INDUSTRIAL SAFETY

MANEGMENT
23108

THANE BELAPUR INDUSTRIES ASSN

INDUSTRIAL SAFETY
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Index
Chapter Content Page
No. No.
1.1 I ntroduction: Management Principles and Types of
Management,
1.2 Line and staff Authority, Role, Responsibility of management,.
Span of Management, Delegation and decentralization of authority.
1.3 Planning for Safety: Planning: Definition, purpose, Nature, scope
and procedure. Range of planning, Types of plans.
1.4 Management by objective ( MBO), Policy formulation and
implementation
1 1.5 Organizing for Safety : 4
Definition, need, nature and principles. Organizing for Safety, Health
and Environment Organization structure, Functions and
responsibilities.
1.6 Directing for Safety: Definition, process, principles and
techniques, Leadership: Role, functions an attributes of a good leader
1.7 Communication: Purpose, process, types and channels of
communication, process group-dynamics and Team building.
National policy on safety, health and environment at workplace
2.1 Safety, Education and Training: Element of training cycle,
training needs Assessment. Techniques of training, design and
development of training programs module, Training methods and
2 strategies types of training. Evaluation and review of training 50
programs.
2.2 Competence Building Techniques (CBT)
Role of Multi-Media, Communication, Applications of Computers
3.1 Employee Participation in Safety :
Purpose, areas of participation, methods, Role of trade union in
Safety Health and Environment Protection. Safety committee –
structure and functions, Tool box talks, safety kaizen, one point lesson
3 62
, safety Promotion and Safety Awards(National state level and unit
level ) and Suggestion Schemes, Safety Competitions, Safety
Incentives, Publicity Schemes, Audio Visual Publicity, other
Promotional Methods
Behavior Based safety ( BBS) :
4.1 Human behavior: Individual differences, Cause of behavior
changes, Behavior as function of self and situation, perception of
danger and acceptance of risk, knowledge and responsibility vis-à-vis
4 safety performance, theories of motivation and their application to 68
safety role of supervisors and safety Departments in motivation.
4.2 Conflict & Frustration: Identification of situations leading to
conflict and frustration and techniques of management

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

5.1 M anagement information System (M I S) :

Sources of information on Safety, Health and Environment,
compilation and collation of information, Analysis & modern methods
5 of programming, storing and retrieval of information for Safety, 87
Health and Environment.
5.2 Computer utilization in safety, health and environment (SHE)
Software development
Accidents Prevention:
6.1 Principles of Accidents Prevention
Program / Plan theories of accident causation, Need of accident
prevention, cause of accident, accident prevention Models, Heinrich
6 Theory, frank bird model, Domino model, motivation for safety 104
accident proneness. Accident cost direct and indirect , Role of
supervisor in accident prevention , Role of workmen, Role of
management, Role of trade union ,Role of factory Medical officer ,
Role of safety officer.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Chapter 1

1.1 Introduction:
Safety Management Defined : Safety management is a management who establish,
motivate and co-ordinate the safety objectives by the process of planning, organizing,
staffing, directing and controlling to achieve those objectives and also have a continual
improvement in the same.
Safety Management Principles
1. Authority and Responsibility - Authority is the right to give orders and power. Official
authority is derived from the post one holds while personal authority is given as per
intelligence, experience and knowledge one holds. Chain of authority runs from the
highest authority to the lowest rank. Responsibility means an obligation to perform duty
(task) in a satisfactory manner. Accountability give success to management System
2. Safe operating System – Indentifying the defects of operational System, monitoring of
various procedures & Controls & taking CAPA
3. MAH Control: Necessary checks & Control on unsafe Conditions which may cause
serious Accidents or Major hazards.
4. Safety Targets: Setting Safety Targets by proper planning & Control.
5. Safety Programme: Execution of Safety Management Programme for rectifying Unsafe
Act & Unsafe Conditions which are the main causes of Accidents.
6. Discipline - Discipline must work throughout an organization for smooth functioning.
Clear understanding between workers and management regarding their Safety rules,
regulations, orders.
7. Communication: Proper communication between the top management & Bottom line
regarding Objectives & Safety Systems.
8. Initiative - Employees should be given scope for initiative to prepare and execute safety
Programme planned by safety management. It helps in growth and development of man &
management.
9. Team Spirit - Instead of 'divide and rule' management should install team spirit, co-
operation and harmony among workers to make the management united and powerful.
Types of Management: Management is an integral role in any business or organization;
They have to utilize 5M resources like Man, Machine, Material, Money & Method. The
objective for the manager is PDCA and implements those resources in a way which will
achieve the best results for the company.
Different Types of Management:
Democratic management: (Lokshahi) In this style, management decisions are agreed upon
by the majority of employees, By involving the employees, management will make the right

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

decisions and harvest new ideas from the people who are involved in the day to day business
of the company.
Autocratic Management: Here, decisions are made quickly and forcefully without
involvement from anyone else. Other people’s judgments and suggestions are usually neither
listened to nor considered.
Laissez-faire management: The Laissez-faire management will take a back seat role,
providing guidance when needed; the employees are allowed to let their own ideas and
creativity flourish in their specific areas. The manager is looked upon as more of a mentor
(main coordinator) than a leader.
Paternalistic Management: It encourages feedback from the workers to the leaders,
essentially to maintain good morale and loyalty. It is the manager who will make the final
decision, but the leader will listen to ideas and suggestions from the workers. Decisions are
usually made in the best interest of the employees and business.
Different Management Levels
Top-level Management: Top-level managers are the big bosses, Managing Director & Board
of Directors. They are responsible for overseeing and organizing the entire organization.
Middle-level Management: They are HODs & Managers answerable to the top-level
managers. The role of middle management is to execute and monitor organizational plans
handed down from the top-level managers.
Low-level Management: Low-level managers are usually responsible for general
supervision and motivation; examples of low-level managers are Supervisors, Safety
Representatives & workers. Low-level managers are accountable to the middle-level
managers.
Manager ultimately has to be flexible, certain situations call for a certain styles of
management. Each style of management has their advantages and disadvantages, sticking to
one rigid management model have disadvantages
Types of Safety Organization: There are seven types of organization: '
1. Line, military (Autocratic Management) scalar (Grade-wise authority) or vertical
organization. (Occupier-plant head-dept. head-line managers & staff-)
2. Line & staff organization. (Democratic management)
3. Functional organization. (More Importance is given to function)
4. Product organization. ( R & D is much involved )
5. Project organization. (Project separate or inside the existing Factory)
6. Matrix organization, and (MBO or MBR organization)

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

7. Committees.( Committees for every function)

1.2 General principles of Management

General and Scientific Functions:
The Scientific Method of Management considers more productive or improved
method of management by careful and accurate classification of facts, their sequence and
correlation, discovery of scientific laws and its impartial application, new concepts,
experiments and observations. The six functions of scientific safety management are:
1. Planning: It includes setting safety objectives, formulating safety policy, safety
programming, budgeting and determining SOPs. Good planning at the design stage always
helps. Planning for site, effluent disposal, facilities for storing and handling raw materials,
intermediates and products, types of floor, roof, construction, lighting, ventilation, layout of
machinery, pressure vessels, lifting machines, hazardous processes, boilers, storage tanks,
repair services, auxiliaries, utilities, fire protection, training, welfare and sanitary facilities
etc., must consider safety points at this initial stage so that the planning and design defects
can be eliminated or minimized from the beginning. Previous plans approval and correction
after operation are also necessary.
2. Organizing: Structure of authorized team through which work subdivisions are defined,
arranged, and co-ordinate for the planned safety objectives. An organizational set-up
describes three classes of management - Top, Middle and Supervisory management. The set-
up may vary according to the size and nature of establishment. The Company Board decides
the safety policy and objectives and monitors its implementation. Safety department reports
to MD. Managers are answerable to the Safety Department Supervisors are reportable to the
Managers for shop floor. Workers are responsible to their supervisors. Safety Representatives
selected from workers and supervisors advise and assist to Safety Committee. Safety
Committee advises on all matters of safety and health to the Managers and the Managing
Director.
3. Staffing: Recruitment and training the staff and maintaining safe and favourable
conditions of work through personnel.
4. Analyzing: Delegation of duties to the Staff function as per Policy Statement
5. Directing: It is a continuous task of taking decisions, ordering, instructing, guiding and
advising on all matters of safety.
6. Decision Making : For sustainability ( Plant, People & Planet )

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

7. Controlling: Performing, evaluating and correcting the performance according to

objectives, procedures and plans. It is concerned with quality, times, uses and cost in safety.
8. Coordinating: It includes interrelating and synchronizing the different activities for
Achieving safety goals.
9. Interacting: Step for fulfilling Safety Objectives.
10. Financial: Providing budget for SHE management Programme
11. Personal: Improving BBS
Authority & Responsibility in Safety Management: A manager alone cannot
perform all the tasks assigned to him. In order to meet the targets, the manager should
delegate authority.
Delegation of Authority means division of authority and powers downwards to the
subordinate. Delegation is about entrusting someone else to do parts of your job.
Delegation of authority can be defined as subdivision and sub-allocation of powers to the
subordinates in order to achieve effective results.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Authority - in context of a business organization, authority can be defined as the power

and right of a person to use and allocate the resources efficiently, to take decisions and to
give orders so as to achieve the organizational objectives. Authority must be well- defined.
All people who have the authority should know what is the scope of their authority is and
they shouldn’t mis-utilize it. Authority is the right to give commands, orders and get the
things done. The top level management has greatest authority. Authority always flows from
top to bottom. It explains how a superior gets work done from his subordinate by clearly
explaining what is expected of him and how he should go about it. Authority should be
accompanied with an equal amount of responsibility. Delegating the authority to someone
else doesn’t imply escaping from accountability. Accountability still rest with the person
having the utmost authority.
Responsibility - is the duty of the person to complete the task assigned to him. A person
who is given the responsibility should ensure that he accomplishes the tasks assigned to him.
If the tasks for which he was held responsible are not completed, then he should not give
explanations or excuses. Responsibility without adequate authority leads to discontent and
dissatisfaction among the person. Responsibility flows from bottom to top. The middle level
and lower level management holds more responsibility. The person held responsible for a job
is answerable for it. If he performs the tasks assigned as expected, he is bound for praises.
While if he doesn’t accomplish tasks assigned as expected, then also he is answerable for
that.
Accountability:- means giving explanations for any variance in the actual performance
from the expectations. Accountability cannot be delegated. For example, if ’A’ is given a task
with sufficient authority, and ’A’ delegates this task to B and asks him to ensure that task is
done well, responsibility rest with ’B’, but accountability still rest with ’A’. The top level
management is most accountable. Being accountable means being innovative as the person
will think beyond his scope of job. Accountability, in short, means being answerable for the
end result. Accountability can’t be escaped. It arises from responsibility.
Power : Power means ability or capacity to do something, to act, to control, to exercise
force or command etc. Power also comes with authority because authority gives right and that
right gives power. Powerless person cannot do anything. Manager without power cannot
manage things, subordinates do not follow his orders and goals of management can never be
achieved. Therefore, power should be vested by giving authority to manager. In case of doubt
or ambiguity, powers are to be assumed by the manager to get the work done. Power is to be
exercised with due care and reasonable requirement. Undue use of power may create
opposition. A manager's power may be measured in term of his ability to give order or
reward, punish individuals, withdraw order or reward etc. Power is an important means to
enforce obedience to the rules, regulations and decisions of the organization. Its use

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

(exercise) may affect the behavior of people. Distinction between authority and power can be
explained as under :
No. Authority Power

1 Right to do or command. Ability to do or command.

2 Derived from position in organization or Derived from many sources like
institution. authority, seniority, knowledge,
competence etc.
3 Flows downward – can be delegated. Flows in all direction – cannot be
delegated.
4 Legitimate – resides in the position. May be illegitimate, extra constitutional
or assumed.
5 Increases as one goes up in hierarchy. May or may not accompany increase in
authority.
6 Right to allocate resources. Ability to control resources.
7 Narrow term- one source or subset of Broad concept – can achieve result when
power. authority fails.
8 Visible from organization chart. It is Not visible from organization chart.
institutionalized power.
Thus, authority, responsibility and power go side by side and are useful tools for managers to
achieve the organizational goals.
Delegation of authority is the base of superior-subordinate relationship, it involves
following steps:-
Assignment of Duties - The delegator first tries to define the task and duties to the
subordinate. He also has to define the result expected from the subordinates. Clarity of duty
as well as result expected has to be the first step in delegation.
Granting of authority - Subdivision of authority takes place when a superior divides and
shares his authority with the subordinate. It is for this reason; every subordinate should be
given enough independence to carry the task given to him by his superiors. The managers at
all levels delegate authority and power which is attached to their job positions. The
subdivision of powers is very important to get effective results.
Creating Responsibility and Accountability - The delegation process does not end once
powers are granted to the subordinates. They at the same time have to be obligatory towards
the duties assigned to them. Responsibility is said to be the factor or obligation of an
individual to carry out his duties in best of his ability as per the directions of superior.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Responsibility is very important. Therefore, it is that which gives effectiveness to authority.

At the same time, responsibility is absolute and cannot be shifted. Accountability, on the
others hand, is the obligation of the individual to carry out his duties as per the standards of
performance. Therefore, it is said that authority is delegated, responsibility is created and
accountability is imposed. Accountability arises out of responsibility and responsibility arises
out of authority. Therefore, it becomes important that with every authority position an equal
and opposite responsibility should be attached.
Relationship between Authority and Responsibility Authority is the legal right of person
or superior to command his subordinates while accountability is the obligation of individual
to carry out his duties as per standards of performance Authority flows from the superiors to
subordinates, in which orders and instructions are given to subordinates to complete the task.
It is only through authority, a manager exercises control. In a way through exercising the
control the superior is demanding accountability from subordinates. If the marketing manager
directs the sales supervisor for 50 units of sale to be undertaken in a month. If the above
standards are not accomplished, it is the marketing manager who will be accountable to the
chief executive officer. Therefore, we can say that authority flows from top to bottom and
responsibility flows from bottom to top. Accountability is a result of responsibility and
responsibility is result of authority. Therefore, for every authority an equal accountability is
attached.
Differences between Authority and Responsibility

Authority Responsibility

It is the legal right of a It is the obligation of subordinate to

person or a superior to perform the work assigned to him.
command his subordinates.

Authority is attached to the Responsibility arises out of superior-

position of a superior in subordinate relationship in which
concern. subordinate agrees to carry out duty given
to him.

Authority can be delegated Responsibility cannot be shifted and is

by a superior to a absolute
subordinate

It flows from top to bottom. It flows from bottom to top.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Span of Management (PWD-CCCATT): Refers to the number of subordinates that

a manger can efficiently manage. Number of subordinate directly reporting to a manager is
known as span. Span of management is important for determining the complexity of an
individual manager’s job and Determining shape and structure of the organization. Fewer the
number of subordinates reporting to a manger larger the number of managers required.
Therefore span for control should be fixed.
Factors determining the span of management: (PWD – CCCATT)
Planning: If the planning is effectively done particularly if standing plans procedures rules
methods are clear then subordinates can make their decisions on their own. If they have to
make their own plans they would require more guidelines by superiors and manager can
handle narrow span in the case of improper planning.
Nature of work: If subordinates are performing similar and repetitive routine work they can
do their work without having much time of the manager. Frequent changes in work would
require more detailed instructions from manager whenever there is change in work. Type of
technology used also affects the span of control.
Distance of subordinates: If all the persons to be supervised are located at same place within
the direct supervision of manager, he can supervise more number of people. If subordinates
are at different locations then manager can supervise less number of spans.
Capacity of manager: Each manager has different capacity and ability in terms of decision
making, leadership, communication, judgment, guidance and control etc. mangers having
more abilities in respect to these factors may have more number of subordinates.
Capacity of subordinates: capacity of subordinates also affects the span of a manager.
Efficient and trained subordinates may work without much help of their manager. They may
just need broad guidelines and they will perform accordingly. They would require lesser time
from their superior due to which manager can have large number of subordinates under him.
Communication System: If communication system is modern i.e. tools like electronic
devices will save time of face to face interaction, which require more time, span of manager
can be increased
Ability of Management: Ability of management also affects the span. Higher the Ability of
management lesser the number of subordinates as higher ability management does not have
much time to supervise. They spend their most of time in planning and other functions.
Time: Time available affects the span. If manager clearly delegates his authority and defines
it fully this would require less time to devote to manage his subordinates as subordinates will
take most of the actions by their own. Hence manager can have wider span.
Techniques: Use of effective Techniques can boost efficiency of management to achieve the
objectives.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

1.3 Safety, Health and Environment:

The safety department is found in all types of plant the function and responsibility of the
safety department are as follows:
1. To arrange for education & training on safety for the personal. This includes proper
motivation to the workers coupled with in calculating the spirit of safety among them.
2. To maintain adequate safety standard conforming to safety laws as envisaged by central,
state & local authorities.
3. To improve and promote the safety system & to advise and safety management this
includes safety campaigns, safety communication system. Safety research and
development programs etc.
4. To access, review and grant approval to safety norms, procedure & policy related to plant
safety & occupational safety.
5. To carry out safety Inspection & Surveys & accident inspection s pertaining to safety.
6. To identify unsafe conditions & Act and try to suggest suitable measures for rectification
of the condition of a worker affected by these condition or act.
7. Assist & advise for Accident Investigation also investigate peculiar Accidents.
1.4 Role of Management in Industrial Safety:
Planning : It includes setting safety objectives, formulating safety policy, safety
programming, budgeting and determining SOPs. Good planning at the design stage always
helps. Planning for site, effluent disposal, facilities for storing and handling raw materials,
intermediates and products, types of floor, roof, construction, lighting, ventilation, layout of
machinery, pressure vessels, lifting machines, hazardous processes, boilers, storage tanks,
repair services, auxiliaries, utilities, fire protection, training, welfare and sanitary facilities
etc., must consider safety points at this initial stage so that the planning and design defects
can be eliminated or minimized from the beginning. Previous plans approval and correction
after operation are also necessary.
Organising: Structure of authorized team through which work subdivisions are defined,
arranged, and co-ordinate for the planned safety objectives.
An organizational set-up describes three classes of management - Top, Middle and
Supervisory management. The set-up may vary according to the size and nature of
establishment.
Organization Behaviaraion Human Factors contributing to Accident:
1. Not following Pathway while coming in or going out the shop floor.
2. Not crossing roads inside the Factory from level crossing.
3. Not wearing Safety Goggle where foreign particles are flying
4. Improper wearing of safety Goggle
5. Not wearing Ear Protection in Noisy area.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

6. Not wearing Safety Harness while working at Height

7. Not acquiring Hook of Safety Harness to rigid Structure while working at Height or
working on ACC sheet.
8. Using bad words, playing, distressing, in the shop floor.
9. Throwing tool to the coworker instead of giving in hand.
10. Inserting open wire in the Electrical Socket
11. Stopping Blades of Industrial Fan by hand instead of allowing to stop at its own.
12. Working on unguarded machinery.
13. Not using Welding Screen while welding.
14. Forklift not blowing horn while taking turn
15. Not stripping Chin band while using Helmet
Organization Behavior and Safety Human Factor Contributing To
Accident
• Human factors contributing to accident: - Human error is the major contributing
factor for occurrence of accident. Many a time an operator either forget to perform a correct
thing in right manner or performs a wrong thing such as unsafe act can be attributed to
physical deficiencies in the individual for his attitude towards the job. Any physical and the
psychological deficiency factor associated with the person can i.e. detect in the pre -
employment examination. It will avoid the miss much of specific job requirement and the
personal quality of the individual. This will help to reduce accident possibilities on the job
due to physical deficiencies of employee.
• Individual Differences: - It is matter of common experience that people differ from
one another. There physical appearance and traits such as height, strength intelligence, ability
of work, memory, speed of reacting a signal, honest or emotional stability and mental traits.
Personality traits, sensory capacities, muscular co – ordination etc are some of the factor of
individual differences.
Classification of differences: -
a) Individual variable (Human Factor): - Aptitudes, personality characteristics, physical
characteristics interest & motivation age and other personal variables.
b) Situational variables (Environment Factor): -
1. Work place variables: - Physical environment, work place & arrangement, design &
condition of work equipment, and method of work.
2. Organizational & social variables: - Character of the organization, type of training &
supervision, type of incentives & social environment.
• Perception of danger and risk: - Different person have different degree of
perception of danger and risk. Due to individual differences capacity of understanding and

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

identifying the hazard differs while crossing highway, open person may have correct
judgment of chances of accident lowing to the distance and speed of the vehicles coming
from sides different working have difference of opinion or judgment regarding hazard
arising out of moving machinery of risk from chemicals.
In danger then important think is the response time required for quick action to protect
our self or other from the danger or risk slow response time indicates more chance of
accidents and vice – versa. Safety training can help to improve ability of good perception of
danger and risk & help to minimize accidents.
BEHAVIOUR BASED SAFETY (BBS)
This is a psychological approach to improve human behavior for the purpose of reducing accidents.
Criteria and Strategies: Psychological concept of 'behavioral safety' or behavior based
safety (BBS) was studied and applied during the years 1968 to 1972 by Aubrey Daniels,
Wanda Myers and others. The research continued and studies during last 15 years showed
good results that by observing and changing behaviors of the workers (motivation), accidents
can be reduced significantly.
In Hawthorne studies (Part 8.3.1) it was found that 'behavioral approach' was giving good
results (accident reduction) than the changes in effects of working conditions like lighting,
working hours, rest interval etc. This is die base of BBS concept.
In BBS approach, 'safe behaviors’ are targeted, decided and explained to the workers.
Then performance of these behaviors is observed. It is also called performance management.
Feedback is obtained and reduction in accident rate is measured.
Sometimes a 'design team' is formed by selecting shop-floor workers including
representative of supervision and safety department.
This team decides following steps:
1. How to observe unsafe practices or acts and to design observation criteria for this.
2. Coaching process to give brief guidelines to improve safety -behaviors to eliminate or reduce
those unsafe acts.
3. Plan to use data of observations regarding unsafe acts.
4. Plan to support the process of improvement (motivation for target).
5. Plan training if still required.
6. Plan for maintaining the process.
Thus by such systemic planning, behavioral psychology is used to promote safety at work.
BBS approach proceeds as under:

