SAFETY AUDIT A KEY FOR HAZARD IDENTIFICATION TECHNIQUE

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-14489 -1998 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 Survey: Survey Detailed examination of a narrower field of activity-e. g. - key areas revealed by safety audits • Safety Inspection: Inspection Routine inspection-work is being carried in accordance with procedures etc. • Safety Tour: Tour Unscheduled examinationhazards are removed-standards are removed GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER

• Safety Sampling: 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 PROCEDURESDEGRADED 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-IS 14489 • • 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, GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER Transportation of Hazardous substances

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

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 SCIENTIFIC COMBINED OF STUDY 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

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

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

Coincident or Not ? If, ABC D EFGHI J K L M N O PQ R S T U V W X Y Z Equals, 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Then, K+ N +O +W+ L +E+D+G+E 11 + 14 + 15 + 23 + 12 + 5 + 4 + 7 + 5 = 96% H+A+R +D+W+ O+ R +K 8 + 18 + 4 + 23 + 15 + 18 + 11 = 98% Both are important, but the total falls just short of 100% But, A+T +T + I+T + U +D+E 1 + 20 + 9 + 20 + 21 + 4 + 5 = 100% Safety really is about attitude. Make 100% Safe Behavior your choice GOPAL DUTT PANDEY both ON and OFF the job JOINT SECRETARY NSC UP CHAPTER

Safety and Incident Prevention Depends how much on ATTITUDE ? A T T I T U D E = = = = 1 20 20 9 20 21 4 5 100% GOPAL DUTT PANDEY JOINT SECRETARY NSC UP CHAPTER