRODUCED IN RELATION TO PRODUCTION SCHEDULE AND MARKET REQUIREMENT PRODUCT QUALITY PRODUCTION COSTS INTEGRATING THE STAKEHOLDERS CONCERNS Is Safety Important? Not always

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER SAFE AND SOUND A study of top companies in the world indicated that ‘Safety and Loss Prevention Programmes were essential for a company’s prosperity and accepted as part of good Business'.

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Why do organizations have to bother about Safety Corporate Strategy Finance Human Resources Marketing, Product Design and Product Liability Manufacturing and operating policy Information Management and systems Societal Concerns

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Societal Concerns Increased concern about the impact on the public not just the workforce concerned Public intolerance of risks which do not have clear benefits to those affected Readiness to press for retribution on those who cause harm and to seek compensation Demand for increased transparency

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Demand for full information and for public involvement A willingness to challenge and complain

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Corporate Strategy Business Mission, Philosophy and codes of ethics Company image in the community Environment impact Management Professionalism

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Finance Loss Control and cost reduction strategies Product liability, Legal liability, Property damage Risk retention or transfer Investment decisions concerning business acquisitions

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Human Resources Work and job structuring Morale and retaining people Positive health structure

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Marketing, product design and product liability Specification of product and service Legal requirement International requirement Consumer protection act

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Manufacturing and operating policy Design/selection/construction/maintenance of premises, plant, equipment and substances Quality management Environment management and waste disposal

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Information management and systems Identification of data critical to the management of health and safety Selection of appropriate performance indicators Use of information technology in the collection and analysis of essential data.

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Organizations carry out Safety Audit Safety Survey Safety Inspection Safety Tour Safety Sampling HAZOP

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Safety SurveySafety Survey: Detailed examination of a narrower field of activity-e.g.- key areas revealed by safety audits Safety InspectionSafety Inspection: Routine inspection-work is being carried in accordance with procedures etc. Safety TourSafety Tour: Unscheduled examination- hazards are removed-standards are removed

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Safety SamplingSafety Sampling: Trained observers record the number of safety defects seen while touring specified locations by a prescribed route. Typically tours last for 15 min. and are conducted at weekly intervals. The unweighted count of defects is used to portray trends in the safety situation.

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER SAFETY AUDIT MONITORING COMPARE ACTUAL PERFORMANCE - STANDARDS COMPREHENSIVE CONTINUOS AUDIT NOT DONE BY INSIDER NOT COMPREHENSIVE- DEPENDS ON SCOPE PERIODIC

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER DIFFERENT TYPES OF AUDIT Electrical Audit Fire Safety Audit Pressure vessels Audit Lifting Tackles Audit Statutory Regulations Compliance Audit Emergency Communication Audit Pipe lines Audit

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER SAFETY AUDIT OCCUPIERS ARE REQUIRED TO DEMONSTRATE THEIR CAPABILITY TO DESIGN LOCATE OPERATE AND MAINTAIN THEIR FACILITIES TO STANDARDS ACCEPTABLE TO THE GOVT. AND PUBLIC.

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER AUDIT AN AUDIT IS A SYSTEMATIC INDEPENDENT REVIEW TO VERIFY CONFORMANCE WITH ESTABLISHED GUIDE LINES OR STANDARDS. IT EMPLOYS WELL DEFINED REVIEW PROCESS TO ENSURE CONSISTENCE AND TO ALLOW THE AUDITOR TO REACH DEFENSIBLE CONCLUSIONS.

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER OBJECTIVES OF THE SAFETY AUDIT DESIGN DEFICIENCIES AND ALSO WEAKNESSES WHICH MIGHT HAVE CROPPED UP DURING MODIFICATIONS /ADDITIONS. FIRE PROTECTION ARRANGEMENTS AND SAFETY SYSTEMS. OPERATING /MAINTENANCE PROCEDURES- DEGRADED WITH TIME TRAINING, PREPAREDNESS FOR HANDLING EMERGENCIES.