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

1. Observing unsafe behaviors or acts of the workers in the organization and collecting then
data.
2. Defining a set of model behaviors to reduce the unsafe acts..
3. To give short duration training to workers regarding their unsafe acts, management
observations and explaining safe (model) behaviors.
4. Observing new (improved) behaviors and recording their consistency and frequency.
5. Getting feedback and supporting new behaviors.
6. Data collected is used for recognition, problem solving and continuous improvement.
Management Techniques: Management control for implementing above
BBS concept includes following techniques:
1. Design team of selected workers to record observations, develop support materials and
provide training.
2. Identify elements or targets and decide steps to focus on each of them.
3. Organize a full day meeting instead of one or two hours meeting to plan the process after
full discussion.
4. Design own steps instead of copying the same from other companies.
5. Do not waste time to complete training of all the workers. Start implementation after
training some 20% workers and continue training for others. Thus the time cycle will
begin soon to observe the result.
6. Avoid unnecessary training of team members. Those who are already trained need not
require training.
Planning for Safety: Planning is the most fundamental and the first function or element of
management process. Other functions rest on it- Need for planning is increasing because of
changes in technology, materials, methods, processes, demands, law, government policy,
procedure and competition.
Definitions of General Planning :
1.Henry Fayol - Planning refers to a preview of future activities.
2.UrWick - It is fundamentally a mental predisposition to do things in an orderly way, to
think before acting and to act in the light of facts rather than of guesses.
3.Haynes & Massie - Planning is that function of manager in which he decides in advance
what he will do. It is a decision making process of a special kind, its essence is futurity.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

4.Koontz and O'Donnell -It is an intellectual process, a conscious determination of course of

action, the basing of decisions on purpose, facts and considered estimates.
5.George R. Terry - Planning is the selecting and relating of facts and using of assumptions
regarding the future in the visualization of formulation of proposed activities believed
necessary to achieve desired goals.
6.Dalton McFarland - It is defined as the activity by which managers analyze present
conditions to determine ways of reaching a desired future stage. It embodies the skills of
anticipation, influencing and controlling the nature and direction of change.
7.Theo Haimann - Planning is the function that determines in advance what should be done.
It consists of selecting the enterprise objectives, policies, programmes, procedures and other
means of achieving these objectives .Planning is a process, as explained by above tinkers, and
a 'plan' is the outcome of this process.
Safety Planning defined : From above general definitions, we can define safety planning as
the first step of safety management wherein a safety manager decides in advance safety
objectives, policy, procedure, strategies, rules, programmes, methods, budgets, schedules and
necessary means for achieving these objectives, considering facts (of accidents and other
hazards) and anticipating foreseeable events that may affect safety of plant, people and
environment.
Purpose (importance) of General Planning :
Purpose, importance, significance, advantages or utility of planning are summarized as under
a) Focuses on Objectives and results.
b) Activities become purposeful and orderly.
c) Reduces uncertainly, risk, wastage etc.
d) Helps in controlling future events (loss).
e) Helps in saving of costs.
f) Imparts accuracy.
g) Helps other functions of management i.e. organizing, staffing, budgeting, directing,
controlling
h) Provides direction.
i) Creates healthy organizational climate.
j) Provides framework.
k) Helps to visualize a clear and complete picture of the business or activity.
l) Secures co-operation from employees.
m) Maintains balance between various activities.
n) Encourages innovation and creativity.
o) Guides decision making.
p) Provides basis for decentralization.
q) Provides efficiency in operations.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Purpose (Areas) of Safety Planning: It includes all above 17 aspects with reference to
health and safety of workers and public, safety of plant and surrounding environment, and
prevention of total losses. Some subjects of safety planning are given below.
1. To draft health and safety policy and environmental policy for the management.
2. To decide safety committee, its objectives and effective functioning.
3. To decide safety targets like zero/minimum accidents, maximum working hours
without accident, safety education, training and awareness programmes for the
workers and the public.
4. Areas of hazards and their detection, inspection, audit, risk assessment and measures
for their removal or minimization.
5. Accidents investigation, analysis, costs calculation and introducing safety measures to
prevent their recurrence.
6. Organization structure, staff, key persons and their roles for safety.
7. Standards for safety equipment, tools, permissible exposures etc.
8. Preparation, rehearsal and updating of on-site emergency plans.
9. Details of safe or standard operating procedures (SOP), close-down procedures,
methods, fire fighting procedures, emergency preparedness, first-aid etc.
10. Testing, inspection and records of lifting machines, pressure vessels, ventilation,
lighting, safe environment etc., as per statutory need.
11. Medical examination of workers, records and corrective action as directed by doctors.
12. Compliance of statutory and non-statutory safety provisions, their records and
reporting.
13. Search for safe and clean technology for the process and hazard control techniques for
detection and removal of all hidden hazards.
14. Follow-up action, evaluation of safety programmes and improvement of future plans,
strategies etc.
15. Planning to achieve national and international standards, awards etc.
Nature of Planning: Nature, features or characteristics of planning are as under
a) It is a primary and most important function of management.
b) It is goal oriented.
c) It is an intellectual or rational process.
d) It is pervasive; it encompasses all levels of management.
e) It is a continuous process (function).
f) It is conscious activity.
g) It is flexible.
h) Forecasting or forward looking is the essence of planning.
i) Accuracy is essential to planning.
j) It is a choice of alternatives.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

k) It is concerned with group objectives.

l) It is an integrated process.
m) It is directed towards efficiency and achievement of decided goals.
Scope of Planning: Factors (Limitations / Constraints) affecting scope of Planning:
They are:
a) Inaccuracy.
b) Time consumption.
c) Rigidity.
d) Cost.
e) Attitudes of management.
f) Faults in planning system i.e. lack of reward, lack of participation or specific
activities and incompetence of the planner.
g) Lack of orientation and training for managers.
h) Uncertainty.
i) Resistance to change.
j) False sense of security.
k) Environmental constraints i.e. technological, social, legal, economic and other
outside forces.

Effective Planning: According to Gray Dessler, managers should consider following points
to plan effectively.

a) Develop accurate forecasts.

b) Gain acceptance for the plan.
c) Plan must be sound one.
d) Develop effective planning organization.
e) Be objective.
f) Measure firm's market value.
g) Decide in advance the criteria for abandoning a project.
h) Set up a monitoring system. (Get Idea of where are we so far)
i) Revise long-term plans every year. ( Mfg. of Vehicles As per Mkt. demand)
j) Fit the plan to the situation.(Changes in Quality rivaling to our competitors)
Plans should be simple, easy to understand, clear to followers, selective, thorough, based
on well defined objectives, flexible to adopt changes, balanced, comprehensive, economical,
practical and should provide standards for evaluation procedure and, proper analysis and
classification of actions.

18
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Procedure for Planning: Procedure (steps) of Planning:

Basic steps in planning are as under
1. Identify problems.
2. Establish objectives (goals).
3. Develop 'planning premises' (e.g. land, labour, capital, market, money, time, production,
public relation, employee relation, reputation, morals, policy, programmes, rules,
emergencies, new inventions, population trends, supply position; economic,
technological, political and social conditions etc.)
4. Determine alternative courses of action.
5. Evaluate the alternatives.
6. Select a course of action.
7. Formulate derivative (final) plan and sub-plans as per need.
These procedural steps are to be applied in planning for safety. Here planning premises
for safety would be safely objectives, safety standards, safety procedures, safety rules, safety
provisions, safety training, safety programmes, safety policy, committee, inspection, audit,
analysis, assessment, accident analysis, other control methods, forecasting of emergencies
and planning for that, development of new methods, purchase policy, safety equipment,
safety reports & records, use of new material, process or technology, process revision and
various subjects of safety including fire, explosion, toxic exposure etc.
A safety manager requires wide knowledge and help of other departmental heads,
consultants, experts etc., while planning on above specialized areas.
Range of Planning: Based on time schedules three types of plans can be prepared as
under-
A. Short-term (operational) plans - For a period up to one year. They are specific and
detailed and cover forms and contents of long term plan. They are prepared on the
basis of strategic and tactical plans. Examples are daily operations, repairs and
maintenance plan, purchase plan, product plan, activity planning, working methods,
procedure, accident investigation & analysis,
B. Medium-term (intermediate) plans - For a period of more than one year and less
than 5 years. They are co-coordinative and tactical in nature. They are less detailed
than short-term plan. Examples are proposed product and its safety aspects,
emergency planning and forecasting of emergencies, refresher courses etc.
C. Long-term (strategic) plans - For a period of 5, 10, 15 or more years. It considers
future changes in environment and provides overall targets toward which all
activities of the organization are to be directed. It results in long term commitment of

19
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

resources. It takes a macro view of the organization and provides direction for the
growth of the enterprise. It involves uncertainty because of the long period.
Examples are environmental impact assessment, future opportunities, scientific
development and its forecasting, future need of people and market trends, future
expansion, competition etc.
Variety (types) of Plans: They are classified as under –
1. Based on objectives - Production plan, sales plan, financial plan, investment plan,
expansion plan, research and development plan, training plan, existing business plan,
reform oriented plan etc.
2. Based on time - Short, medium and long term plans as explained earlier.
3. Single use plan - Programmer projects, budgets etc.
(Fire Detection System in 1st Phase & Fire extinguishing System in Second Phase)
4. Repeated use (standing) plans - they consider objectives, policies, procedures, rules and
strategies.
Strategic planning: The word 'strategy' is used in military indicating its art (technique) of
fighting the enemy. In business or industry it means a special type of plan to meet challenges,
competitions, emergencies and other environmental forces. On-site and off-site emergency
(contingent) plans are the best examples of such strategic planning. Their details are given in
Part 7 of Chapter - 19. Strategic Plan is a master plan for the whole company and is framed
by the chief executive, top level management or experts on the subject.
Definitions:
A. McFarland - Strategy is the executive behavior whose purpose is to achieve success for
the company or personal goals in a competitive environment based on the actual or
probable action of others.
B. Stoner and Wankel - Strategic planning is the formalized, long range planning process
used to define and achieve organizational goals.
C. Koontz and Weihrich - Strategic planning means to analyze the current and expected
future situation, determine the direction of the firm and develop means for achieving
the mission.
D. L. Cleland and W.R. King -Strategy is the complex plan for bringing the organization
from a given posture to a desired position in a future period of time.
Thus strategic planning links the resources of the organization with the risks and
challenges posed by external forces and lays down a long-term direction for the enterprise.
In this sense strategic safety plans means on-site and off-site emergency plans to fight
internal and external grave emergencies and long-term s public awareness and
involvement programmes to deal with public or massive emergency due to industrial disaster.

20
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Nature (characteristics) of Strategic Planning :

1. It is a long-term planning to fight future external forces.
2. It is action oriented, flexible, and dynamic and forward looking.
3. It deals with basic questions.
4. It is a function of the top management.
5. It becomes a base for the detailed plans.
6. It focuses on energies and resources.
7. It analyses the environment.
8. It evolves assumption of certain calculated risks.
9. It is a contingent plan to meet demands of a particular situation.

Essentials (evaluation) of a good strategic plans: Factors governing are.:

a) Internal consistency.
b) Consistency with environment.
c) Appropriate time horizon.
d) Realistic.
e) Acceptable degree of risk.
f) Feasibility and
g) Social or legal sanction.
Need of Strategic Planning: Need, advantages or importance of strategic planning are :
a) Helps in facing environmental or future challenges.
b) Provides direction.
c) Improved functioning.
d) Exploiting favorable opportunities.
e) Minimization of chances of mistakes or losses.
f) Effective/efficient utilization of resources like time, money, talent, equipment etc.
g) Facilities co-ordination and control
h) Competitive strength.
Process (steps) of Strategic Planning :
a. Decide mission and long range objectives.
b. Collect and analyse relevant information.
c. Assess the environmental and risk factors.
d. Conduct - resource audit (self-appraisal).

21
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

e. Think of strategic alternatives.

f. Select the best alternative (decision making).
g. Implement and control it.

Develop programmes and budgets for each function. Short term operational plan should b(
prepared to utilize the resources. Proper sequence and timing efforts are decided to take every
step at the right time. Performance should be evaluated, where result; are below expectations,
strategy should be reviewed and modified as per need.
Strategic Planning:

The word 'strategy' is used in military indicating its art (technique) of fighting the enemy. In
business or industry it means a special type of plan to meet challenges, competitions,
emergencies and other environmental forces. On-site and off-site emergency (contingent)
plans are the best examples of such strategic planning. Their details are given. Strategic Plan
is a master plan for the whole company and is framed by the chief executive, top level
management or experts on the subject.
Definitions:
1. McFarland - Strategy is the executive behaviour whose purpose is to achieve success for
the company or personal goals in a competitive environment based on the actual or probable
action of others.
2. Stoner and Wankel - Strategic planning is the formalised, long range planning process
used to define and achieve organisational goals.
3. Koontz and Weihrich - Strategic planning means to analyse the current and expected
future situation, determine the direction of the firm and develop means for achieving the
mission.
4. D. L. Cleland and W.R. King -Strategy is the complex plan for bringing the organisation
from a given posture to a desired position in a future period of time.
Thus strategic planning links the resources of the organisation with the risks and challenges
posed by external forces and lays down a long-term direction for the enterprise. In this sense
strategic safety plans means on-site and off-site emergency plans to fight internal and
external grave emergencies and long-term s public awareness and involvement
programmes to deal with public or massive emergency due to industrial disaster.

22
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Nature (characteristics) of Strategic Planning :

1. It is a long-term planning to fight future external forces.
2. It is action oriented, flexible, and dynamic and forward looking.
3. It deals with basic questions.
4. It is a function of the top management.
5. It becomes a base for the detailed plans.
6. It focuses on energies and resources.
7. It analyses the environment.
8. It evolves assumption of certain calculated risks.
9. It is a contingent plan to meet demands of a particular situation.
Essentials (evaluation) of a good strategic plans: Factors governing are:
1. Internal consistency. (Preventive Maintenance like working of Emergency devices)
2. Consistency with environment. (Direction of Air- Wind-sack used)
3. Appropriate time horizon. (6 monthly mock-drill)
4. Realistic.
5. Acceptable degree of risk. (Leakage, Fire, explosion by LPG)
6. Feasibility and (Social or legal sanction.(OEP guidelines in 13 points are given in F.A &
EP Act)
Need of Strategic Planning : Need, advantages or importance of strategic planning are :
1. Helps in facing environmental or future challenges.
2. Provides direction. (Assembly Point, Evacuation)
3. Improved functioning. (By repeated Mock-drills & revising OEP)
4. Exploiting favorable opportunities.
5. Minimization of chances of mistakes or losses. (Preventive Maintenance.)
6. Effective/efficient utilization of resources like time, money, talent, equipment etc.
7. Facilities co-ordination and control
8. Competitive strength.
Process (steps) of Strategic Planning :
1. Decide mission and long range objectives. (viz. OEP)
2. Collect and analyze relevant information. (Hazan )
3. Assess the environmental and risk factors. (Hazop )
4. Conduct - resource audit (self-appraisal).
5. Think of strategic alternatives.( CNG Instead of LPG –more heat, cheap)
6. Select the best alternative (decision making).
7. Implement and control it.

23
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Develop programmes and budgets for each function. Short term operational plan should b(
prepared to utilize the resources. Proper sequence and timing efforts are decided to take every
step at the right time. Performance should be evaluated, where result; are below expectations,
strategy should be reviewed and modified as per need.
Management by Objectives (MBO) :This concept was first given by Alfred Shown in
1950 but Peter Drucker popularized it in 1954 in his book 'The Practice of Management'.
This approach is also known as management by results, goal management,
performance management and accountability management. It is a system of management
where (i) goals for the business as a whole are set and (ii) managers and staff members at
every organizational level are actively involved in goal setting. The idea is that when
employees are involved in goal setting for them, they will put their heart to achieve them.
Definitions:
a. Peter Drucker - Business performance require that each job be directed towards the
objective of the whole business.
b. George Odiorne - It is a process whereby the superior and subordinate managers of an
organisation jointly identify its common goals, define each individual's major areas of
responsibility in terms of result expected of him and use these measures as guides for
operating the unit and assessing the contribution of each of its members.
c. W. J. Reddin -It is the establishment of objective areas and effectiveness standards '
for management positions and the periodic conversions of these into measurable time
bound objectives linked vertically and horizontally with future planning.
d. S. K. Chakravarty -It is a result oriented non-specialist, operational managerial process
for the effective utilization of the material, physical and human resources of the
organization, by integrating the individual with the organization and the organization
with the environment.
Nature (characteristics) of MBO :
1. It is a system approach integrating all employees for goal setting and achievement.
2. It is a behaviorist approach where human element is recognized at each level.
3. It is democratic approach because it is participative.
4. It measures results with the standards prescribed and suggests corrective measures.
5. It focuses on goals of the individuals and the organization.
6. It has autonomous control because employees are not controlled from outside but they
themselves evaluate their performance in terms of predetermined goals and devise
corrective measures if their performance is below the norms.
7. It boosts up employees' morale and motivation because they are called for participation.

24
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Process (steps) of MBO : Steps in sequence are:

• Set objectives of the organization.
• Set objectives of the departments.
• Set objectives of the individuals.
• Develop action plans.
• Implement plans.
• Take periodic reviews.
• Appraise results.
• Take corrective action for improvement.
Advantages of MBO : They are :
a) Better management.
b) Clarifies organization.
c) Harmony of objectives.
d) Motivation.
e) Evaluation of results.
f) Development of managers.
g) Improvement in superior - subordinate relations.
Scope (limitations) of MBO:
a) Difficulty of introducing for reaching changes.
b) Difficulty in setting goals.
c) Too much emphasis on results.
d) Pressure on employees.
e) Too high expectations.
f) Neglect of some important goals.
g) Not useful for all.
h) Rigidity.
Requisites (preconditions) of MBO :
1. Setting real objectives.
2. Ends - means distinction.
3. Clarity of objectives.
4. Active support from all participants
5. Active support of top management.
6. Three elements that objectives should be - helpful in evaluating performance,
measurable and convertible into targets.
7. Multiple objectives and sub-optimization.
8. Displacement of objectives.
9. Quantitative cum qualitative objectives.
10. Receptivity.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

11. Training for fulfillment of objectives.

12. The 'why' spirit (why cannot be obtained?)
13. Individual growth.
14. Study of environment and flexibility.
15. Provision of performance.
Organization for Safety : It is planned and organized set up of personnel whose purpose is
to do and maintain the combined efforts for the purpose of Safety, Occupational Health and
Environmental protection in an industry .
Definitions: (Different personnel have given their different views)
Overall Definition derived from them about the definitions of organisation are:
1. A business unit is divided into different sections or departments.
2. Each section or department is assigned a definite function or duty.
3. The authority and responsibility of each section or department or a group of people are
clearly defined.
4. The co-ordination among various departments and among the groups of people working in
them is clearly specified. (Who will report to whom?)
General organization structure.

In one sentence Safety Organization is defined as: Safety organization can be defined as
the structure and process by which groups of people (employees) are divided into sections or
departments, each section or department is assigned specific safety function or duty.
Authority and responsibility of everybody is clearly defined and coordination between them
is specified for the accomplishment of organizational safely goals.

26
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Need (Significance) of Organization : Organization is the foundation structure of

management and contributes greatly to success and continuity of an enterprise in the
following ways -
1. Facilitates functions of management process.
2. Facilitates growth and diversification.
3. Providing technological improvements.
4. Encourages use of human beings.
5. Stimulates creativity.
6. Maximum efficiency with minimum costs.
All managerial functions like planning, organizing, staffing, directing, co-coordinating,
controlling, budgeting, etc. are performed through the medium of organization.
Nature (Characteristics) of Organization: Briefly they can be stated as under
1. It is a set up to realize the objectives (common purpose).(Safety Awareness)
2. It is a co-operative activity. (Top to bottom)
3. It is a process (function) and structures both.
4. Division into Departments or groups. Division of labor.
5. Delegation of authority and responsibility. The chain of superior – subordinate
Relationship is known as 'chain of command'. (Authority structure).
6. Importance of human element (people). (Individual is respected. Even foolish
suggestions shall be scrutinized)
7. Vertical and horizontal relationship between man to man, job to job .and department to
department. (Transparency in thought)
8. It is closely linked with planning. Other functions of management are not possible
without organization.
9. It is flexible and accommodates environmental changes.
10. It is stable and resists challenges. (Rugged & accept change)
11. Provides supervision, control and review.
12. Provides mechanism of co-ordination.
13. Provides channels of communication. (Computers, Laptops, Telephones, Mobiles etc.)
14. Provides policies, procedures, rules and regulations for systematic functioning.
Principles of Organization :( Features of a good Organization Structure) : They are
summarized as under
1. Unity of objective - all is geared to common objectives. (Safety DMRs % rise in
annual Appraisal System)
2. Span of organization - each superior has limited subordinates to report him.
3. Single Reporting - each subordinate has only one superior to get command. (To avoid
puzzle
a. from duel reporting)

27
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

4. Scalar principle - clear chain of command from top to bottom.(Grade & reporting)
5. Co-ordination - should exist among all individuals and groups.
6. Communication - should be open and clear. (Transparent - in morning meeting)
Facilitates leadership. (HOD denoted on paper by Circular))
7. Delegation of authority and responsibility - exist by way of delegation.
8. Exception principle - only matters beyond control may be referred to higher levels.
Functions (duties), authority and responsibility of every position should be clearly
defined so as to avoid duplication or overlapping.
9. Efficiency - optimum use of resources at minimum possible costs.
10. Flexibility - should accommodate changes.
11. Stability - should resist challenges.
12. Continuity - by training and development of executives and employees.
13. Balance - between centralization and decentralization.
14. Unity of direction - clear-cut direction at all levels. Directions should be simple, easy
to understand and unambiguous.
Organizing for Safety:
Meaning: The term 'organization' is used in management in different ways as under
1. It refers an activity, process or function of management i.e. organizing.
2. It is used in a dynamic way referring to e process by which the structure is created
maintained and used.
3. It is used in a static way referring a static structure (skeleton) of responsibilities and
authorities i.e. a network & relationships among individuals and positions in an organization.
4. It refers to an ongoing business unit i.e. a unit which is purposefully created to attain some
objectives with resources.
Organizing for SHE Structure: It includes establishment of the formal structure of
authority through which work subdivisions are defined, arranged, and co-ordinate for the
planned safety objectives. An organizational set-up describes four classes of management -
Top, Middle and Supervisory management.
Organizing for Safety, Health and Environment Organization structure, Factions &
Responsibilities
1. Top Management: Company Board & Managing Director & Occupier is the Top
Management. They decide the safety policy and objectives and monitor its
implementation. Managing Director is reportable to the Board for implementation of
safety policy
Occupier: - Occupier is a person who has got ultimate responsibility on the affairs of Safety,
health & Environment on sector level, he is signing legal safety Occupational Health and
environment policy, he is nominated by board of director for the purpose.

28
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Middle Management: Safety HOD or Safety department & Other Dept. Managers & their
HODs: Safety HOD or Safety department report to Chief executive or MD. Other Dept.
Managers are answerable to the Safety Department or Safety HOD for application of the
safety arrangements
Plant head: - Individual plant head of the plant has to implement occupier’s policy in his
plant.
Safety in charge: - He is heading safety officers as per the requirement of his plant.
Safety officers: - They prepare program to implement SHE policy in their unit. They advice
as to how SHE policy is related with the shop function

Safety Department: The safety department is found in all types of plant the function and
responsibility of the safety department are as follows:
To arrange for education & training on safety for the personal. This includes proper
motivation to the workers coupled with in calculating the spirit of safety among them.

29
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

1. To maintain adequate safety standard conforming to safety laws as envisaged by

central, state & local authorities.
2. To improve and promote the safety system & to advise and safety management this
includes safety campaigns, safety communication system. Safety research and
development programs etc.
3. To access, review and grant approval to safety norms, procedure & policy related to
plant safety & occupational safety.
4. To carry out safety Inspection & Surveys & accident inspection s pertaining to safety.
5. To identify unsafe conditions & Act and try to suggest suitable measures for
rectification of the condition of a worker affected by these condition or act.
6. Assist & advise for Accident Investigation also investigate peculiar Accidents
Supervisory Management: Dept. Supervisors are reportable to the Managers for shop floor
implementation of safety policy, rules and procedures. Workers are responsible to their
supervisors for effectively carrying out the safety rules and precautions.
Safety representative: - With the guidance and advice of safety department and their
program, safety representative implement safety policy and safety program in their individual
department for promoting health and safety.
Safety Committee advises on all matters of safety and health to the Departmental Managers
and the Managing Director.

Safety Committee : Structure and Function :

Statutory Provisions: As per F.A 1948 Section 41 and 41 G & Under Maharashtra Factory
Rules 1963 Rule No. 73 J
Applicability:
1. Factories employing 250 or more workers
2. Factories carrying Dangerous Operations under Section 87.
3. Factories carrying Hazardous Process under Section 2(cb) employing more than 50
workers.
Formation, Tenure & Rights: Structure
1. A senior official shall be the Chairman.
2. A Safety Officer or Factory Medical Officer shall be the Secretary.
3. A representative each from the production, maintenance and purchase departments shall
be members.
4. Workers representatives, of equal number, shall be elected by the workers.
5. The tenure of the committee shall be 2 years.
6. At least one meeting in 3 months. Minutes shall be recorded and produced before the
Factory Inspector on demand.
7. The committee has right to ask or seek any information w.r.t. health & safety of workers.

30
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Functions & duties:

1. Co-operation to implement health and safety policy of Occupier.
2. Dealing with all matters of health, safety and environment and arrive to the practicable
solutions to problems in that regard.
3. Creation of safety awareness amongst workers.
4. To conduct educational, training and promotional activities.
5. To discuss reports on safety, health and environmental surveys, safety audits, risk
assessment, emergency plans and implementation of the recommendations of the reports.
6. To carry out health and safety surveys and identify causes of accidents.
7. To look into complaints of imminent danger and suggest corrective measures.
8. To review the implementation of its own recommendations.
9. To form sub-committees, if necessary.

Its Safety Committee Advantages are:

1) It brings together varying view points; yield sounder .decisions than the individual
members.
2) widens interest by allowing participants of work-people in their own .work
3) Allows checks and cross-checks by different opinions which are essential for safety.
Its Safety Committee Disadvantages are:
1) It causes delay in Decisions till the meetings are held.
2) Consumes more time in meetings.
3) May sometimes turn into a trade union meeting if so pulled by the employees.
Therefore its good control to the point is necessary.
Types of Committees :
(1) Main or Central Safety Committee
(2) Plant or Shop Safety Committee
(3) Technical Safety Committee
(4) Special purpose Safety Committee etc.
Technical Safety Committee is useful for specialized knowledge viz. guard design, process
and engineering revision, hazard and risk analysis, special investigation etc. It comprises of
chief engineer, safety engineer/officer, head mechanic, chief chemist and similar expert
technicians. Special Purpose Safety Committee can be setup for specific jobs and dissolved
when its purpose is accomplished. Such jobs include special accident investigation, specific
problems of worker behavior, off-the job safety, rehabilitation or relief problem, safety
celebration or contest or award occasions etc.
For a big concern different safety committees as ' stated above are possible, but in a small
factory a single committee can carry out all functions.

31
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

• Line and Staff Function for Safety, Health and Environment :

Functions of Main/ Central Safety Committee :
(Sector-level having more than Plant. It is legal Committee & signed by the Occupier)

1) To decide safety policy and planning for purchase of equipment with in-built safety
devices, relationship between departments standards to be followed in guarding,
testing designing, layout, housekeeping, material handling and placing, inspections,
accident investigation and records etc.
2) To plan and supervise programmes of safety propaganda, education, training and
maintaining interest of employees in safety.
3) To make arrangement or develop safe work practices and procedures; inspection,
audit and appraisal systems and all efforts to avoid or reduce accidents. To discuss
and control the accident rates.
4) To discuss and initiate action for correction of unsafe conditions and actions. Action
plan should be drawn and suitable dates fixed for completion of each task.
5) To suggest safety devices and protective equipment.
6) To carry out fire drill and rehearsal of on-site emergency plan.
7) To scrutinize safety suggestions received through plant safety committees and to
initiate action to implement the accepted suggestions.
8) To arrange safety competitions and to decide awards for encouragement.(In terms of
kind or money)
9) To improve co-operative spirit between management and employees and among
various departments to promote safety.
10) The safety knowledge of committee members should be increased by arranging
lectures of safety experts of the plant and outside and by sending the members to
seminars. Factories inspectors and safety specialists can be utilized for this purpose.
11) To discuss and approve safety budget.
12) To discuss, distribute and supervise responsibilities for quick compliance of safety
remarks.
13) To suggests changes in safety organization and its activities for better performance.
14) To suggests safety aspects of new design and construction of plant, machinery and
equipment and Process.
15) To decide disciplinary procedures and disposal of specific safety problems.
Functions of Plant Safety Committees are: (Individual Plant in the Sector):
1) Percolate Safety Policy down the line
2) To review accident records.
3) To investigate accidents and to implement corrective actions.
4) To implement directives of the Central Safety Committee.

32
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

5) Enforcement of safety rules, procedures an accepted safe practices.

6) To encourage and enforce the use of persona protective equipment
7) Status of CAPA on Safety inspection rounds of various shops and sections.
8) To encourage safety suggestions from worker and to forward them to the Central
Safety Committee.

Plant Sub-safety Committees: Where the size of the plant is bigger, Safety Sub-Committees
are formed wherein the Safety Representative of the Area is a Secretary, HOD is the
Chairman & equal no. of elected workmen & officers from Production, Purchase &
maintenance are the Members. Apart from the Structure the Functions are similar to that of
Plant Safety Committee,
Line & Staff Organization : 'Line & staff organization' is a combination of line and
functional structures, line of authority flows in a vertical line, but staff specialists are attached
to line positions to advise them on important matters and these specialists do not have power
of command over subordinates in other departments, but they possess it over subordinates in
their own department e.g. Chief Safety Officer has command over safely officers in his
department but he has no command over accounts officer in other department. He has only
advisory relationship with other departments like production, personnel, HRD etc. A common
model of line & staff organization is shown in
No. Advantages Disadvantages
1. Relief to line managers Line-staff conflicts
2. Expert advice (specialization) Confusion in relationships
3. Better decisions Staff becomes ineffective or irresponsible
4. Training of personnel Expensive for small units
5. Flexibility – opportunity for advancement

33
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Line and Staff Organisation

One model of line & staff organization for safety is shown in'. For another model.

34
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Line & Staff Function of Safety:

a) Director or Safety & Health Executive is at the MD of the line of authority.
b) He has PA for assistance. Under him there are Managers for Safety, Occupational
Health, Industrial Hygiene and Environment departments.
c) They are reportable to Director but not to each other. They may consult or advise each
other but cannot compel work.
d) Safety Manager has Safety Officer(s) with staff. They have Safety Supervisors under
them who supervise their respective areas and workers allotted to them.
e) Similarly Health department has doctors under them with OHC.
f) Environment dept. has environment engineers, lab and staff.
General and Scientific Functions :The basic safety role of any industrial management is
well derived from the five steps of accident prevention suggested by H.W. Heinrich. These
are organization, facts finding, analysis of the facts found, selection of remedy and
application of the remedy. The Scientific Method of Management considers more productive
or improved method of management by careful and accurate classification of facts, their
sequence and correlation, discovery of scientific laws and its impartial application, new
concepts, experiments and observations.
The six functions of scientific safety management are:
1. Planning : It includes setting safety objectives, formulating safety policy, safety
programming, budgeting and determining safe or standard procedures. Good planting at the
design stage always helps. Planning for site, effluent disposal, facilities for storing and
handling raw materials, intermediates and products, types of floor, roof, construction,
lighting, ventilation, layout of machinery, pressure vessels, lifting machines, hazardous
processes, boilers, storage tanks, repair services, auxiliaries, utilities, fire protection, training,
welfare and sanitary facilities etc., must consider safety points at this initial stage so that the
planning and design defects can be eliminated or minimized from the beginning. Previous
plans approval and correction after operation are also necessary.
2. Organising: It includes establishment of the formal structure of authority through which
work subdivisions are defined, arranged, and co-ordinate for the planned safety objectives.
An organizational set-up describes four classes of management - Top or Executive,
Intermediate, Middle and Supervisory management. The set-up may vary according to the
size and nature of establishment. A model safety organization is shown in Fig 6.6.
Directing for Safety: (By Board of Directors – Occupier nominated for the purpose- Policy)
Meaning: This process of inspiring and guiding people what to do and how to do the best of
their ability is known as 'directing'. (In Policy who will do what is mentioned)

35
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

STEPS:
Planning to achieve Objective (Zero Accidents) Staffing Organization Structure
Employees are 'directed' to carry the orders. It is that part of the management process which
guides, inspires, instructs and harnesses (Supports) people to work effectively and efficiently
to achieve the goals (Awareness). (PDCA Cycle)
Definitions:
1. Urwick and Brech – Directors (Occupier on behalf of Board of Directors) guiding,
inspiring & leading to conduct core responsibility of management.
2. J. L. Massie - Directing concerns the total manner in which a manager influences the
actions of subordinates..
Process: The process of directing consists of, the following steps: (Ex. Performance
Appraisal System)
a) Issue orders (Goal Setting) and instructions. They should be clear, complete and within
capabilities of the followers. (Achievable & Measurable)
b) Provide and continue guidance and supervision to ensure that the assigned tasks are
carried out effectively and efficiently.( By Meeting)
c) Maintain discipline and reward for good work. (Performance Pay from M.I. to E.S.*)
d) Inspire and motivate to work hard to achieve the goals. (Promotions)
e) Thus motivation, supervision, leadership and communication are the main elements of
directing.
*(M.I. = Must Improve, E.S. Expectation Surpassed.)
Principles of Direction:
They are :
1. Harmony of objectives - Management should take care of personal goals of employees
with the organizational goals. (Core Objective & Dept Objective in Line)
2. Unity of command. - One subordinate should get orders/instructions from one superior
only.(Single Reporting Boss & his reporter)
3. Direct supervision - There should be personal or direct supervision.(By Immediate
Supervisor)
4. Good communication - Helps to improve understanding and speed of work. (Morning
Meeting)
5. Maximum contribution - Managers should try maximum contribution from each
subordinate.
6. Appropriate techniques - The techniques should be suitable to superior, subordinates
and situation to get efficiency.
7. Strategic use of informal organisation - Some informal groups should be contacted to
decide direction. (Outsourced Agencies)
8. Comprehension - Orders should be clear, complete and understandable.(Measurable)

36
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

9. Good Leadership - Managers should guide and counsel subordinates to win their
confidence.
10. Follow-up - Managers should follow-up their orders and modify if necessary.(In
Meetings)
Techniques of Direction : Generally four techniques are available for directing. They are
• delegation of authority, (To listen orders)
• supervision, (To control)
• orders and (Policy)
• Instructions. (Meetings & Shop floor)
Above definitions, principles and techniques of direction are equally applicable to the area of
safety and safety managers should know and follow them while guiding, inspiring,
motivating and instructing workers to detect and remove unsafe conditions and actions and to
maintain safe environment in their day to day activities.
Leadership : Meaning:
It is a tool to make direction effective. Leadership Manages business by instill in them
a) desire to achieve the goals,
b) desire to improve their performance
c) sense of co-operation
d) and If the managers fail to provide such 'leadership the employees will search the
leadership outside which may lead to conflict or distraction.

Definitions: Leadership is a Quality of influencing people to achieve common Goal &

Objective
1. Koontz and. O'Donnell - Leadership is influencing people to follow in the
achievement of common goal.
2. Terry - It is the ability of influencing people to strive willingly for natural objectives.
3. R. T. Livingston - It is the ability to awaken in others the desire to follow a common
objective.
Role and Functions of a Leader :
1. He should be clear about common objectives (goals) and should communicate them
clearly. (On Goal-setting paper)
2. He has to direct his subordinates (influence, guide, instruct, inspire and supervise) to
work efficiently and effectively.
3. He has to inspire followers to achieve the common goal.
4. He works with his followers, shows them how to work and gets their co-operation in
return. (mix with them)

37
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

5. He should convince the followers that in protection of organizational (group) goals,

lies the protection of their personal goals. (As interlinked with the Performance
Appraisal & if Company survives then Employee survives)
6. Provide guidance till the achievement of goals.
7. Depending on situation he should alter, modify or stop order and should not be rigid
in his decision. (Inform Top Management accordingly)
8. He has to set an example by his own behavior ( Can I talk with you…?).
Attributes of a Leader : Certain qualities are necessary for leadership but they must be
applied at the correct place and time. Dr. Terry mentioned following qualities of a leader -
1. Energy - Physical and mental fitness to work by self and to guide for a longer time.
2. Teaching ability - He should be a good teacher. (Communication Skill)
3. Emotional stability- should be free from bias and anger and not emotional.(Boss gives
more facility to liking person & less to others)
4. Empathy - It means the ability to understand other's viewpoint. He should have respect
for others and their beliefs. (Silly suggestions shall not be neglected)
5. Objectivity -He should Understand Others
6. Enthusiasm - Have interest at his own & create in others
7. Knowledge of HR - Leader has to deal with human beings and therefore he should posses
knowledge of human resources. (Personal touch)
8. Communicative skill - He should be effective in his speech, talk and forceful impression.
9.Social skill - He should mix with his followers freely. He should appreciate others' opinion
and work with close co-operation.
10. Technical competence - Doubtlessly he must be technically more competent so that he
can successfully teach technical aspects.
Leadership Styles (Techniques) : They are of three types -
1. Autocratic or Dictatorial leadership.
2. Democratic or Consultative or Participative leadership.
3. Free .Rein or Laissez Faire leadership.
In autocratic leadership subordinates have less freedom which increases in democratic
leadership. Superior enjoys more authority in autocratic leadership arid less authority in
democratic leadership.

Authority of
Superior
Autocratic Democratic
Leadership Freedom leadership
of Subordinates

38
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Autocratic leadership: Relationship of two types of leadership is useful for untrained and
secrecy in decision making is required. Its features are retention of power, relying on orders
only and close supervision.( Training to Apprentices as untrained. Also used in War for
secrecy : Captain & subordinates have to follow orders of Major in Army Example : Hum
Dono )
In democratic or consultative leadership method: The manager consults his subordinates
and invites their suggestions before making decision. Formal or informal meetings are also
held. Here subordinates work heartily because their views and opinions are respected.
Develops trust, co-operation and leadership among employees. This stage is useful when
subordinates are literate, have sense of responsibility and organized. It requires much time in
decision making. (Viz. Steering Committee Meeting: Chairman takes suggestion from HODs
of different shops)
In free - rein leadership technique: The manager delegate authority to his subordinates and
they are encouraged to develop and contribute independent thought and action. This method
is preferred mostly by highly educated and independent (free minded) persons. Here details
are prepared by the subordinates. There is a free communication between superior and his
subordinates. They don't feel difficulty in consulting each other. It is more creative and
develops latent abilities of subordinates. (Viz. While preparing Safety Policy, Factory
Manager or Plant Head signing Authority takes help of Safety Officer . Similarly, while
preparing Corporate Legal Policy Occupier consults Safety HOD + Legal Dept. )
Selection of leadership style depends on (1) force in Manager (2) force in Subordinates and
(3) force in Situation.
In Safety Management, autocratic leadership style is not suitable as safety is not to be
imposed like military discipline, and involvement of employees (educated or uneducated) at
all levels is required. The concept of employees participation, safety committee, safety
education and training and "Safety is everybody's duty" can be well implemented by
democratic or consultative leadership style. In designing safely guard or its improvement by
ergonomic factors, developing safe work method, meeting safety targets by group co-
operation, celebrating safety programme, creating and maintaining safety awareness and
emergency preparedness, suggestions and involvement in decision-making of employees are
most useful. Therefore, democratic leadership style at workers and middle level and free-rein
leadership style at higher (executive) level are desirable for safety management.
Communication :This is another element of the management 'directing' and also useful for
effective motivation, supervision and getting the work done.
Motivation cannot succeed without communication. It is a process involving the
transmission and-reception of message, eliciting meaning in the mind of the receiver and
resulting in appropriate action which is desired.Though one way communication such as
speech, posters, instruction, radio, TV has their uses, two way communications is the only

39
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

effective way to transfer an idea from one mind to another. Two way communications allows
for clarification and amplification.
Safety communication should be more clear, loud and effective. By good efforts
create responses, desires, insight and action as soon as possible. Audio visual display,
transparency arid modern teaching aid should be used for effective communication.
Definitions and Meaning:
1. Haimann - Communication means the process of passing information and understanding
from one person to another. It is the process of imparting ideas and making oneself
understand by others. It is fundamental and vital to all managerial functions.
2. Newman and summer -It is an exchange of facts, ideas, opinions or emotions by two or
more persons.
3. Koontz and O'Donnell -It is an intercourse (Contact ) by words, letters, symbols or
messages, and is a way that one member shares with another.
Chester Bernard has stated "'The first executive function is to develop and maintain a system
of communication". (If a particular man is not there then also Sy. Shall work)
It is communication when we speak, tell, write, read, watch, listen, hear or act or
convey or transmit our message by expression or any other way of understanding feeling,
attitudes, wishes, ideas, opinions, emotions, thoughts etc. Poor communication creates
problem and good communication solves it.
Purpose (Role or significance) of Communication:

1. It is utmost necessary for planning, decision making, organizing, directing and

controlling. (PP, D, CA )
2. Plans cannot be implemented without effective communication.
3. Its basic purpose is to create mutual understanding and to secure desired response.
4. Motivation and morale can be boost up. (Boss not calling for Inauguration of Tr.
Centre)
5. Human relations can be improved. (Personal Touch)
6. Training and development is not possible without communication. (Competence
Building)
7. Co-ordination can be bridged by communication. (When more persons working
together)
8. Public relations can be maintained and strengthened. (Inter-relation)
9. It increases productivity and performance.
10. It assists other functions. (This is a part of co-operation like give & takes policy)
11. It gives job satisfaction. (Boss not communicating when F.I. visits .Informs S.O. to
comply. One S.O. left the job due to no job satisfaction)
12. It is a basis of leadership. (Lacking in communication hamper proper leadership)

40
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

13. It gives success to enterprise. (Because of non-communication unsatisfied Competent

employee quit the organization which may hamper in the success of the Origination)
Process of Communication: According to Shannon and Weaver, it consists of following
components or elements:
1. Sender - One who sends a message?
2. Message - What is conveyed by the sender
3. Encoding - Words, symbols (Activist –Dial 1090, Speed 20 symbol), gestures
(Example) etc. by which the message is transmitted.
4. Channel -Medium or route through which, the message is passed" i.e. face to face, talk,
phone, pager, radio, TV, letter etc. (Video Conference of 4 plants).
5. Receiver- Who receives the message? He may be a listener, reader or observer.(Second
Party)
6. Decoding - The process of understanding or interpreting by the receiver. (Crane
handling)
7. Feedback - Means reply, response or acknowledgement of the receiver that he has
understood the message. It may be by words, actions or expressions. When the sender
receives such feedback, the process of communication becomes complete. See Fig. 6.11
The Process of Communication
Sender Message Encoding
1 2 3

7 Feedback

Decoding Receiver Channel

6 5 4

Nature of Communication :
1. It is a continuous process. Its stoppage means stoppage of human activity (Telephone)
2. It is a two way process between sender and receiver. .(Confined Place)
3. It creates mutual understanding and human relation.(HRD using Appraisal Process)
4. It is a pervasive function i.e. required in all managerial functions(Adjective Influence)

41
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Types of Channels and Media of Communication:

Communication

Channels Media

Oral
Formal Informal Written
(Grapevine, Electronic
in all Gesture
Downward
directions)
Upward
Horizontal
Diagonal Gesture = Deaf & Dump

Channels & Media of Communication: A communication channel is a route through which

messages flow from the sender to the receiver. It is either formal or informal. Formal
(planned or systematic) communication may flow in downward, upward, horizontal or
diagonal direction and creates communication networks. Informal i.e. unofficial or inter-
personal (unplanned and need base) communication flows in all directions and therefore it is
called structure less or grapevine. Type of communication media are oral, written or gesture
i.e. implied or posture.
Their differences are shown below:
No. Formal Communication(Education in Informal Communication(Safety Day
College) Celebration)
1 Official Channel. Unofficial Channel.
2 Intentional, deliberate, planned or Interpersonal, unplanned or spontaneous.
systematic. (Organizational Structure)
3 Impersonal. ( For all Students) Personal and Social. (Safety is everybody’s
concern)
4 Slow and structured. ( For Academic Fast and unstructured. ( Boss told to
Year+ Subjects, Syllabus or Curriculum Celebrated & Principal planned for the same)
with Chapters
5 Stable and rigid. Flexible and unstable. (One can do others role
)
6 Oriented towards goals and tasks. (Pass in Directed towards goals and need satisfaction.
Exam) (Safety Awareness )
7 Part of organization structure. (Teaching) Cuts across formal relationship.