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER SCOPE OF AUDIT FIRE AND EXPLOSION; PREVENTION, PROTECTION AND EMERGENCY MANAGEMENT. WORK INJURY PREVENTION. HEALTH HAZARDS CONTROL. CONSEQUENCES OF EMERGENCIES. ON SITE EMERGENCY CONTROL

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Elements of Occupational Safety and Health System-IS14489 Occupational Health and Safety Policy OS&H organizational set up Education and Training Employees participation in OS&H Management Motivational and Promotional measures for OS&H Safety Manual and Rules Compliance with Statutory Requirements New Equipment review and inspection

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Elements contd.. Accident reporting analysis investigation and implementation and recommendations Risk Assessment including hazard identification Safety inspections Health and safety improvement plan/targets First aid facilities-Occupational health center Personal Protective Equipment Good housekeeping Machine and general area guarding Material handling equipment

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Elements contd.. Electrical and Personal safeguarding Ventilation, illumination and noise Work environment monitoring system Prevention of occupational diseases including periodic medical examination Safe operating procedures Work Permit systems Fire Prevention, Protection and fighting systems Emergency Preparedness plans(onsite/offsite) Process Plant modification procedure

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Elements contd.. Transportation of hazardous substances Hazardous waste treatment and disposal Safety in storage and warehousing Contractor safety systems Safety for customers(including MSDS)

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Records to be examined during Audit OS&H Policy Safety organization chart Training Records on safety, fire and first aid Accident investigation reports Accidents and dangerous occurrences-Statistics and analysis Records of tests and examination of equipment and structures Safe operating procedures for various operations Record of work permits Record of montioring of flammable and explosives

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Records- Contd.. Maintenance and testing records of fire detection and fire fighting equipment Medical records of employees Records of industrial hygiene surveys(noise, ventilation, illumination levels, airborne and toxic substances, explosive gases) MSDS Onsite emergency plans and record of mockdrills Records of waste disposal Records of effluent discharge to the environment Housekeeping inspection records

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Records contd.. Minutes of Safety committee meetings Approval of layouts and other approvals from statutory authorities Records of any modifications carried out in plant and process Maintenance procedure records Calibration and testing records Shutdown maintenance procedures In service inspection manuals, records including that of material handling Safety Budget Statutory Records, Previous audit reports, Transportation of Hazardous substances

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER TOPICS ON WHICH INFORMATION IS COLLECTED SAFETY ORGANIZATION. CONTRACTOR EMPLOYEE ACTIVITIES. MATERIAL SAFETY DATA. OCCUPANCY. SAFETY AND HEALTH POLICY. OPERATION AND MAINTENANCE OF SAFETY MANUAL.

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER EXPANSION MODIFICATION - AUTHORIZATION PROCEDURES. SAFETY EDUCATION, TRAINING. STATUTORY STANDARDS, SAFETY IF JOB SAFETY ANALYSIS. JOB SAFETY INSTRUCTIONS

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER.TOPICS CONTD. SAFETY INSPECTION. SAFETY OBSERVATIONS. WORK PERMIT SYSTEM. FIRE PROTECTION ARRANGEMENTS FIRE EMERGENCY CONTROL PROCEDURES. WORK ENVIRONMENT MONITORING.

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER PERSONAL PROTECTIVE EQUIPMENT. MEDICAL/AMBULANCE FACILITIES. ACCIDENT/INCIDENT-REPORTING INVESTIGATION ANALYSIS. IDENTIFICATION OF CRITICAL EQUIPMENT AND PREUSE INSPECTION OF CRITICAL EQUIPMENT OFF THE JOB -SAFETY. STATISTICAL INF. ON LOSSES INJURIES.

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER EMERGENCY COMMUNICATION FACILITIES. EVACUATION FACILITIES. PRODUCT/SERVICE-LIABILITY

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Manufacture, Storage and import of Hazardous Chemicals Rules, 1989 Safety Audit is required to be carried out by by the occupiers of both the new and the existing industrial activities with the help of an expert not associated with such industrial activities. This is required under Rule No.10-subrule (4) This has come into effect from 3/10/94

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Traits of an auditor Dispel the myth that it is policing on behalf of management Is questionnaire useful? Knowledge in the area being visited Blinkered view? Discussion is more important- Facilitator rather than an inspector.

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Are you a good auditor? FINISHED FILES ARE THE RESULT OF YEARS OF SCIENTIFIC STUDY COMBINED WITH THE EXPERIENCE OF YEARS

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Safety Leadership is key to success

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Hardware Software Humanware Safety Depends on Engineering Procurement Maintenance Accident and incident analysis Work permit Health and Hygiene Emergency PPE Leadership Task observation

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Safety Culture Liveware Safety Culture HardwareSoftware Acts-Practice-Habit-Behavior-Culture

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Coincident or Not ? If, A B C D E F G H I J K L M N O P Q R S T U V W X Y Z Equals, Then, K + N + O + W + L + E + D + G + E = 96% H + A + R + D + W + O + R + K = 98% Both are important, but the total falls just short of 100% But, A + T + T + I + T + U + D + E = 100% Safety really is about attitude. Make 100% Safe Behavior your choice both ON and OFF the job

GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Safety and Incident Prevention Depends how much on ATTITUDE ? ATTITUDE ================ %