42
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

No. Downward Communication Upward Communication

1 From higher to lower level. (Boss to Jr.) From lower to higher level. (Jr. to Boss)
2 Flows downward and fast. (Immediate) Flows upward and slow.( With fear )
3 Directive in nature. (Order) Non-directive. (Shall talk or not Puzzle)
4 Purpose is to get plans implemented. Purpose is to provide feedback on performance
(Leadership) or to ask something. (Reporting)
5 Examples: Orders, instructions, lectures, Examples: Reports, queries, Suggestions,
manuals, handbooks etc. appeals, protests, grievances, surveys etc.
No. Oral Communication Written Communication
1. Generally informal. Generally formal
2. Involves talking and listening. Involves writing and reading.
3. Feedback is quick and instantaneous. Feedback is delayed due to time of
transmission.
4. Economical. (Phone) Expensive and stable. (Letter writing)
5. Flexible and faster. Rigid, slow and elaborate.
6. Suitable for short messages. (Otherwise Suitable for lengthy and organized
Bill) messages.(E-mail)
7. No permanent record. Hear and forget. Authentic and credible record is
Recording is possible (In Meeting) possible.(MOM)
8. Examples : Face to face talk, group Examples : letters, memos, CDs, handbooks,
meetings, phone etc. manuals reports, Email, etc.

43
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Difference of Types with Media:- Which media will be used for Oral & Written
communication
Oral Written
Downward Communications :-
Personal instructions, lectures, meetings, Orders and instructions, letters, Email,
conferences, interviews, employee circulars, memos, posters, bulletin, house
counseling, bells, whistles, telephone, organs, handbooks, CDs, manuals, annual
movies, slides, public address system reports, policy statements, union
(PAS), social and cultural gatherings, union publications, informational racks.
activities.
Upward Communications :-
Face to face talk, oral report, exit Personal letters, Email, written reports,
interviews, phone, meetings and CDs, suggestion scheme, grievance
conferences, social and cultural affairs. procedure, surveys, unions publications.
Horizontal Communications :- ( To all concerned)
Lectures, talks, meetings and conferences, Letters and memos, reports, carbons,
phone and intercom, movies and slides, memo, graphs, posters, bulletin, handbooks,
social affairs, union activities. manuals, house organs, union publications,
Email.
Diagonal Communications :-
Inter-departmental oral inquiry, talks and Inter-departmental letters, memos, reports,
meetings, phone and intercom to other suggestions, objections. Email etc
department, social gatherings of mixed
groups.

44
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Essentials of Effective Communication: (Essentials Rules): It is exactly opposite to

barriers) Rules, principles or guidelines of effective communication or the measures to
overcome its barriers are as under:
1. Message should be clear, complete, unambiguous (confusing) and expressed properly.
2. Information should be in proper order/sequence.
3. Medium should be proper and effective. (For Mass Communication mere Computer
display will not serve)
4. Channel should be sound and undistorted. (Formal or Informal)
5. Clarity - There should be clarity of thought.
6. Brevity - Message should be brief, precise and perfect. Meaningless words, repetitions,
and excessive details should be avoided. (Briefly but to the point)
7. Timeliness - Message should reach in time. (Fatal case message to DISH shall reach in 4
hrs. Otherwise Bamboo)
8. Compassion - Sender should be aware of level of understanding and background of the
receiver. (Category: Contractor or apprentices or Permanent workmen of Supervisor or
middle management )
9. Integrity - Message must be consistent with objectives, policies and programmes. Action
and behavior of the sender should support his message.
10. Feedback - There should be follow up action (if necessary) to get feedback.
11. Careful listening by the receiver is necessary.
12. Strategic use of grapevine - The sender should try to fill up gaps in formal
communication by strategic use of informal channel.
13. Create a faith, trust and good human relations to make the communication effective and
respectful.
14. Communication should be purposeful, at propel speed, sound and with synchronizing.
15. Line of communication (reporting) should be clear.
16. Evaluation of communication system is useful for improvement.
Two-way communication: First a sender passes information to a receiver. He then gives
feedback to the sender. If it is not as per expectation (correct),, the sender supplies adjusted
information to the receiver. Then clear understanding takes place between them and in both
the ways. Thus two-way communication (with correct feedback) is the effective
communication. See Fig. Group discussion, practical, assignment etc. are good programmes
of two-way communication. In two-way communication feedback is required which is not
possible without good listening

45
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Information
Feedback

SENDER RECEIVER

Adjusted Information
Understanding

Fig. Process of two-way communication.

Factors of good listening are :
1. Stop talking and thinking other subject.
2. Emphasize.
3. Maintain eye-contact.
4. Share responsibility for communication and
5. Clarify and interrogate if not understood. Two way communications is a key of success.
Communication and Group Dynamics: Keith Davis defines "Group Dynamics" as
the social process by which people interact face to face in small groups.
Group dynamics is the study of forces operating within a group.
It is the study of field that deals with
(1) Interactions and forces between group members in a social situation.
(2) The nature and development of small groups.
(3) Interactions among members and inter group behavior.
(4) How a group should be organized and operated and
(5) Nature, Structure and processes of a group, and their influence on the behavior and
performance of group members.
The assumptions underlying the study of group dynamics are as under:
1. Groups are inevitable and ubiquitous. (Ever-present) Available
2. Groups can produce both good and bad consequences.
3. Desirable consequences from groups can be obtained through correct understanding of
groups and their functioning.
4. Groups mobilize powerful sources that produce effects of utmost importance to
individuals.(Vasundhara Environment award)

46
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Kurt Lewin is considered to be the founder of group dynamics principle in

management. Barry M. Staw suggests following steps to utilize groups to enhance
satisfaction and performance:
1. Organizing work around intact groups. (SHE DMRs)
2. Having groups charged with selection, training and rewarding of members.(Sending for
Audit awareness Course)
3. Using groups to enforce strong norms for on-the job and off-the-job group behavior.
4. Distributing resources on a group rather than on individual basis, and (Policy, Safety
Boards, Posters for display, Budget provision
5. Allowing and perhaps even promoting inter group rivalry (competition) so as to build
within group solidarity.
The groups perform four functions of (1) Socializing the new employees (2) Getting the work
done (3) Decision making and (4) Control measures.
Group dynamics states following characteristics of a group :
1. Structure - Each member occupies a position in the group depending on his status, power,
experience, aggressiveness etc. Leadership is a special status.(Plant Safety Committee)
2. Roles - Depending on position, the members perform three types of roles : expected role,
perceived role and enacted role.(Production, Maint. & Purchase dept.)
3. Norms - mean prescriptions for acceptable behavior determined by the group. (Safe
Behavior decided both by workmen & Management representative))
4. Informal managerial roles - Managers can perform three types of roles (1) Interpersonal '
roles as a figurehead, leader and liaison officer (2) Informational roles as disseminator,
monitor and spokesperson (3) Decisional roles as entrepreneur, disturbance handler, resource
allocator and negotiator (Henry Mintzberg). (Management Representative in Committee)
5. Informal communication system - or grapevine communications in all directions should
be utilized to attain objectives by assigning duty to all members covering all Directions/
Areas.
(Safety is for everybody & everybody’s Function )
Tools of Communication: They are the means through which information is communicated.
They can be classified as under:
a) Oral (Verbal): Personal contact, talk, phone, meetings, audio, video etc.
b) Written: Letters, circulars, memos, reports, notices, handbooks, manuals, booklets,
magazines, bulletins. Email etc.

47
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

c) Visual: Newsreel, film, video, play, posters, pictures, boards etc.

d) Informal: Casual or incidental talk, meetings etc.
Barriers to Communication: Despite of growth in communication system and modern
electronic media, it may fail due to following barriers or obstacles.
a) Incomplete, ambiguous (Confusing) or badly expressed message.
b) Absence of clarity of thought. ( If Unskilled in Communication & Knowledge )
c) Absence of brevity and exactness, unwanted length, words, repetitions, over-
elaboration etc.
d) Timeliness i.e. the message does not reach in time. ( Hang-up Computer )
e) Lack of attention by the receivers. ( Does not go through the E-mail )
f) Organizational barrier - Scalar chain of command, filtering of message,
discouragement to informal communication, excessive control etc. (Organization may
tell to hide certain information of Third Party Audit or conveying to other Agency)
g) Status barrier - Subordinate has fear to report everything to superior and may hide
unpleasant facts. (During Accident Investigation if Actual cause of Accd. Is not given.
Remedial Measure will be diverted. Just like Stomachache medicine during headache)
h) Perceptual barrier - Receiver may pay attention only on that part where he has
interest or liking and may underrate or filter the message.
i) Information overload - Due to overload work, managers may ignore some message,
may forget to inform some people or may send incomplete message. ( Lengthy
Knowledge mails siding)
j) Premature evaluation - The receiver evaluates the message before getting complete
information i.e. he derives premature conclusion. (Little Knowledge is always
dangerous)
k) Channel distortion - Physical, Mechanical or electronic disturbance due to channel
distortion. ( In video Conference in Industry & T V Chanel)
l) Improper order of information. (Sequence not proper)
m) Improper selection of medium. (Electrical communication without Electrician)
n) Emotional or sentimental messages.(Gopal Handa Case: Mother suicide after her
daughter subsided with a foot-note)

48
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

o) Change of meaning during transmission. (Due to spelling mistakes)

p) Unwanted assumptions either by sender or receiver: (Due to indifferent way if
thinking of each individual)

49
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Chapter -2

SAFETY, HEALTH AND ENVIRONMENT(SHE) SAFETY EDUCATION AND

TRAINING
Definitions :R. P. Blake has explained the difference of education and training.
Education Training
Broadening of knowledge Development of Skill in performance

Safety Education is for developing Safety Tr. is for developing the worker's
awareness of correcting unsafe skill in the use of safe work techniques and
conditions and practices that practices. It is a detailed extension of the
educational safety programme applied to
might lead to injury
specific Product, Activities & Services.

Defi. of Different personalities on Training emphasize on Skill

a) Hesseling : It is on behavior
b) Hamblin: It is personal development
c) McCormic& llegen : It is management of learning.
functional definition of training is getting knowledge, skills and attitudes to increase efficiency of the
organization & job satisfaction.
Elements of Training Cycle:
As per OSHA (Occupational Safety & Health Act)’s training guidelines, seven steps are
suggested to complete a training cycle. These are called elements of any safety training
programme.
Fig. shows them in a cyclic order.
(1) Determine whether training is needed or start up of
improved programme from step (7)

(7) Improve the (2) Identify training

programme needs

(6) Evaluate Programme

effectiveness

(3) Identify goals and

objectives
(5) Conduct the training
(methods & tvpes)

(4) Design and Develop Training Programme

(activities) Fig Training cycle

50
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Quality Systems talk about PDCA Cycle*which. In line with above cycle
Steps 1,2 & 3 covers Planning part,Step 4 & 5 covers Do part,Step 6 covers Check part &
Step 7 resembles to Act, Audit for Continual Improvement * Plan, Do, Check & Act
Above 7 steps are explained as under:
a) Determine if training is needed or any other tool is required for improved Training
programme.
b) Identify training needs - Analyze the worker's duties and what he or she needs to
perform the job more skillfully and safely.
c) Identify goals and objectives –After listing duties, + & - Points about knowledge and
skill is known from Step-2, will fell employers what workers should do & not to do.
d) Design & Develop training programme - After listing precise objectives and goals, as
per the available resources Training programme is designed w.r.t. Job-Knowledge,
Attitude & Behavior.
e) Conduct the training – Relevant Training by suitable Methods & Types to be conducted
w.r.t. Skill used to achieve the worker's goals..
f) Evaluate programme effectiveness - By knowing trainee's opinion, supervisor's
observation, work place improvement, hazard reduction, performance improvement etc.,
it should be checked whether the training has accomplished its goals.
g) Improve the programme - Based on feedback from the workers, supervisors etc., and
from evaluation and observing the gap, the training programme should be improved
(revised) as per need.
Assessment of Training Needs :This is first step / Element of any training cycle.
Following four questions should be considered:
1. Any Hindrance to performance? (Viz. unsafe conditions, acts, Personal Factors &
efficiency).
2. Is it important to the Company? (w.r.t. of cost of accident, hazards, losses etc.).
3. Is it important to the employees? (viz. basic training to new employees, refresher course
for old employees, Tr. to Accident Prone persons )
4. Whether above 3 points are correctable through training? (If yes, then only the training
becomes useful and cost effective.
How General training needs are assessed ?
Gen. Tr. needs are assessed on following ground:
1. Tr. is must for new employees as they don’t know about routine work.
2. Old employees require knowledge of new topics, new technology, process revision, new
methods and forgotten old items. Training for emergency preparedness, safety audit, fire
fighting, HIRA (Hazard Identification & Risk Assessment), OHSAS, EMS, BBS &
Sustainability.
3. Transferred employees in new Depts.

51
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

4. Technological changes in the organization. Addition of new material, machine, method,

process, equipment etc.
5. Multi machine operation/Jobs involved (safety supervision, computer data feeding &
accident analysis).
6. When Safety performance, productivity and efficiency fall down at any level, training
may improve them.
7. For creating Retainers to give Training to other.
8. Safety Records & Productivity Graphs are not satisfactory
When safety training programmes needed?
1. New recruitments
2. New plant with 3Ms (Machine, material, method) or equipment are introduced
3. Change in procedures (Improvement n method)
4. New information of hazard is received after any Accident or Incident
5. When Accident Rates hiked.
6. When safe behavior need Improvement
7. When Employee strength increased.
8. When Hazardous & Non- Hazardous Waste increases.
What are the Four-approaches to decide safety training needs?
No. Approach Content
1. Common concepts approach. Specific Topics instead of General Awareness Tr.
Prog.
2. Safety needs analysis approach. From Job Safety Analysis, External Safety Audit,
Risk Analysis of Haz. Area, Hazop Study & Hazan
gaps are identified create need
3. Problem Identification approach. From employee's Annual performance appraisal
report, gaps identified, assessed and fulfilled by
H.R. Dept. by need base Special Tr.
4. Organizational Safety Survey approach. From Accd. Record, Classification, Analysis,
Accd. Rates, conduct Hazard Survey & Priorities
Safety Measures.
Competence Building Technique (CBT) Techniques (Procedure) of Training:
a) Tr. Techniques are manly for building Competence in participants (workers).
b) Only Knowledge cannot give Competence or Confidence of safe or Successful working.
c) Knowledge is put in practice by necessary Tr.
d) Tr. shows practical part of knowledge to build Competence slowly.
e) In most of the companies HR Dept. is preparing Competence Matrix for the progress.
f) Techniques of training are generally the "training methods" which are discussed in detail
in Part-10.7 of KUV Book.

52
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Also given in Tr. Types. Training Techniques (Teaching Methods=Types) are classified in
two types such as
a) Off-the-job Techniques
b) On-the- job Techniques
(A) Off-the-job training techniques :
No. Category Techniques (methods)
1. Information presentation techniques Includes Correspondence course, Films,
(less involvement of trainee). Lecture, Panel discussion, Programmed or
Computer based instruction.
2. Information processing techniques Includes Conference (APOHSO) or
(trainees are involved). discussion group, (Safety Champions), Tr.
Gr. (Initiative group)
3. Simulation techniques (experiment or Occurrence of Incident, role playing, In-
practice). basket, Vestibule, Mock-drill, Business
game.
(B) On-the job training techniques :
No. Category Techniques (methods)
1. Regular job assignment. Coaching, Job instruction training (JIT).
2. Temporary job assignment. Special assignment/recruitment on job,
committee, project etc.
job rotation in different dept of the
company
Design and Development of Training Programme :
What are the useful points in designing and developing any training programme?
1. Motivation (Proschahan)
2. Sequence of Topic (Event, Defi. Causes of Accds……)
3. Length of Tr. Topic shall fit in given period.
4. Tr. Literature shall fulfill the Objective (Zero Accd.).
5. List of Tr. Aids (Boards, Charts, Drawing, Posters, Transparencies, Overhead
Projector, TV/AV, DVDs, Handouts, Computer, LCD Projector)
6. Actual doing (F.E.) is imp. Than Hearing & Seeing.
7. Questions of trainees should be properly replied by trainer.
8. Encourage trainees by ample of opportunities.

53
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

9. Give example, show picture, practice frequently.

10. The training should be aimed to the goal (Awareness)
11. Effectiveness of the training should be evaluated to make improvement in next
prog.( Use PPE= Use given PPE)
12. Use Instructional Techniques (Book, Computer)
Training Methods and Strategies :
2 Training Aspects Classroom Training (Theoretical)
On-the-job Training (Practical)
2 Basic goals: Explain worker to do job correctly
Confirm for worker doing job correctly
6 Steps for Training Methods: Any training method should have following steps:
1. Lay down the objective of the training 4. Use of AV
programme. 5. Review the contents and
2. Prepare the training programme. 6. Follow up for Feed back
3. Brief the trainee.
Effect of Training - as stated by Bird……
Participant remember 10% by reading
20% by hearing
30% by seeing
50% by seeing & Hearing
70% by seeing & talking
90% by practically doing
Effects of Tr. depends on Grasping power of Trainee & Explanation Power of Trainer
common methods in use are mentioned below:
1. Lecture Method: Oldest and most basic method. Large amount of information in a
short time. for big mob.
2. Discussion Method: Useful for small group. All involved and don't feel boredom.
3. Case-study Method : Accident case study- Q & A discussion for CAPA. It is
effective.

54
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

4. Role playing method : A play of Mock-drill by giving a situation of an Emergency &

different roles acted by a separate Trainee.
5. Business Games Method: More useful for business people to sell a product / Services
with the details of safety. It may be purchasing with correct details.
6. Sending at training Centers: Like Institutes, seminars, workshops, special courses
etc. utilises external resources for required training.
7. Job instruction training: Train the Trainer to teach other employees. Train for Job
safety Training with HIRA (Hazard Identification & Risk Assessment) (JST) involves
four steps
a) Preparing the trainee (Planning)
b) Demonstrating the job (Doing)
c) Having the trainee performed the job and (Doing)
d) Checking frequently the trainee’s performance. (Checking)
8. Programmed instructions: In Book form or Quiz Type (Q-A Type)
9. Project work: Project writing is given to trainees. They apply their knowledge to
practical situations.
10. Other methods: Job rotation, New assignments, HRD training, BBS training,
creativity training, etc. are other specific methods.
Types of Safety Training: Types of safety training are formal and informal. Formal
training may be general or specific.
General Training includes:–
a) Induction Tr. for new employees.
b) On-going safety training.
c) Safety representative training. (DMR Tr.)
d) Senior/ middle management training and Supervisory training.
e) Directors training.
f) Safety Techniques-Audit, Risk Analysis
g) Safety Work Permit Systems
Special Tr. Includes:
a) HIRA
b) First Aid
c) Emergency Preparedness & Response

55
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

d) PPE
e) Fire Prevention & Fighting
f) Safety Inspection & BBS
g) On-the-Job Tr. for newcomer
h) Hazop Study , Hazan
Types of Safety Training:
a) Induction(Orientation) Tr. to new joiners
b) Safety Policy, Rules, Procedures
c) On-Site Emergency Plan for MAH Unit & Other Emergencies
d) PPE (Types, Usage & maint.)
e) Types of Accds. In his area ( B/s, Assy, Foundry, Paint shop, Forging etc.)
f) Reporting of U.A & U.C.
g) On-the-job Safety Tr. by Supervisor
h) JSA / HIRA
i) SOPs
j) Safety signs & Signals
k) Code of Standards to be followed ( for Computation of Accd. Rates, Audits etc.)
2.In case of Injury :
a) Taking Treatment & Reporting to Supervisors
b) Need for Good House-keeping
Apprentices Tr. : Since new shall be given following Tr.
a) On-the-job Tr b) Off-the-job Tr
3. On-the-job Tr. : To be given on the stage of the line
a) On the job Tr. & Job Safety Tr. By the Supervisor
b) Acquaint with Safety signs & Singles.
c) Supervisors shall be trained in HIRA to train down the line
d) Given to Apprentices, transferred employees, Trainees, FTAs who are new.
4. Off-the-job Tr. : All other Trainings other than On-the-job Training
a) It includes 10 common Tr. Methods as earlier like………
b) Lectures, Discussions, Case Study, Role playing, Bussiness games, Sending tr. Centres,
Job Instruction, Vestibule, Mock-ups.

56
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

1. Vestibule Tr. :
a) Tr. Takes place away from actual workplace, when the job is dangerous & can harm
b) Trainee if taught on the job. It is the link between On-the-job & Of-the-job Tr.
2. Individual & Team Simulations :
a) When cost due to Human error or damage to the Equipment is too
b) high, Duplicate Equipment/ Work condition similar to original
is set up for the purpose of Tr. For safety and Economy.
3. Team Training : For Co-ordination & Co-operation amongst Team members
(Sticker applier & Driver)
4. Programmed Instructions : Safety Manual, Q-A type, Check-List, Films,
Pla-card for visitors Banners, Notices,
5. Modern Methods : Computer use for Instructions
6. Other : Technical, HRD, System Tr. ( ISO , OHSAS, EMS, ISMS etc)
7. Training to Supervisors :
a) Supervisors are in immediate contact with Shop floor workers & upper Management.
b) Being a Key Person in Accident Prevention programme, he must be trainined for Rules
c) Company's Policy, H.K., Procedures, Accd. Investigation.
d) Maintaining Safe working Condition.
e) Display MSDS for Hazardous-Materials, Signs, Accd. Reports
f) Recording, Analysis,, Safety Committee Meetings
Evaluation = It is measure of effectiveness of Tr. Prog.
Conducted Useful in Reviewing the Prog. Content,
Method, Tr. Aid as per feedback for improvement
1. Increase in Productivity
2. Increase in Competence of the job
3. Increase in job satisfaction & motivation
4. Decrease in Accd. Rate.
5. Decrease in Break-down time
6. Decrease in Absenteeism

57
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

7. Decrease in labour turnover

8. Decrease in Opn. Cost
9. Improvement in Behavourial Based Safety.
Benefits of Value measurements of Safety Tr. Prog.
1. Top management covincesed usefulness & Cost Effectiveness due to reduction of Accds.
2. Confidence, Skill, Status of Employee & Employer are boosted
3. Most Effective Loss Prevention Measures can be repeated
4. Strength & Weakness are highlighted
5. Safety Officers can Promote most effective Programme
6. Evaluate Objectives & Goal with the gaps if any.
Integration of Safety Training with Job Training : This is necessary to increase overall knowledge o
doing the job safely. With specific subjects if some safety subjects are integrated, it promotes safety in bett
ways. In a big concern the manager of training and the safety manager should work together in the plannin
of various kinds of training programmes. Generally safety training should be job oriented to bring perfectio
in job performance. If safety training is not so integrated, it is of little use. Therefore at the planning lev
such integration should be designed to extend the maximum benefit of safety training. Safety should be pa
and parcel of the job or industrial activity and such integration should be -like a chemical compound which
deferred from mixture. Curriculum for degree, diploma and craftsman courses in engineering must conta
more and more safety subjects at teaching and training levels.

Types of Training Aids : Following aids are useful in training:

1. Black boards, magnetic boards and flannel boards.

2. Charts, drawings and posters.
3. Slides, filmstrips, transparencies and overhead projector.
4. Printed material like books, manuals, handouts etc.
5. TV and Movies.
6. Scale, models, mock-ups, training devices and simulators.
7. Computers, Software (e.g. power point, page maker, graphic design and display etc.), CDs, LCD
projector etc.

58
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Training or teaching aid should be selected judiciously to make learning interesting, meaningful and
without boredom or monotony. Just after lunch interval in the afternoon, film may be more effective
than mere lecture. Where machines and equipment are used as aid, they should be safe and clean and
their safety and ergonomic aspect should also be explained.
Applications of Computers :
Computers usage is very effective for online Training Communication.
• Accident Recording & Analysis Software Programme: Feeding of Daily Accident data in the
computer received from the Dispensary of the Company, Firm is done. We can get the periodical
Analysis Report as per our requirement. i.e. weekly, fortnightly, monthly, Quarterly, Six monthly &
Yearly.
• These Analysis Reports can be sent to respective areas for information of HOD & Safety
representative of the Department for taking Action to reduce the Accidents for increasing Safety
Performance.
• Accident Investigation Report of one dept. can be sent to other depts. having similar Hazards. So
that they will take Parallel Action to avoid similar type of Accident in their location.
• Accident Investigation Report of one Plant in the Sector can be sent to other Plants of the Sector
having similar Hazards. So that they will take Parallel Action to avoid similar type of Accident at
their location.
• Video Clips of Emergency Preparedness & Response can be shooting run on the Computer at the
Entrance Gate for the knowledge of Visitors.
• In the individual Dept. Safety Instructions can be displayed on electronic digital display boards to
create awareness in individual area.
• Different types of Monthly Accident Reports can be sent to the concerned through the computers.
• Safety Training Module prepared in Computer can be displayed through LCD/LED Projector on the
front Screen to have an effective Training Programme.
• The principal coordinator of WTO contribution was Deputy Director-General Miguel
Rodríguez Mendoza with the assistance of many other coordinators.
• The WTO is based in Geneva but unlike the WHO it has no regional offices.
• It has total 560 staff headed by a Director-General, and a limited budget. By February
2002, 144 countries (Developing + Developed) were Members of the WTO. Together
they account for more than 90 per cent of world trade. Since WTO's establishment in
1995, over 40 developing countries have sought admission to the WTO with agreements
• With the entry into force of the WTO in January 1995, the Committee on Trade and
Environment was established. Its work programme builds on the work that had already
taken place in GATT since 1991 to identify the relationship between trade and
environmental measures in order to promote sustainable development, and to make
recommendations on whether any modifications to the provisions of the multilateral
trading system are required.

59
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

WTO : World Trade Organisation(GATS):

General Agreement on Trade in Services: There are specific agreements or, under General
Agreement on Trade in Services (GATS), annexes dealing with the special requirements of
specific sectors or issues. For example, for trade in goods there are specific agreements
relating to quality and safety regulations
Specific agreements (GATT) (General Agreements on Tariffs & Trades): Both GATT and
GATS: authorizes Members to take measures to restrict services for the protection of human,
animal or plant life or health. WTO Members have the right to determine the level of health
protection they deem appropriate(TBT): Agreement on Technical Barriers to Trade deals
various Standards (Quality, Safety, labeling) (SPS): Agreements on Sanitary &
Phytosanitary Standards deals risk to human, animal, plant health arising from pests,
Contaminants, & other diseases causing agent
The definition of an SPS agreement measure at a glance:
Measures taken to protect: from:
human or animal life additives: contaminants, toxins or disease-causing
organisms in their food, beverages, feedstuffs;
human life plant- or animal-carried diseases (zoo noses);
animal or plant life pests, diseases, or disease-causing organisms
a country damage caused by the entry, establishment or
Spread of pests (including invasive species).

One of the key Principle of WTO is (iii) The Most-favoured-nation ( MFN = means treating
other WTO Members equally ) principle and public health: Fruit from countries that do not
fulfill the sanitary requirement could, justifiably, be banned. But the same fruit with an
acceptable level of pesticide residues would be allowed in.
Structure of WTO: The WTO's top decision-making body is the Ministerial Conference
which meets at least once every two years. The General Council, which is normally attended
by ambassadors and other Geneva-based delegates, or capital-based officials (who may
include health experts), meets several times a year in the Geneva headquarters. The General
Council also meets as the Trade Policy Review Body and the Dispute Settlement Body
(DSB). Delegates at the day-to-day meetings of the WTO are government representatives of
all WTO Members and representatives of observer organizations. Both during negotiations
and in the WTO committee work, decisions are made by consensus. Voting is possible but it
has never been used in the WTO.

60
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Objective: To raising standards of living & sustainable development,Basic function of WTO

Trade negotiations. Technical assistance to acceding countries. The training is often rather
"legal" and is aimed at providing an understanding of rights and obligations Members have
under the various agreements
WTO publish EXECUTIVE SUMMARY of Agreement: This report deals with the
relevant WTO Agreements and the way they may influence health and health policies. In
undertaking this joint study, the WHO and WTO Secretariats seek to examine the linkages
between trade and health policies, so as to enable both trade and health officials to better
understand and monitor the effects of these linkages. The WTO Agreements and public
health The first chapter of the report examines the main WTO Agreements related to health
and health policies. The WTO Agreements and some specific health issues Infectious disease
control The world today has witnessed the emergence of new global health threats, for which
control measures are still evolving (viz: HIV/AIDS)Food Safety Several new sources of food-
borne illness are of increasing relevance to International Trade Tobacco control
Environment: Removing trade barriers to modern "green" technologies and to suppliers of
environmental friendly goods and services can potentially benefit both the environment and
health. For example, the removal of subsidies to polluting industries or to the energy and
agricultural sectors could benefit both the environment and associated occupational health.
Trade liberalization for developing country exports, along with financial and technology
transfers, may help developing countries generate resources to protect the environment and
work towards sustainable development. 18. Although the environment per se is not a WTO
issue WTO concluded that an import ban on asbestos was a "necessary" measure to protect
human health. Course of action to address specific environmental issues which may also be
relevant to health, such as, for example, limiting the use of ozone-depleting substances.
Access to drugs and vaccine censuring that drug prices in poor developing countries are as
low as possible while higher prices in rich countries continue Health services
International trade in health services is growing in many areas. Health professionals are
moving to other countries, whether on a temporary or permanent basis
At the national level, health policy makers are increasingly interested in the two way
connection between trade and health. The principal objective of this report is to describe the
actual and potential linkages between relevant WTO agreements and health so as to enable
trade and health officials to better understand, and monitor the effect of, these linkages.
It is focusing on eight health issues:
(a) Infectious disease control;
(b) Food safety; Reduce Pesticide (g) Food security and nutrition; and,
(c) Tobacco; (h) Emerging issues (such as
(d) Environment; biotechnology).
(e) Access to drugs;
(f) Health services;

61
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Chapter -3

EMPLOYEE PARTICIPATION IN SAFETY

Purpose: Employees are the major work force working under hazards. Some know the
hazards and some do not It is of great importance that they must realize that they would be
the first victim of any accident, their safety awareness and all accident prevention work is in
their interest and therefore their active participation in showing hazards and helping in
removing them by the joint efforts of management and all employees is most desirable.
Section 41G of the Factories Act speaks worker's participation in safety management. A
method of safety committee is suggested. Right of workers to warn about imminent danger is
also created by sections 41 H 111A of the Act. Display of the Extract of the Act and Rules
(Section 108(1), Rule 106 and Form No. 23) is for the same purpose of making workers
aware and to call for their participation. Some areas and methods of participation are
discussed below:
Areas of Participation :
General areas of participation are as under:
• To set safety goals and training programmes.
• To design and improve standard operating procedures (SOPs) and methods of
operation.
• Appraisal of progress towards goals.
• To give, collect and discuss safety suggestions and to implement which are necessary.
Rewards for good suggestions boost up motivation for participation. '
Methods of Participation :
Safety Committee: Statutory Provisions: As per F.A 1948 Section 41 and 41 G & Under
Maharashtra Factory Rules 1963 Rule No. 73 J
Applicability:
• Factories employing 250 or more workers
• Factories carrying Dangerous Operations under Section 87.
• Factories carrying Hazardous Process under Section 2(cb) employing more than 50
workers.
Formation, Tenure & Rights: Structure
• A senior official shall be the Chairman.
• A Safety Officer or Factory Medical Officer shall be the Secretary.

62
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

• A representative each from the production, maintenance and purchase departments shall
be members.
• Workers representatives, of equal number, shall be elected by the workers.
• The tenure of the committee shall be 2 years.
• At least one meeting in 3 months. Minutes shall be recorded and produced before the
Factory Inspector on demand.
• The committee has right to ask or seek any information w.r.t. health & safety of workers.
Functions & duties:
• Co-operation to implement health and safety policy of Occupier.
• Dealing with all matters of health, safety and environment and arrive to the practicable
• Solutions to problems in that regard.
• Creation of safety awareness amongst workers.
• To conduct educational, training and promotional activities.
• To discuss reports on safety, health and environmental surveys, safety audits, risk
assessment, emergency plans and implementation of the recommendations of the
reports.
• To carry out health and safety surveys and identify causes of accidents.
• To look into complaints of imminent danger and suggest corrective measures.
• To review the implementation of its own recommendations.
• To form sub-committees, if necessary.
Types of Committees may be: (1) Main or Central Safety Committee (2) Plant or Shop
Safety Committee (3) Technical Safety Committee (4) Special purpose Safety Committee
etc. Technical Safety Committee is useful for specialized knowledge viz. guard design,
process and engineering revision, hazard and risk analysis, special investigation etc. It
comprises of chief engineer, safety engineer/officer, head mechanic, chief chemist and
similar expert technicians. Special Purpose Safety Committee can be setup for specific jobs
and dissolved when its purpose is accomplished. Such jobs include special accident
investigation, specific problems of worker behaviour, off-the job safety, rehabilitation or
relief problem, safety celebration or contest or award occasions etc. For a big concern
different safety committees as ' stated above are possible, but in a small factory a single
committee can carry out all functions.

63
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Functions of Main/ Central Safety Committee :

(Sector-level having more than 1 Plant. It is legal Committee & signed by the Occupier)
• To decide safety policy and planning for purchase of equipment with in-built safety
devices, relationship between departments standards to be followed in guarding, testing
designing, layout, housekeeping, material handling and placing, inspections, accident
investigation and records etc.
• To plan and supervise programmes of safety propaganda, education, training and
maintaining interest of employees in safety.
• To make arrangement or develop safe work practices and procedures; inspection, audit
and appraisal systems and all efforts to avoid or reduce accidents. To discuss and control
the accident rates.
• To discuss and initiate action for correction of unsafe conditions and actions. Action plan
should be drawn and suitable dates fixed for completion of each task.
• To suggest safety devices and protective equipment.
• To carry out fire drill and rehearsal of on-site emergency plan.
• To scrutinize safety suggestions received through plant safety committees and to initiate
action to implement the accepted suggestions.
• To arrange safety competitions and to decide awards for encouragement.(In terms of kind
or money)
• To improve co-operative spirit between management and employees and among various
departments to promote safety.
• The safety knowledge of committee members should be increased by arranging lectures
of safety experts of the plant and outside and by sending the members to seminars.
Factories inspectors and safety specialists can be utilised for this purpose.
• To discuss and approve safety budget.
• To discuss, distribute and supervise responsibilities for quick compliance of safety
remarks.
• To suggests changes in safety organisation and its activities for better performance.

64
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

• To suggests safety aspects of new design and construction of plant, machinery and
equipment and Process.
• To decide disciplinary procedures and disposal of specific safety problems.
Functions of Plant Safety Committees are: (Individual Plant in the Sector)
• Percolate Safety Policy down the line
• To review accident records.
• To investigate accidents and to implement corrective actions.
• To implement directives of the Central Safety Committee.
• Enforcement of safety rules, procedures an accepted safe practices.
• To encourage and enforce the use of persona protective equipment.
• Status of CAPA on Safety inspection rounds of various shops and sections.
• To encourage safety suggestions from worker and to forward them to the Central Safety
Committee.
Plant Sub-safety Committees: Where the size of the plant is bigger, Safety Sub-Committees
are formed wherein the Safety Representative of the Area is a the Secretary, HOD is the
Chairman & equal no. of elected workmen & officers from Production, Purchase &
maintenance are the Members. Apart from the Structure the Functions are similar to that of
Plant Safety Committee,

Workers' and Union's Participation : Equal number of safety representatives from workers
(or their union) and management should constitute their joint safety committee. This may be
a central one or different in different plants. All must be sincere in their desire to co-operate
in the matters of safety. Scope of the activities and agreement should be limited to Safety.
Union representatives should be selected from the basis of their safety knowledge, interest
and experience and should be cooperative and sincere. They should not bring other union
demands like bargaining, grievance setting etc. in the meeting of safety committee. Union
must recognise management's right of leadership in a joint safety programme. Accident
prevention is an area of mutual interest and not of dispute or quarrel. Therefore the workers
or union must participate to show their abilities in this area and thus strengthening their
relationship with the management and saving their own lives from accidents.
Central Board for Workers' Education, Ministry 'of Labour, Govt. of India runs many
schemes for workers' education and training such as (1) Tripartite scheme (2) A worker to
worker training scheme (3) Voluntary scheme (4) Need based education (5) Education
Officer's training programme (6) Worker Teacher’s training programme (7) Workers'
training programme etc. In Gujarat the first workers' education I centre was established in
1967 with the co-operation of the State Govt, employers and trade unions.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

The Central Labour Institute at Bombay, Gandhi V- Labour Institute at Ahmedabad and
some trade unions also run such education and training classes for workers. All such efforts
should increase workers' participation in safety.
Supervisor's Safety Contact :By their key position between workers and management and
by their constant contact with workers they can easily and effectively promote workers'
participation in safety. The supervisor should always try to get such participation. A critical
incident technique like Tool box talk. Safety contact by safety manager, safety
engineer/officer is also useful.
Safety Suggestion Scheme : These is also a requirement of Statutory Annual Submissions
to DISH Office. This is an old practice to invite safety suggestion for improvement in
process, method, equipment, safety meetings, inspection procedure etc. Criticisms should be
replied in the plant magazine or on the notice board to provoke further suggestions and ideas.
Good suggestions should be rewarded among others to encourage them to participate. Written
suggestions are the best, but, the oral or telephonic should also be allowed. Sometimes a
contest of submitting good suggestions provides useful information and stimulates such
effort. This system is effectively accepted by Japanese management. Boxes and forms can
also be used to collect suggestions.
Safety Competitions:
• Individual comparison - Examples are safety Elocution Contest, Safety quiz, essay,
poem or slogan writing, posters or cartoons etc.
• Group comparison - Examples are department wise housekeeping competition.
Safety Incentive Schemes :
• Financial Incentive: Financial reward to the most useful suggestion or activity in
safety is the commonest method. Other financial incentives should also be given for
suggestion to solve particular safety problem of plant or process, machine or
equipment etc. Suggestion of good design for a guard or safety device should always
be rewarded by handsome amount.
• Non-Financial Incentives: Award for safety performance, trophy, memento,
certificate of merit, public honour, praise or pride, awarding special safety hat or kit
or symbol of recognition, awarding special status and duties of safety work, giving
special position such as honorary member of safety committee, raising the cadre or
post, giving extra designation for any remarkable safety contribution are all examples
of non-financial incentives.
If these incentives are properly utilised they help much in accident prevention work.
Safety performance (frequency and severity rates) of different groups can be compared for
the same period. Here groups are motivated for competition.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Winners may get shield, certificate or good prize but non-winning participants should also be
compensated for encouragement. Competition should be fair and fine and fitting to its noble
cause. Safety Quiz is one type of safety competition or contest. It can be conducted by asking
questions to participants or by giving them an objective question paper containing quiz
questions to be answered in a stipulated time. It touches wide area of safety in short time and
participation looks live.
Audio-Visual Publicity :Safety education and training by safety films on TV is the most
powerful method. Slides, filmstrips and transparencies are easily available or prepared and
therefore they should be used to die extent possible to hold the picture to discuss and
understand it in details which is not possible with a moving film.
Modern media is a closed circuit television with the control room. Such unit can be hired
also.
Other Promotional Methods :Methods for employees' participation are safety posters,
cartoons, signs and slogans, publications, booklets, bulletin boards, safety contests and
rewards, counseling of education and training, demonstration, safety meetings, safety
campaigns and stunts, first-aid training, fire brigades, safety- inventory or questionnaire,
accident investigation, inspection, job safety analysis etc.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

CHAPTER -4
Human behavior :
• Organization Behavior and Safety Human Factor Contributing To
Accident
Human factors contributing to accident: - Human error is the major contributing factor for
occurrence of accident. Many a time an operator either forget to perform a correct thing in
right manner or performs a wrong thing such as unsafe act can be attributed to physical
deficiencies in the individual for his attitude towards the job. Any physical and the
psychological deficiency factor associated with the person can i.e. detect in the pre -
employment examination. It will avoid the miss much of specific job requirement and the
personal quality of the individual. This will help to reduce accident possibilities on the job
due to physical deficiencies of employee.
Individual Differences: - It is matter of common experience that people differ from one
another. There physical appearance and traits such as height, strength intelligence, ability of
work, memory, speed of reacting a signal, honest or emotional stability and mental traits.
Personality traits, sensory capacities, muscular co – ordination etc are some of the factor of
individual differences.
Classification of differences: -
1. Individual variable (Human Factor): - Aptitudes, personality characteristics,
physical characteristics interest & motivation age and other personal variables.
2. Work place variables: - Physical environment, work place & arrangement, design &
condition of work equipment, and method of work.
3. Organizational & social variables: - Character of the organization, type of training
& supervision, type of incentives & social environment.
4. Perception of danger and risk: - Different person have different degree of
perception of danger and risk. Due to individual differences capacity of understanding
and identifying the hazard differs while crossing highway, open person may have
correct judgment of chances of accident lowing to the distance and speed of the
vehicles coming from sides different working have difference of opinion or judgment
regarding hazard arising out of moving machinery of risk from chemicals.

In danger then important think is the response time required for quick action to protect
our self or other from the danger or risk slow response time indicates more chance of
accidents and vice – versa. Safety training can help to improve ability of good perception of
danger and risk & help to minimize accidents.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

• MOTIVATION FOR SAFETY

Need (Purpose) of Motivation: Motivation includes inspiration, aspiration,
communication, education, participation and training. All these factors are most essential to
mould a man to achieve a desired goal in a desired manner. It is a fuel or driving force for all
human activities, which should be refined, channeled, rectified, shaped or directed as per
requirement. To minimize the human errors or unsafe acts or omissions, motivation helps
much and it promotes safety.
If people are not motivated for safety, other efforts will not help much. Even if other
measures are taken, motivation is necessary to mould the. people to achieve our goals more
speedily and yet safely. Various theories are available for motivating people for work.
Periodical feedback to maintain motivation is also necessary.
Our present problem is not of lack of knowledge of safety. The real problem is of
implementation of that knowledge, at the shop floor level. This is because of the lack of self-
motivation, lack of communication and motivation. People should be made participative by
inviting them to say their opinion, reaction or views and guided to act for implementing the
safety. Direct communication is more useful than indirect communication. Thus
communication and motivation helps in implementing the safety laws.
Formula of Performance = Ability X Motivation, explains basic need of motivation to
increase or improve the work performance of individual or group.
Total loss control can be achieved by motivation of employers, employees, trade unions
and the Government. Losses of time, money, property and production because of accidents,
conflicts etc., must be reduced and that is possible by motivation at all fronts.

Nature of Motivation: Motivation is one of the factors that stimulates or influences job
performance. A Latin word "mover' means to move. A motive is what moves a person or
impels a person. Motivation is concerned with 'Why' and "How' of behavior.
P. T. Young defined motivation as "the process of arousing action, sustaining the activity in
progress and regularizing the pattern of activity."
Steers & Porter and Greenberg & Baron identified 3 major components of motivation:
1. Force or drive to lead to some behavior.
2. Function to guide behavior in desired direction and
3. Maintaining or sustaining behavior once it has occurred.
Herbert Moore says 'To motivate is to cause a release of energy in relation to a desired goal.
Effective motivation is determined by three factors: the goal that is to be realized, the energy
that is to be released and the tools that are to be used to direct and control that energy. The
Whole problem of motivation is the problem of the development of attitudes, loyalties and
capacities for making sacrifices toward an entity that is of greater consequence to the
individual worker than his job or •his personal welfare.'

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Motivation runs top to bottom; therefore the top management and supervisors should be
motivated first. Motivation should be self generated; otherwise it should be supplied or
induced.
NRF Maier explains motivating as a way of bringing to expression an ability, which a
person already possesses. He describes two aspects: subjective and objective. The subjective
side is a condition in the individual, which is called a need, a drive or a desire. The objective
side is an object outside the individual, which may be called the incentive or goal. When an
incentive satisfies the need (as food satisfies hunger or money satisfies economic need), the
situation is called motivating. The types of needs and incentives vary from time to time and
from person to person. It is an industrial problem to find out needs and their appropriate
incentives. This is explained below.
Theories of Motivation: Some 'psychological theories are developed to motivate people
to improve their performance. These theories are based on varieties of needs and, their
satisfaction (incentives or rewards).
Hawthorne Studies (Behavioral Approach):In an old study conducted at the Hawthorne
works of the Western Electric Company, Chicago for 15 years, beginning in 1924, concluded
that the attitudes of employees could be significantly changed by the development of a co-
operative atmosphere between workers and supervisors.
Change in temperature, humidity, lighting, rest pauses and length of workday have little
effect if the employees are well motivated with friendly, social and co-operative relations.
Thus motivation has more effect than the improvement in working conditions. If a good
confidence is generated in people, they can work hard for their company.
Success of Japanese management seems relied on this theory. Motivated soldiers have
won many battles with inferior weapons and being less in number. On power-press machines,
workers mostly injure their fingers and get demoralized if the frequency rate is not reduced.
Here a supervisor can play an important role by standing near the worker, explaining and
training him for pre-start safety •devices, guarding on machine and safe work method, thus
giving special attention, co-operation and building confidence in the worker to work accident
free. If workers receive personal touch i.e. special attention for their safety, health and
welfare by upper management, they get motivated to give more production even if working
conditions like light, space, layout etc. are not fully favorable. This is the abstract of this
oldest study.
Maslow's and McGregor's Hierarchy Theory of Human Needs; (Need Satisfaction for
Safe Performance): A.H. Maslow classified the human needs and determined priorities for
them. These needs should be satisfied in the following order.
• Physiological needs: Basic or survival needs of food, water, air and rest.
• Safety needs: Protection against danger, threat and deprivation, body and position or

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

• Social or Affiliation needs: Love, affection, friendship, acceptance, association and

belongingness.
• Ego or Esteem needs: Two types - (a) Relating to one's self-esteem i.e. needs for self-
confidence, achievement, competence and knowledge (b) Relating to one's reputation i.e.
needs for status, recognition, appreciation and respect of one's fellows.
• Self-fulfillment needs: Relating to one's own potentialities, for continual self-
development or self-actualization.
This theory helps management to detect needs of their people and to satisfy them priority
wise for better or safe performance. Providing safety goggles to welder, grinder etc., giving
mask/respirator/hand gloves/aprons etc., to chemical workers and to provide ear plugs to
weavers working on high-noise looms, fulfill safety needs of the workers and motivate them
for safety. Then after they need love and affection.
The steps of this theory can be shown as under:
Human needs  Detection  Satisfaction  Incentive or Reward  Feedback for improved
performance  Rethinking of type of satisfaction or incentive, if necessary.
Hierarchy of human needs in this theory can be shown as under:

Fig Hierarchy of Human Needs

First need should be satisfied first, then second, then third etc. If person is already satisfied
with the first need of food, water, rest etc., beginning should be made with the second need
and so on.
Maslow's theory was criticized by W. Bridewell, Luthans, Hall & Naligam (1968), Walba
& Bridewell and surveys in Japan and European countries raising more questions against
such needs and their satisfaction.
However it should be noted that Maslow's research work is some 50 years old and
represents priority of needs of that time. Owing to improved standard of living and many
changes during last 50 years, priorities have been changed and may continue to change.
Effects of liberalization, privatization and globalisation (LPG), decrease in trade union
activities and increase in unemployment can bring new challenges and new needs;
nevertheless Maslow's needs still seem important and are useful for motivation.

71
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Our Indian concept is to minimize the human needs for real happiness but how to implement
it for industrial workers is a psychological problem. Self motivation and satisfaction seems to
be the best remedy.
ERG Theory: Clayton Alderson offered this theory in 1969 based on needs of Existence,
Relatedness and Growth (ERG). His theory is an improvement over Maslow's theory.
Existence needs are basic needs of food, clothing, shelter etc., and management can satisfy
them by pay, allowances, better working conditions, job security etc.
Relatedness needs are affiliation and esteem needs.
Growth needs are self- actualization need stated by Maslow.
By knowing needs of the workers if management takes necessary action to feed those needs,
the workers can be motivated for better performance.
Suppose some workers do not take part in Safety Committee because of their belief that
they know little about industrial safety. If knowing this need of knowledge, they are given
proper training for safety; they will be motivated to participate in Safety Committee.

Herzberg's and Myer's Theory (Motivation - Hygiene Theory):Frederick Herzberg and his
followers - Schwartz, Jenusaitis, Stark and Myers, carried out various studies on motivating
factors. Herzberg and his team interviewed 1500 workers for 12 types of investigation to
know what the satisfying factors were and what the dissatisfying factors with their reasons
were. From this extensive study, some more important factors are given below:

Occupational Group Satisfiers Dis-satisfiers

Scientists Work itself Responsibility
Engineers Advancement Work itself Responsibility, Company Policy and
Administration
Supervisors Advancement Responsibility Pay
Technicians Advancement Responsibility Work itself, Pay
Female assemblers Supervision Recognition, Security

Another study points out motivation needs and maintenance needs as follows:
Motivation Needs (Intrinsic Factors) : These are the factors of growth, achievement,
responsibility and recognition such as delegation, access to information, freedom to act,
atmosphere of approval, merit increases, discretionary awards, profit sharing, company
growth, promotions, transfers and rotations, education, memberships, involvement, goal-
setting, planning, problem solving, work simplification, performance appraisal, utilised
aptitudes, work itself, invention & publication.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

An effective intrinsic motivation technique is job enrichment, which includes

• Making employees responsible for the total function or completion of a task instead of
breaking it into assembly line specialization.
• Allowing employees to both start and complete a project or task.
• Diversification of duties so that no one has all of a boring task (there should be interesting
parts in all jobs).
• Delegation-decision making down the hierarchy as much as possible and
• Conducting rotating job assignments.
Maintenance Needs (Hygiene or Extrinsic or Environmental Factors):

These are the factors classified as below

• Physical: Work layout, job demands, work rules, equipment, location, grounds, parking
facilities, rest rooms, temperature, ventilation, lighting, noise.
• Social: Work groups, coffee groups, lunch groups, social groups, office parties, ride
pools, outings, sports, professional groups, interest groups.
• Economic: Wages and salaries, automatic increases, profit sharing, social security,
workmen's compensation, retirement benefit, paid leave, insurance, tuition, discounts.
• Security: Fairness, consistency, reassurance, friendliness, seniority rights, grievance
procedure.
• Orientation: Job instruction, work rules, group meetings, shoptalk, newspaper, bulletins,
handbooks, letters, bulletin boards.
• Status: Job classification, title, furnishings, location, privileges, relationships, company
status.
Neither intrinsic nor extrinsic rewards give a complete motivational package. The
factors vary according to person and atmosphere. Therefore selection of proper reward is a
tough job.
Complete elimination of dis-satisfiers does not give positive satisfaction or motivation. To
inspire motivation, satisfiers are to be provided.
To explain and to give (display) in writing safe operating procedure to workers and to
provide fixed guard on cutters, fulfill physical needs of the workers. Promoting a Safety
Officer on higher post, considering his length of service and performance fulfils his need of
status. Such steps do motivate them.
All top management, supervisors and safety advisors must believe that better
psychological working conditions (stated above) can help to improve the life and cooperation
of the workers.

73
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Peterson's Behaviour Model (Motivation-Reward-Satisfaction Model):Peterson has

developed a model, of motivation and performance as under-

M
O P e rfo rm a n c e
J o b C lim a te
T
S e lf
I R e w a rd
T h e jo b its e lf
V
J o b M o tiv a tio n a l
A S a tis fa c tio n
fa c to rs
T
P e e r g ro u p (s)
I Boss
U n io n
O Peer
N U n io n
S e lf
A b ility

S e le c tio n T ra in in g

1. Here safety performance is dependent upon level of motivation and his ability to
perform.
2. Motivation depends on job climate (by boss-style, staff-climate, management-relations),
self (personality achievement), the job itself, job motivational factors, his peer group
(norms established and performed) and by the union (norms and pressures).
3. Ability depends upon selection (can he do it?) and training (does he know how?).
4. Following performance there are all kinds of rewards (positive and negative), which
influence his level of satisfaction.
5. The' rewards come from the boss, peer groups, union and self.
6. Upon receiving these rewards he then compares the reward received to what he
expected to receive and is either satisfied or dissatisfied to a degree, which influences
(feed back loop) whether or not he shall be motivated enough to perform again.
Vroom's Valance or Expectancy Theory: It is also known as 'instrumentality theory or
process theory'. Historically it goes back to Tolman (1932), Lewin '(1938) and Peak (1955)
but Vroom's version of this .theory introduced it to industrial psychology
Outcomes like salary, security, recognition etc. have different values (attractiveness) for
different people. Motivation according to this theory is a product of valance (desire),
expectancy and instrumentality.

74
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Valance is the attractiveness of a goal or outcome. It has two propositions: (1) The desire
(Valance) for any particular objective (outcome) on the part of an individual is directly
related to the likelihood that the objective will in turn lead to other subsequent objectives of
given desirability and (2) The greater the valance of any outcome, the more quick is a person
to take action.
In Vroom's theory, money acquires valance due to its perceived instrumentality for
obtaining other desired outcomes i.e. its power of exchange or purchase.
The abstract of the theory is that the linkage between behaviour and reward should be
declared in advance, the linkage should be implemented and reward should be given every
time when a desired behaviour is achieved. This looks like a conditional motivation.
For example, if promotion or pay-rise (valance or attractiveness of the goal, outcome or
reward) is declared for certain target (desired performance) and if a worker feels it achievable
(expectancy perception), he will be motivated to engage in performing to achieve that target.
On performance, declared reward should be given to him.
By providing better comfort by ergonomic design of machines, tools, equipment,
controls etc., and reward for safety attitude and effort, management can generate desire in
workers for safe performance.
Magregor's X & Y theory: Magregor developed this theory, which has two parts - theory
'X' and theory 'Y'. Theory 'Y' is more useful to develop safety culture by motivation.

Theory X Theory Y
Normal, conventional or old views regarding Modern or correct views regarding human
human behaviour behaviour
1. An average worker has inherent dislike of 1. An average worker does not inherently
work and will avoid it if he can. dislike the work.
2. An average worker prefers direction, 2. An average worker learns not only to
wishes to avoid responsibility, has relatively accept, but also to sick responsibility under
little ambition and wants security above all. proper conditions.
3. Workers must be corrected, controlled, 3. Self-control and self-directive are
directed, threatened or punished to achieve preferred by the workers to achieve
objectives. objectives.

75
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Goal-setting Theory: Rayon (1970) put more stress on 'intention' to motivate behaviour.
Locke & Latham (1990) supported this theory explaining to set goals to motivate people to
show their ability (efficiency). Research studies by Miller (1978), Latham & Locke (1979)
showed that performance could be improved by setting 'specific goals' and not the general
goal like 'do your best'.
Reward for zero accident goal, accident free month, year or department, good
housekeeping and a fixed target and guidelines motivate workers to attain them. Goals should
not be too easy or too difficult. Moderately difficult goals pose a challenge to an individual
and impose the commitment. Steady & Ka/s study (1964) showed that goals, which were
perceived as difficult but attainable, led to increased performance than goals, which were
easy or impossible to achieve.
Workers should be involved in goal setting process instead of assigning goals by
others. Workers' understanding and appreciating of goals are necessary. Latham and Saari's
study (1979) showed that it becomes easy to achieve difficult goals through supervisory
support. Chhokar and Wallin's study (1984) to improve safety performance showed that
'feedback to workers how to reach the goal' found useful and percentage of workers working
with safety precaution was raised from 65% to 95%.
Feedback improves individual as well as group performance. In Britchard, et al
(1988) study, group performance showed 75% improvement by group goal setting and
feedback. Northcraft, Lee and Litucy (1990) pointed out two types of feedback - outcome
feedback and process feedback. Outcome feedback provides information about consequences
of one's actions and process feedback about ways to improve task performance.
Zero accidents goal by NASA (USA) is the best example of this theory. In some Tata
Companies, incentives to all workers of a department where no accident occurs during a
month motivated the workers. Supervisors were giving guidance to their workers to achieve
the goal for their department.
Summary: Psychological principles discussed in all above theories suggest-various means
and ways for management (including supervisors and safety officers) to motivate people for
safety and to identify situations leading to conflict, frustration, non-co-operation etc., and
techniques to remove them. For further techniques see Chapter-6 on Safety Management.
Methods of Motivation (Incentives or Rewards) :
While discussing nature of motivation, we have seen that there are human needs,
drives or desires (explained by various theories) which- should be satisfied by necessary
incentives or rewards for the purpose of motivation. Various methods are available to apply
these incentive schemes.
Some are given below:
(A) Money as an incentive: Money, in itself has no incentive value. But it can be used to
obtain the desired incentives, because of its exchange power or value.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Money can satisfy

(1) Basic necessities of life (food, shelter, clothes and the like)
(2) Necessities for health and education (doctors, choice of foods and so on)
(3) Luxuries (mostly acquired needs)
(4) Social position and
(5) Power.
If first need is satisfied men want money for second and so on. Various methods of pay are
applied according to the need or nature of job. Pay in terms of production, time, seniority,
need etc., are in practice. Pay in terms of production (work output) is the only method, which
utilizes pay for motivating all men to produce in accordance with their abilities. But only
money cannot satisfy all needs and other methods of motivation are as follows.
(B) Work and Play: Men should learn to play while they are still young, so that this activity
can replace work when the latter becomes too strenuous for their energies.
(C) Use of Praise as an incentive: Praise is a form of ego satisfaction, and adults and
children can readily be motivated by it.
(D) Competition: It is a motivating factor and highly effective in sports and safety. It can be
used in work and it transforms unpleasant work into a game. Competition between equals
produces better motivating conditions then competition between unequal in ability.
To promote and maintain safety, various types of safety competitions should be arranged viz.,
good housekeeping, accident free man-hours worked, production quantity and quality with
safe performance, better maintenance of machines, stores, plant and premises, safety slogans,
posters, maxims, essays, awards of various kinds etc.
(E) Other Incentives: Among other incentives more important are job security,
compensation, opportunities for promotion and advancement, employee financial benefits
(insurance and so forth) and informing employees about their job status.
Various studies have been carried out to find out factors of job satisfaction in different
occupational groups, by Chant, Wyatt, Berdie, Blum and Russ, Jurgensen and others and
many factors (workers' wants) have been recorded. High pay was found to be only at sixth or
seventh in importance. Rank positions of such factors that appeal to workers are : opportunity
for advancement, steady work, opportunity to use your ideas, opportunity to learn a job, good
boss, high pay, opportunity to be of public service, good working companions, comfortable
working conditions, good working hours, clean work and easy work. Other factors like
benefits, communications and recognition also exist.
Incentives are classified as financial and non-financial, competitive and co-operative.
Though money has not lost its importance, non-financial and cooperative incentives are more
preferred in these days both in industrial and educational context But for poor people money
will remain a powerful incentive forever.

77
Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Workers have three types of relations (social system) according to Bray Field and
Crockett:
1. with fellow workers
2. within company structure and
3. Outside the company. Motivation is a function of all these systems.
Role of Safety Management in Motivation: Role of Management, Supervisors and
Safety Department in motivation is most important.
They should adopt following measures:
• Insist for adequate sensory motor abilities, appropriate muscular perceptual speed or right
perceptual style, free from accident proneness, disease and habit of intoxication,
appropriate age, sex, experience, work habits and good safety record.
• By induction training' new workers (including contract workers) should be given
necessary safety instruction and training regarding hazards and control measures in
industry. This basic knowledge will build confidence.
• Schedule for above training should be properly designed to include hazards of raw
materials and processes, safe operating procedures, safety tools and equipment to be used,
safety work permit systems, interpretation of MSDS, labels, signs & signals, rules of
transportation, loading and unloading and role of the workers in fire fighting and
operation of On-site Emergency Plan.
• Company's Safety & Health policy. Environment policy and Quality policy should be
explained with their objectives and benefits. Organizational interests should be explained.
This will bring belongingness and togetherness.
• Workers should be encouraged to participate in safety committee, safety suggestions and
all safety programmes.
• Accident case studies should be explained at all levels by analysing the different roles in
preventing such accidents. See Chapter-30.
• Motivating thoughts as given in next part 8.8 should be explained with examples. These
will help much for motivation.
• Team spirit and competitiveness should be built-up. This will induct group motivation.
• Supervisors should take sufficient rounds to them if any unsafe practice is noticed. For
good work and follow up of safely rules, they should praise the workers. Safe habits
should be cultivated.
• Proper attention should be paid for basic needs of Health, Safety and Welfare facilities
under the Factories Act and Rules for the workers.

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Subject : Industrial safety Management (23108)

• Keep good housekeeping, lighting, ventilation and temperature. Avoid overcrowding,

faulty arrangement of materials, machines etc. Provide sufficient means of access, right
tools and equipment. Prevent leakage, pollution, noise, vibration etc., by good
engineering controls.
• Excessive workload, working hours, overtime work or work on holidays should be
avoided or minimized. Sufficient rest intervals should be given. Statutory provisions shall
be followed. This will prevent physical and mental fatigue, frustration, conflict etc.
• Exploitation of any kind should be avoided. Paying less wages (less than even minimum
prescribed by law) to the workers, not paying in time, not paying according to his
qualification and experience or reasonable living standard, not paying overtime wages for
extra work, requiring regularly to work 12 hours instead of 8 hours in a shift, depriving of
holidays, treating unequally among equals/partiality in giving benefits, not implementing
any legal order in favour of workers and indirect harassment to leave job are some
instances of exploitation. Top management should leave 'them if it desires motivated
workforce for better performance.
• Supervisors should recommend or the top management should take timely decision to
give increment, promotion and other monetary benefits to the workers.
• Job rotation or job enrichment should be practiced as a technique of motivation as
'explained in Herzberg's theory. It should include proper job distribution, job
simplification and job satisfaction.
• Introduce change in job if monotony is observed. Make the job meaningful to develop
interest in it. Take workers in confidence to fulfill goals. Provide welfare and recreational
facilities. Give responsibility and reduce interruption of work. Use colour and music
where appropriate. Consult psychologist for special psychological measures to increase
worker's interest and .efficiency by change in their behaviour.
• Insist for man-machine matching i.e. designing machines, tools, equipment, controls and
situations most convenient to people at work. This can reduce accidents. See Part 3 of
Chapter24 for details.
• Opportunity of advancement for R&D work, new product, new market, new safety
device, diversification and delegation of more powers should be given to the deserving
workers.
• Bureaucratic or dictatorial behaviour retards motivation. Therefore middle and to
management should be cautioned for this negative factor and they should be instructed to
observe flexibility, love, affection, sympathy a good respect to workers.
• Annual work assessment report (as CR in Govt for individual employee should not be
written with any bias or by misusing the power. This will certainly de-motivate the
worker. It should be transparent with opportunity for justification for not meeting any
target. It should have guidance how to improve upon. These are general measures. A

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

company should add more measures specific to its requirement or based on any
psychological study carried out in the industry.
Motivating Thoughts: Fig Display such Motivating Thoughts

1. It is said that 'it is not the gun that fires; it is the heart of iron which fires the gun'. After
all it is the heart (with mind) full of confidence, courage am motivation that drives a
man to achieve the goal.
2. Motivating thoughts or ideas play an important role in this regard. No motivation is
possible if human mind is not appealed by inspiring thought. This is true in case of
safety motivation also.
3. We have to motivate workers to work safely and without accident. Therefore it should
be impressively brought to their mind that any accident will cause ham to them only and
therefore any accident prevention work is in their interest. Some thoughts are given

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

below as an example. Many such thoughts may be developed based on experience and
need of time and situation .

(1) All are losing by Accidents:

1. By working in factories, a finger is cut, eye lost, hearing damaged; skin, lungs,
stomach deteriorated or cancer contracted, then who is benefited?... Nobody.
2. Life lost in accident or life span reduced due to pollution, then, who is benefited?
..Nobody.
3. Nobody is ever benefited by any accident. Everybody loses only. The worker suffers
pain and aftereffects, loses money in transport, medicine and dispensary expenses. His
family members suffer pain and lose time to serve him. Everything is lost of a family
whose main person loses life in accident. The deceased cannot be brought back by
compensation. Original spare-parts of human body are not available in the market

Fig Human body parts are not available in market

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

1. The employer loses the benefit of an experienced (trained) person, has to pay
compensation in court and incur other expenditure including, medical and transport
charges. Time is lost in investigating the accident and repairing the machine if
damaged. Production is interrupted and no such skilled worker can be prepared in a
short time.
2. If the deceased is a social worker, society and nation both lose his services. In
totality everybody is losing and nobody is gaining by accident. Therefore friends!
Do determine from now to stop accident by all means.
2) Accident causes more Harm to the Worker: First victim of any accident is worker
himself, because he is nearer to the place of accident. Who is exposed to gas or leakage?
Worker only. Who hurt by falling, slipping or striking? Worker only. Who hurt by a falling
body? Worker only. Paying fine or compensation in court may relieve an employer, but can
an injured worker be relieved from pain and suffering? No. Can his family get his support if
he is died? No. Thus it is the worker only who loses more by accident. Therefore we have to
think of our safety first.
(3)Foolishness: To provide guard after cutting of fingers, to cause fire and then to
extinguish, to discharge gases and then to search mask, to invite emergency and then to rush
for control measures... Is it not foolishness?
Therefore, awake, arise and remove all unsafe working conditions and actions first.
(4) Worse than an Accident: Every year some 2 lakhs people die in accidents in our
country. Many more are injured. But the most serious matter is that by inhaling polluted air,
we are calling death gradually near and near.
Is it not surprising that this condition of working in polluted air is not called 'accident'
because immediate absenteeism of 48 hours is not noticed thereby?
It is always advisable to consider this condition worse than an accident and try to remove it.
(5) Five years deducted from life: Whatsoever pay-rise and facilities we may obtain, but, if
we continue to inhale polluted air, at the time of retirement, with gratuity, we will certainly
get a certificate from the nature- 'Five years are deducted from your life'.
Do you wish this? If not, awake and build a wall before the water comes. Do whatever you
can do to prevent pollution.
(6) Nothing is costlier than Life: Everybody loves own life because everything can be
experienced till the life is live. Future after life is unknown. All fruits of this world can be
enjoyed only until the eyes are open and live. .Therefore nothing is costlier than life. Then
why should we lose it by our own mistake? Therefore firmly determine not to commit and
mistake to cause an accident to oneself or others.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

(7) Safety must be our Way of Life: Safety motivation must last lifetime. Temporary
determination due to any emotional setback or funeral asceticism (smashan-vaimgya) will not
last long. Safety attitude must become a habit or part of life. Whenever we see and wherever
we see, we must see through the safety-eyes. Our thinking, observing, working or supervising
at the workplace, home or anywhere else, must be with safety-eye, safety-outlook, safety
attitude and safe behaviour in all respects. Safety cannot be confined with any workplace or
any time limit. It has to be with us till we live and enjoy. Therefore it must be our way of life.
(8) Safety needs Active Participation: Safety begins with our selves. 'Others will practice
safety, it is their duty, why should I worry?' is an improper thinking. Safety needs our
participation too, because our mistake can contribute to an accident even if everything is all
right. And if we do not participate, how can we expect others to participate? Therefore safety
needs' our active participation first. Participate yourself in safety and let others encourage or
inspire to follow you. This is the only best way of safe behaviour.
(9)Implement, Implement & Implement: No safety slogan, safety notice or "safety
literature, including such books, will save life unless it is practiced. Therefore, implement
what you know or learn from safety literature. Don't wait till any accident takes place. Think
and prevent the possibility of accident causes. Implement all safety measures. There may be a
thin boundary between what is safe and what is unsafe, what is legal and what is not legal.
Identify this boundary and implement preventive measures to remain within a safe limit.
(10) Protect the Environment: Man is born of food, Food is of plants, Plants are of earth,
and Earth is of water, Water is of air, Air is of space and Space is of God. One, who ignores
this togetherness of life, perishes. Therefore Protect the Air, Water, Earth and Plants - all
elements of the God. They will protect you.
(11) Killing of Nature means killing of Self: By killing, polluting and distorting {he Nature
and its Vicinity, are not committing Suicide ? So, O Man, ‘Be aware and restrict such wrong
practices.
(12) Work of Safety People is Invisible: Accidents, injuries and losses that take place are
visible but those prevented are invisible. By the constant efforts of safety people, hundreds
and thousands of possibilities or events of accidents are prevented. This work is neither
visible nor measurable. Cost of such prevented accidents and losses is uncountable. Its value
is the highest. The work of safety people should be evaluated and assessed in this way.
(13) Safety pledge: "On this day, I solemnly affirm that I will rededicate myself to the cause
of safety, health, and protection of environment and will do my best to observe rules,
regulations and procedures and develop attitudes and habits conducive for achieving these
objectives. I fully realize that accidents and diseases are a drain on the national economy and
may lead to injuries, disablements, deaths, harm to health, and damage to- property, social
suffering and general degradation of environment. I will do everything possible for the

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

prevention of accidents and occupational diseases and protection of environment in the

interest of self, family, community, organization and the nation at large."
• Conflict:
• Conflict means violent collision, a struggle or contest, a mental struggle etc.
• In industries conflicts of both the types - physical and mental - occur. Conflict reduces
productivity.
• Conflict may arise due to attitude, jealousy, bad behaviour, working condition /
environment, power mongering, labour relation, favouritism etc.
• To reduce conflicts, provide all necessary and better tools, equipment, guards, safety
devices, safety clothing, protective equipment and welfare facilities for safe, healthy
and satisfactory environment.
• Conflict may occur between employer and contract workers if the later are not
considered at par with the company employees in respect of providing safety
equipment, training and other facilities. Therefore facilities of safely, health, welfare
and working hours should be equally given to them.
• Similarly safety committee meeting should not become a platform for conflicts.
Safely is not a matter of dispute or conflict.
• Difference of opinion on any matters of safety should be settled by consulting
experienced safety manager or consultant (who is the Secretary of the Plant Safety
Committee)

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Situations of Conflict & Remedial Measures:

Situation Identification Management
1 Supervisor (boss) 1 Try to find out labour 1 Remove the reasons.
favoring one group and unrest. 2 Change supervisor if
disfavoring another Find difference in output necessary.
group. of two groups. Explain Supervisor’s a
2 3
behaviour if he (Boss) is
justified.
2 Wage difference for 1 Labour unrest. 1 Resolve by group
same & similar type of 2 Complaint. discussion and dialogue.
work. 3 Litigation(Minimum 2 Give justification
Wages) Attend properly.
3
3 Settlement with workers 1 Observe go slow, strike 1 Try to make settlement.
delayed. etc.
2 Labour unrest. 2 Justify delay
4 Union rivalry. 1 Entry of new union and 1. Justify right union.
new demands. 2. Take legal action.
2 Workers’ struggle. 3. Settle the issues if
possible.
3 Effect on work.
5 Disciplinary action 1 The worker’s reaction 1. Justify before taking
against worker (s) 2 Support of other workers action and justify after
to him. action.
2. Convince others.
6 Go slow, strike, Non- 1. Find reasons of 1. Remove reasons.
cooperation, Labour dissatisfaction. 2. Provide safe / better tools,
unrest. 2. Effect on work of equipment, facility,
efficiency. condition etc.
Frustration: Frustration means defeat or disappointment toward success. Any interference
with the achievement of goal causes frustration. Characteristics of frustrated behaviour are
suggestion, regression, fixation or resignation and it depends upon individual's tolerance,
work pressure, situation etc. If a worker meets with an accident on a power press machine, he
becomes nervous to operate it and this may result in repeating the accident. By providing the
effective guard and explaining him about its proper use, his frustration can be gradually
removed. Frustration brings morale degradation, which in turn, increases accident rate.
A frustrated person responds in two ways:
1. Adaptive response i.e. acceptation of situation and substituted goal.
2. Maladaptive response i.e. the person may continue trying to reach the unattainable
goal or he may give up trying to reach any goal whatsoever. He may show
withdrawal response, attack response, limitation response or substitution response.'
As propounded by Scott (1966) in his activation theory, human organism needs

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

stimulation and variety in work. Environment without this motivation will suffer and
frustration may result. Change or variety in job and stimulation may reduce
frustration. In industry there are many instances creating frustration. Not providing
proper working conditions, tools, equipment and PPE despite of demand, not
providing necessary guards and safety devices on machines and not giving
promotion, increment, recognition and status as per requirement can cause
frustration. All such dissatisfying factor should be detected in time and appropriate
remedial measures including management functions should be adopted.
Some situations leading to frustration and techniques of identification and
management are given in below Table
Frustrating Situations and Remedial Measures
Situation Identification Management
1 Increasing accidents to 1 Check job or m/c 1 Remove the defect.
an individual condition. 2 Improve them.
2 Check surrounding
space, light etc. 3 Use ergonomic design,
3 Study type of tool, standard tool, equipment etc.
equipment etc. Correct it
Employ psychologist and
4 Study work method. 4 take his advice.
Study his behaviour.

2 Work quantity (goal) 1 Study results, spoilage, 1 Reduce the work reasonably
excessive. effects of workload on (make the goal attainable).
body etc. From the result, adjust the
2 Carry out time motion 2 work, machine, tool
study.
3 Work quality is not 1 Check the material. 1 Have good quality material.
obtained in spite of 2 Observe work method, 2 Give training as required.
good efforts. machine, tool etc.
4 Worker becomes 1 Discuss with him or 1 Try to remove the reasons by
irregular, inattentive or others to know the giving more pay, promotion,
reluctant etc. reasons making permanent etc.
2 Try to know family 2 Try to solve such problems
problems to the extent possible.

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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Chapter -5

MANAGEMENT INFORMATION SYSTEM (MIS): Management Information System

(MIS) has become a powerful tool for industry, trade and business in the modern world. It
should be user friendly and easy to understand. The huge amount of information on accident
statistics, health data and environmental aspects can, now, be easily stored, analyzed,
transmitted and used for many purposes.
In our country the main sources to get such information are as under :
1. LB: The Labour Bureau, Shimla & Chandigadh. Their state offices.
2. BIS: The Bureau of Indian Standards with its HQ at Delhi, four regional offices and
some branches and inspection offices in major cities.
3. LPA: Loss Prevention Association of India with its offices at Bombay, Calcutta,
Cochin, Hyderabad, Madras, Delhi and Visakhapatnam.
4. NSC: National Safety Council with its HQ at Bombay and Chapters in some cities.
5. CLI: The Central Labour Institute with its HQ at Bombay and Regional Labour
Institutes (RLIs) at Calcutta, Kanpur and Madras.
6. NIOH: National Institute of Occupational Health (NIOH), Meghaninagar,
Ahmadabad - 380016.
7. MOE&F: Ministry of Environment & Forests, New Delhi.
8. SHIB: Safety and Health Information Bureau, Sector 16, Vashi, New Bombay - 400
705.
9. The Council of Industrial Safety, Elphinstone Building, 10, Nariman Road, Fort,
Bombay 400023.
10. The Safety First Association of India, 2nd floor, Stadium House, Nariman-Rd.,
Fort, Bombay 400023.
11. Directorate General of Mines Safety, Dhanbad826004, Bihar.
12. NITIE : National Institute of Training for Industrial Engineering (NITIE), Vihar Lake
Rd., Bombay-400087
13. NEERI : National Environmental Engineering Research Institute (NEERI), Nagpur-
440010.

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Subject : Industrial safety Management (23108)

14. Indian Association of Occupational Health, C-62, Defense Colony, New Delhi-
110024.
15. Department of Industrial Health, Tata Services Ltd., Jeevan Vihar, 75, Apollo
Street, Fort, Bombay-400 023.
16. Industrial Toxicology Research Centre, P.B. No. 80, Lucknow-226001.
17. Indian Council of Medical Research, Ansarinagar, Medical Enclave, New Delhi.
18. All India Institute of Hygiene and Public Health, 110, Chittaranjan Avenue,
Calcutta-700012.
19. Safety, Health & Environment Association, 2nd Floor, Vadilonu Ghar, Kasak
Fuvara, Bharuch 392012, Gujarat.
20. Greentech Foundation, 809, Vishwadeep Tower, Distt Centre. Janakpuri, New Delhi
- 110058 (Website: www.greentech.org.)
21. Master of Industrial Hygiene and Safety Division, ISTAR Building, Vallabh
Vidyanagar - 388120, Dist- Anand, Gujarat.
22. HSE Information Services, Caerphilly Business Park, Caerphilly CF83 3GG, UK.
23. Internet, 104 websites and computer software are now available on the subjects of
industrial safety, health and environment including that of British Safety Council,
London, National Safety Council, USA, CSP (Certified Safety Professional) and CIH
(Certified Industrial Hygienist) Examinations etc. See part 13.2 also.
The publications and periodicals of above institutions and Offices of the Labour
Departments and Pollution Control Boards of various States also provide information on
safety, health and environment. NSC, USA publication 'Accident Facts' gives wide
information on accident statistics of USA every year.
Some International organizations are as under :
1. ILO: International Labour Organisation (ILO), Geneva, Switzerland (Office in
India at - 7, Sardar Patel Marg, New Delhi-110021).ILO publication "Encyclopaedia
of Occupational Health and Safety" is worth mentioning for its great service on such
information to the world.
2. World Health Organisation (WHO), Geneva, Switzerland (Office in India at World
Health House, Indraprastha Estate, Ring Road, New Delhi-110002).

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Subject : Industrial safety Management (23108)

3. United Nations Environment Programme (UNEP)

4. Health and Safety Executive (HSE), Information Centre, Broad Lane, Sheffield 53
7HQ (UK).
In addition to law books, standards, codes, periodicals and publications (books),
research reports, seminar or symposia reports, inspection or audit reports, accident case
studies, meetings of specialists or experts and training programmes are also the main vehicles
for the exchange of information on health, safety and environment.
Modern software like CAMEO, EFFECT, WHAZAN, HEGADIS, SAFETI, PHAST,
BLEVE and Explosion packages -IIT, Kanpur, ALOHA, ARCHIE, CIRRUS etc. should be
utilized and updated. Safety Data Banks should be created at National and State level. Global
internet system should be utilized. MIS should be interlinked with National SHE System at
all strategic areas.
Websites on Safety -
1. Chemical safety - www.chemicalsafety.co.in
2. Young Worker Health and Safety www.youngworkers.org
3. CROET Health & Safety Information www.ohsu.edu/ croet
4. Online purchasing of hundreds of safety products - www.compliancesafety.com
5. Risk Control Rating Systems (South Africa) www.rcrs.co.za
6. Free Safety Programs, Training Material, and Safety Information for Business &
Industry www.safetyinfo.com
7. Applied Safety and Risk Management (Australia) - www.aplied-safety.com
8. Ergonomics web site with a lot of free Program, Training, ClipArt, Compliance
information www.ergonext.com
9. On-line databases of information and downloadable software related to the
environment, health & safety. www.ehsfreeware.com
10. National Safety Council, USA - www.nsc.org
11. NYCOSH website - www.nycosh.org
12. Det-Tronics, manufacturer of fire and gas safety systems - www.detronics.com
13. American Bio safety Association www.absa.org
14. Centres for Disease Control - www.cdc.gov/cdc.html
15. Electrical Safety Forum site - www.electricalsafety.com

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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

16. Fall protection - Dynamic Scientific Controls www.fallsafety.com

17. University Safety Program- Florida State University - www.fsu.edu/~safety/
18. MSDS Surfer: Harvest MSDSs from the world-wide-web www.msdssurfer.com
19. MSDS Solutions - www.msdssolutions.com
20. The Computerized IH Data Management System - www.cihsystem.com
21. Safety Assistant (Australian Software for Workplace Health & Safety)
www.safetyassistant.com.au/
22. MSDS FAST SEARCH database of over 230000 MSDS's from Envirowin -
www.envirowin.com / 10196e.htm
23. Industrial Hygiene Java Scripts www.industrialhygiene.com/
24. International Product Safety News - www.safetviink.com
25. International Radiation Protection Association (IRPA) - www.irpa-exof.nl/
26. OSHA DATA (searches of OSHA enforcement data) - www.oshadata.com
27. Fire web - www.fireweb.com
28. National Fire Protection Association, USA - (1) www.nfpa.org (2) www.wpi.edu/
~fpe/nfpa.html
29. LEPC net - www.rtk.net/lepc.net
30. U.S. Chemical Safety and Hazard Investigation Board - www.chemsafety.gov
31. Pesticides-
www.sis.nlm.nih.gov/enviro/pesticides.html.www.cdc.gov/niosh/topics/pesticides/
32. Indoor Air - www.who.int/indoorair/en/
33. Respirator selection - www.cdc.gov/niocs/2005-100/
34. Air Sampling Direct Reading - www.skcinc.com/reference.asp
35. CIH exam preparation - www.abih.org/
36. Advanced topics -
-www.cdc.gov/niosh/homepage.html
- www.osha.gov/
- www.aiha.org/content

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

37. Ergonomics - www.ergonomics.org.uk/ - www.ergonomics.com.au/

38. Emergency Planning and Preparedness - Websites http://globalcrisis.info/
emergencycontro1centers.html#E
39. National Institute of Disaster Management http: / / www.ni dm. net/ index.htm
40. Useful Websites as per National Institute of Disaster Management
http://www.nidm.net/usefullinks.asp
41. Industrial Disaster Management Information System by Gov t. of Gujarat.
http://www.labour&emplovment.gov.m/idmis
42. International Safety Cards By I.L.O.
http://www. ilo.org/encyclopaedia/?d&:nd=857090010&prevDoc=857000002
43. Fact Sheet of Hazardous Chemicals
http://web.doh.state.nj.us/rtkhsfs/factsheets.aspx?lan=english&alph=A&
carcinogen=false&new=false
44. NIOSH Pocket Guide to Chemical Hazards
http://www.cdc.gov/niosh/npg/npgnamea.html
45. Chemical and other safety information – Oxford ' http://physchem.ox.ac.uk/MSDS/
46. M.S.D.S. and Emergency Response for different chemicals Guide – Download
http://hazmat.dot.gov/pubs/erg/psnsort.htm
47. Occupational Safety and health topics by NIOSH http://www.cdc.gov/niosh/topics/ http: /
/ www.cdc.gov/elcosh/ docs/ other/ cdrom software.html
48. Government and Profit Sites http:/ /www.ilpi.com/msds/#Government
49. IPCS INTOX: Databank http://www.mtox.org/databank/mdex.htm
50. IPCS INTOX: Chemical Databank http: / /www.mtox.org/ databank/ pages/
chemical.html
51. Chemical Safety Information http://www.mchem.org/
52. Chemical Safety Reference Databases http://www.safety.vanderbilt.edu/ safety
links/chemsafetydata.htm
53. First aid, & Medical emergency guide http://www.medmdia.net/patients/firstaid.htm

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Subject : Industrial safety Management (23108)

54. Chemical Emergency Preparedness, Prevention & First Aid for Extremely Hazardous
Substances U.S. Environment Protection Agency
http://yosemite.epa.gov/oswer/ceppoehs.nsf/ Alphabetical_Results?openview
55. Explosion Database of Chemicals- NIMCK- Japan
http://www.aist.go.jp/RIODB/db005/ index.html
56. Incompatibility of Chemicals http://www.pp.okstate.edu/ehs/hazmat/ labman/
Appendix-B.htm
57. Laboratory Safety Manual http: / / www. pp.okstate.edu/ ehs/hazmat/
labman/Chaplal.him
58. Hazardous Material Incident Toolkit http://www.oes.ca.gov/0perational/
OESHome.nsf/ Content/ 333G7C454B5PC40B882571070069A855?Opei->Documen
59. Hazardous Material Transport Training Module
http://hazmat.dot.gov/trainmg/mods/mod.htm
60. Data Sheets of Extremely Hazardous Chemicals by US Environmental Protection
Agency http: / / yosemite.epa. gov / oswer/ceppoehs.nsf/ Alphabetical_Results?openview
61. Fact Sheets of Hazardous Substances http:/ /web.doh.state.nj.us/rtkhsfs/ search
.aspx?lan=english
62. MSDS by Scott http://www.scottecatalog.com/msds.nsf/ AII?ReadForm
63. Environment, Health &: Safety Online http://www.ehso.com/contents.php#B
64. Poisons' Information monographs- by CCOHS Canada
http://www.inchem.org/pages/pims.html
65. Chemical Safety in Asia - Law & Practice- by ILO
http://www.ilo.org/public/english/protection/safework/papers/asiachem/index.htm
66. The Chemical Database- By Akron University http://ull.chemistry.uakron.edu/erd/
67. Recurring causes of Chemical Accidents documents http://www.plant-
maintenance.com/articles/ccps.shtml
68. Chemical Accident excellent case study by U.S. Chemical Safety and Hazard
Investigation Board http://www.csb.gov/
69. Incident Investigation Reports from Chemical Safety and Hazard Investigation Board
http://ncsp.tamu.edu/reports/CSB/csbList.htm

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Subject : Industrial safety Management (23108)

70. Ammonia spill incidents summery

http://www.mda.state.mn.us/spills/ammonia/summaries.htm
71. Superb presentations and video on safety and accident case study
http://www.cdc.pov/elcosh/docs/other/cdrom_software.html
72. Site for Bhopal tragedy case study
http://www.cdc.gov/elcosh/docs/other/cdrom_software.html
73. Safety PPT and Posters by Vermont SIRI- superb safety training stuff-free
http://siri.uvm.edu/
74. Chemo genesis web book- good knowledge resource
http://www.meta-svnthesis.com/webbook.html
http://www.safework.sa.gov.au/show_page.1Sp?id=2769
75. Chemical Thesaurus software http://www.chemthes.com/overview.html
76. How to plan work place emergencies document OSHA
http://www.osha.gov/Pubjications/ osha3088.html
77. Encyclopedia-chemical accidents
http://www.reference.com/browse/wild/Chemical_accidents
78. Download CAMEO software http://www.epa.gov/ceppo/cameo/request.htm
79. Safety information on internet http://hazard.com/course/
80. Superb web links page for safety http://www.hazard.com/links.html
81. Safety Training videos and DVDs availability-OSHA
http://www.safetytrainingnetwork.com/
82. Central Crisis Group-India http://envfor.nic.m/divisions/hsmd/red.html#intro
83. Gujarat Safety Council http://www.gscgujarat.com/
84. Mahatma Gandhi Labour Institute http://www.mgliahd.org/
85. National Institute of Health, U.S. http://www.cdc.gov/niosh/homepage.html
86. National Institute of Occupational Health (NIOH) http://www.nioh.org/
87. Directory of Central Government Websites
http://www.manupatra.com/about/search.asp#Simple
88. Gujarat State Disaster Management Authority (GSDMA) http://www.gsdma.org/

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Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

89. DGFASU http://dgfasli.mc.m/

90. National Safety Council, India
http://dgfasli.nic.in/dgfasli/masterdetail2.asp?orgid=4009
91. Controller of Explosives http://explosives.nic.in/
92. Enviornment Department, Govt of India http://envfor.nic.in/
93. Labour Bureau Chandigadh http://labourbureau.nic.in/
94. Website on Safety http://www.safetyforeveryone.coni/doyoukriow/dyk.html
95. For all Pollution Laws text http://edugreen.teri.res.in/explore/laws.htm
96. Portal of Government of Gujarat http://www.guiaratindia.com/
97. PPE Directory http://www.infobanc.com/index_s3.htm
98. Fire Safety Eq. Supplier http://dir.indiamart.com/indiammporters/s_safety.html
99. U.S. Consumer Product Safety Commission www.cpsc.gov
100. American Chemical Society www.acs.org
101. International Agency for Research on Cancer www.iarc.fr
102. Laboratory Safety Institute www.labsafety.org.
103. MSDS Online www.msdsonline.com
104. Safety Information Resources Inc MSDS Collection www.hazard.com

Compilation, Collation & Analysis of Information: At a factory or workplace level,

information of hazards and past and current accidents should be collected first with facts and
details. This is compilation. As an example, accidents of one particular year are first
collected. This is compilation, (viz. Accidents for the year 1996, accidents costs, 1995 etc.
After collecting accident data of last 5 years, they are grouped (combined) together as
mechanical accidents, chemical accidents, reportable and non-reportable accidents, fatal and
non-fatal accidents, cost calculations etc. This is collation of information. Here comparison is
possible. Mechanical accidents of factory A can be compared with those of factory B.
If they are arranged in some order, say, date wise or code wise, it is also collation of
information. But when the information is classified as male and female wise, day and night
wise, different hazard or causation wise, equal cost wise, severity wise, frequency wise, body
part wise etc., it is called analysis.
HAZOP, HAZAN, fault-tree, event tree, risk and consequence assessment etc., and
detailed information can be compiled, analyzed and used for accident prevention work.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Modern Methods of Programming: Such methods use computer as basic tool and
software of required programmes. Therefore various software programmes are being
developed and used for specific purpose Programming means the process of providing a
series of instructions to the CPU to get the desired actions s.
Communicating media of the PROGRAMME :Computer, FAX, Internet, E-Mail
and V-mail system
Software: Modern software like CAMEO, EFFECT, WHAZAN, HEGADIS, SAFETI,
PHAST, BLEVE and Explosion packages -IIT, Kanpur, ALOHA, ARCHIE, CIRRUS etc.
should be utilized and updated. Safety Data Banks should be created at National and State
level. Global internet system should be utilized. MIS should be interlinked with National
SHE System at all strategic areas.
Data Storing in Programme: Above software can be used
• To store the information pertaining to day-to-day accident Recording, Accident
Investigations, Inspection Rounds, Monthly/Qtly/Yearly Accident Reports, Statutory
requirements & compliance, Training programmes, Safety meetings, future planning,
budgeting, Environmental monitoring, Work permit systems, Safety audits etc…Input
• To store various formats, tables, charts, symbols, graphs and documents to report,
analyse, reply …Output
• MIS for SMS : MIS for Safety Management System Programme should be designed by
I.T. Experts as per own need. One general model may be of the following type:

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

• A loop of effective communication system with safety department should be

effectively arranged based on existing organization set-up. A simple chart may be as under:

Storing and Retrieval of Information: A floppy disk. Zip, CD and pen drive store
computer programs and data and can be read through a floppy or CD drive. Hard disk stores
permanent memory until erased .or replaced. Graphics is a display of information in picture
form. File is a collection of information stored on a disk.. The main computer functions are
input, output, storage and processing. CD writers are used to write a CD.
Computer can store, process, change and print tremendous information. Capacity of
storing is day by day increasing. Floppy, Zip, CD, VCD, Pen drive, Server etc. are the
examples of progress. Hard disk capacity is also increasing. E-mail and V-mail transforms
this stored information very fast. They connect all departments of a factory, all offices of a
State or Nation and all countries in the world. Storing and presenting of MIS has become
very fast and very easy. Laptop and palmtop are very handy. Handwriting is being replaced
by keyboard writing. Correspondence and examination through keyboard have become a part
of modern culture. Volumes of books and libraries have been reduced to small CDs.
Here 'retrieval' means taking back, finding or extracting information stored in a computer.
Any information can be directly fed to the CPU or it can be copied by inserting floppy, CD or
pen drive or through an internet. Such information stored in CPU can be recovered by a
floppy or CD drive. Such information can also be modified, corrected, altered or added. Thus
computer is useful in retrieving much information as per requirement. It saves too much time,
labour and volume of work.
Causes of MIS failure: They are of the following types:
1. Insufficient, incorrect or ambiguous information.
2. No two-way communication.
3. Confused reporting.
4. Poor exchange of information.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

5. Poor system of communication.

6. Insufficient employee involvement.
7. Untrained employees.
8. No system of feedback receiving for the improvement of MIS.
9. No advanced planning to meet and control emergencies.
10. No advance planning for protection of MIS, e.g. Steps to prevent virus in computers.
QCC HS Computer Application and Use:Use of computers for safety and health
information systems became critical from 1.970s with the inception of Occupational Safety
and Health Act in USA as much documentation, reporting and analysis were required by that
Act. In our country, still it is in process.
Manifold use of computers for safety, health and environment is as under :
• As its general use in science and engineering, computers are used for mathematical and
statistical calculations, graphics, documentation, typing, printing, indexing, searching for
literature, data reduction, recording and maintenance of data, control of automated
production lines (CAD, Computer Aided Design, CAM, Computer Aided Manufacturing
and DCS process control) etc.
• Automation of information paths and use of Safety Internet System.
• Process control in plants and laboratories.
• Accident and medical records.
• Costing of accidents and losses.
• Causation analysis of accidents or hazardous events.
• Signal analysis and medical decision making, e.g. ECG analysis and diagnosis of heart
problems, sonography, scanning, surgery etc.
• Preventive Medicine and Epidemiology, screening, examinations of ill population and
comparison of their data with the healthy population for early diagnosis of diseases.
• Maintaining a long-time qualitative and quantitative record of chemical exposures to
workers.
• Maintaining environmental sampling and measurement data. Using for gas dispersion
models and mathematical models for reliability engineering.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

• Preparing and maintaining periodical statements of accidents, injuries, causation

wise break-ups, compensation and other costing, first aid cases, near miss cases, safety
training, status of compliance etc.
• Safety reports, manuals, procedures, audit points, mutual aid systems and emergency
plan items can be quickly stored, updated and reproduced.
• Maintaining information of workplace conditions, engineering controls, fire and gas
leak controls, administrative controls, medical controls, personal protective equipment
and their selection, training programmes etc.
• Maintaining employee demographics and job histories.
• Scheduling of inspections, surveys, meetings, workplace monitoring, biological
monitoring, condition monitoring, corrosion monitoring, maintenance programmes etc.
• Reporting at any time to internal management or external statutory authorities or private
agencies.
• Keeping records of Material Safety Data. Sheets, Indian Standards, Statutory Provisions
and Forms, Reports for Pollution Control Boards etc.
• Statistical analysis by using ready-made or self-designed software.
• Using robots, auto-controls and safety-devices to avoid accidents to persons and
property.
• Simulations to determine where hazards reductions would be more effective and the
change in failure probability that would result. Useful to carry out hazard analyses, fault-
tree analysis etc.
The special use of computers in addition to general benefits of software (Expertise, Up-
to-date information and Improved management) is for Accident recording and analysis.
Information on chemical hazards. Audit recording and analysis etc.
Data on such points are as under:
• Automatic printing of statutory and other safety forms.
• Automatic generation of periodical reports.
• Analysis of near misses in the same details as injury accidents.
• Multiple records of injury, property and vehicle damage from the same incident
• Linked incident costing so that reports can automatically include details of the costs
involved.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

• Automatic summaries and their graphical displays.

• On-line computing using own computer to contact the library or publisher's computer to
obtain and read off the information required.
• CD-ROM (Compact Disc - Read Only Memory) and player for the computer and
special software on chemical hazards and control technology. The information from the
disc is displayed on the computer screen. Conversely, information in the computer can
be copied on CD by using CD writer.
• Use of floppy-discs, CDs and Pendrive to read off the information.
• Database from CAMEO, COSHH, APELL etc. and onsite and offsite emergency plans
(see Chapter-2 for definitions).
• Safety audit and environmental audit details by using a set of audit questions (also
known as audit protocol).
Such audit software packages include:
a) The ability to edit the audit questions and add audit questions as new risks are
identified.
b) The ability to add guidance for the auditors to specific questions, including details of
any relevant standards.
c) Displaying two or more sets of audit results on the screen at a time and to compare
them.
d) Graphical display of audit summaries.
e) Automatic generation of audit reports, including action plans.
f) Diary facilities to assist in managing an audit schedule and keeping track of
recommendations for remedial action.

Advantages and Disadvantages of Computerized System:

• Advantages of computerized information systems are -

1. Ready availability of data and ready reproduction (printed copy) of the stored data.
2. Elimination of monotonous or exhaustive manual labour.
3. No need to keep duplicate records (copies). Reducing files and their storing space. A
shared information can be seen at many places (i.e. in different department, conference
hall etc.).
4. Improved communication with neat, clean and correct copies. Electronic mail systems
can facilitate communication within and between facilities and within short time.
5. Data standardization and accuracy.
6. Improved analytical capabilities. Analyses not manually practical, can be easily done by a
computer. Graphs and Charts also available.
7. Cost savings by increasing employee productivity, decreasing manpower etc.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Disadvantages (limitations) of computerised systems are

1. According to circumstances, need of computers is not always justified. Sometimes it

may be premature or totally unjustified on economic grounds.( Software Program
costly )
2. An operator is required to make data-entry or supply basic information (programme)
to computers and his Mistakes can become repetitive if not corrected in time.
3. Computers can suggest references to documents. They cannot eliminate the need to
go through these documents to locate the required information.
4. A typical virus can wash out all information stored in the computer. Then retrieval or
restoration of data becomes necessary.
5. Manpower reduction for unemployment.
Hazards and Controls of Working on Computer: Following hazards have been
reported:
1. Ergonomic problems may arise with computer operators. Computer room should not
be too noisy, too warm, too cold, unpleasant, humid, congested or poorly lighted.
Wrongly designed furniture and sitting arrangement can cause pain in neck and back.
2. Radiation from screen (VDU) and bad contrast can cause eye fatigue and headache.
Antiglare ' screen or auto glare (strain) removal device is useful.
3. Psychological problems like monotonous work in isolated position, waiting times,
intense concentration (e.g. traffic control) may also arise. Good design and layout of
computer room, equipment, fire protection system, records protection, utilities
protection and safe storage practices are necessary.
4. A study report of Davis School of Medicine, California, USA, says that pain in waist,
shoulders and neck, tension on eyes and legs pain due to decreased blood-circulation
are all ill effects of constantly sitting on key-boards. Long sitting in particular
posture is hazardous to health. Ergonomic design of sitting and working arrangement
and training to computer operator are essential to reduce such pains (News 11-1-
2000).
5. It is also reported that using a computer mouse for a long time exposes some people
to carpal tunnel pressure levels that may lead to repetitive strain injury to the wrist
and hand. This was said by David Rampel, Director of the Ergonomics Program at
UC San Francisco (News, Bridges, COEH, June 2000).
6. It is reported that increasing use of computers will develop cataract at younger age
and in the year 2050, most of the people will be able to read on computer only after
laser surgery (News 23-8-2000).
7. One study report in California revealed that the women working more than 20 hours
in a week on video display unit have 80% more chances of abortion than those not
working in this way.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

8. Another survey in western countries states that 10 to 15% employees working on

computers daily complain of body pain and eye strain. Other 40 to 50% employees
complain occasionally.
9. As per one Japanese study, eye flickering reduces to 7/min. from normal level of
22/min. Eye watering, burning, temporary dimness or vision lose, to see double
things etc. are known as computer vision syndrome (CVS).
10. Indian people are habituated to work in 27°C temperature. If they are compelled to
work in 17 to 23°C temp, (VDT operators), their health is adversely affected.
Control Measures: Ergonomists suggest many remedial measures to reduce 'computer-
trauma' and other health effects. Some of them are as under:
1. Computer Vision Syndrome (CVS) - Eye strain is mainly due to monochromic
light or burden of glare (excessive light) on eye. Pain in neck or back is caused
due to improper seating of monitor from our face. Monitor should be kept at 10 to
15° below the angle of eye level and 20 to 28 inch away from the face. There
should be a balance between monitor light and room light. In darkness, computer
should not be operated. Eyes should be turned aside and closed for a few seconds
at the interval of half an hour. A vision guard programme is available to remind
this relaxation exercise. It should be loaded in the computer.
2. Hand below the elbow should remain parallel on computer-table, and fingers on
key-board.
3. Table and chair should be fully flexible so as to rearrange as requirement.
Specially designed back rest necessary.
4. VDU should be so placed that the sight will fall on the correct place on the screen.
Computer screen should remain below the eyes so that the eyes and neck are not
unnecessarily raised.
5. Key-board should be thin, easy to operate and move and separate from the display
unit..
6. Noise from printer should not be more than 55 dB, otherwise hood is required.
7. Operators having sitting work and standing work should be interchanged by job
rotation. This will relax the contracted muscles and maintain the body tone-up.
8. Eyes should be examined by Ophthalmologist for internal defects if any. After the
age of 40, spectacles become necessary to see from a short distance. Considering
the length between the eyes and the computer screen, the special spectacles (not
bi-focal) should be worn while working on computer.
9. Lighting, shining and colour have also some effects. They should not be
excessive. At every 15, to 30 minutes, eyes should be turned away from the screen
to see aside or take rest raise-or move hands, press fingers etc. Legs should be
freed from one position. They should have rest support.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

10. Working hours on computer should be reduced with increasing age or difficulty.

Status and Future Goals of Computer Utilization in SHE Services:

Status of computer utilization is being increased and spreading very fast. Today we
are rapidly entering in the age of information technology, information highways, internet
systems, super-computers to design, scan, develop, store, exchange and transmit data for
many complex systems and for many purposes. Paper files and record rooms are all shortened
and it seems that in every walk of life computer has to" play some role. Safety, health and
environment being the vital subject, cannot remain without the use of computers. Process
technology, instrument and control devices, hazard control technology, emergency planning
including training, education and information to workers, public, management and
Government ... everywhere use of computers is being increased.
One earlier software for SHE services is CAMEO i.e. Computer Aided Management
of Emergency Operations. It is a Computer Software Package developed by the Environment
Protection Agency (EPA) of USA. The CAMEO software is made operational and available
from the National Safety Council, Mumbai. It was explained with the APELL/ CEP
workshops at Manali, Mumbai, Kanpur, Cochin, Haldia and Vadodara during 1992 to 1995.
CAMEO gives emergency planner, first responder (fire brigade, police etc.) or safety
professional vital information to help handle chemical accidents safely.
What does CAMEO provide?:
CAMEO provides tools to help address issues, including
1. Response information for over 4000 chemicals commonly transported.
2. Database templates to help manage chemical inventory information.
3. A mapping capability that allows to identify the proximity and potential hazard posed
by facilities to sensitive populations.
4. The ability to create scenario using hazard analysis calculations to assist .in
emergency planning and overlay the estimated vulnerable zone on maps.
5. A drawing capability to pinpoint locations of chemicals stored in-community or
facility floor plans that are created.
6. An air dispersion model that can be used to help evaluate spill scenarios and
evacuation options for 700 airborne toxic chemicals (this features is available for the
Macintosh and is being developed for CAMEO DOS).
Integration between Departmental MIS:Because of wide use of computer software for
many purposes, use of internal and external e-mail and information transfer systems,
transferring presentation from any computer to the computer of conference room or
auditorium, using stored or communicated information for design, production, sale, purchase,

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

taxation, audit, assessment etc, good and effective integration of MIS between all
departments is essential and constantly-required.
Information on safety management system, SOP, PPE, safety work permits, statutory and
other safety provisions, forms and annexure, training subjects and schedules, safety
Suggestions, compliance etc is required by many departments from safety department.
Similarly safety department needs feedback and other information from other departments.
This is not possible without effective integration of MIS between all departments.
Therefore continuous integration between departmental MIS should be maintained and
updated.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Chapter -6
6.1 Principles of Accidents Prevention :
Incident: (Near miss + F. A. + Minor + Major + Fatal + Direct Occurrence (D.O.)+ Property
Damage + Environmental Accident)
An incident is any observable human activity sufficiently complete in itself to permit
references and predictions to be made about the persons performing the act viz. cleaning an
unguarded machine, failing to wear PPE, using compressed air on body, raising pressure or
temperature unnecessarily. It may result in accident or a near miss.
Incident for accident is defined as, 'an unplanned event or series of events that has or could
have, caused injury to people and / or damage to assets and / or damage to the environment
and / or loss of reputation.
Accident: Accident is an Unexpected, Unintended, Unforeseen, Unplanned event
interrupting orderly progress of the work in Question which may lead to an Injury or /&
property damage.
An accident is defined in different ways
Dictionary meaning of ‘accident’ is an unexpected event or mishap.
• It is defined as an event that is not expected, intended or imagined. It refers the event not
the result or effect.
• An accident is an unplanned event that interrupts the completion of an activity and that
may (or may not) cause damage to person, property or environment.
• Unintentional injury is the preferred term for accidental injury in the public health
community. It refers to the result of an accident.
• An accident is unintended, unplanned event or its sequence caused by unsafe condition(s)
or/and unsafe act(s) and may result in immediate or delayed undesirable effects.
• An accident is an unplanned and uncontrolled event in which the action or reaction of an
object, substance, person, or radiation results in personal injury or the probability thereof.
• It is also defined as an unexpected, unintended or unforeseen event that causes injury, loss
or damage.
• An accident is any unplanned, sudden event, which causes or is liable to cause or is liable
to cause an injury to man materials (including plant) or environment.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

• An accident is any occurrence that interrupts or interferes with the orderly progress of the
activity which causes or likely to cause injury with or without damage to property or
environment.
• An accident is the result of carelessness, casualness or any fault known or unknown.
• An accident is an unwanted transfer of energy beyond the threshold limits. In case of
accident to a person, physiological energy loss is an accident while in other cases it may
be an energy loss from material.
• It is an event, which is unexpected, unavoidable, unintentional act resulting from the
interaction of host (accident victim), agent (injury deliverer) and environmental factors
within situations, without involve risk taking and perception of danger – Such man.
• An accident is an unexpected, unplanned event which has a probability of causing
personal injury or property damage or both. It may result in physical harm (injury or
disease) to person(s), damage to property, loss to the company, a near miss or any
combination of these effects including delayed effect.
• An accident is an unexpected, unplanned event in a sequence of events, that occurs
through a combination of causes, it results in physical harm (injury or disease) to an
individual, damage to property, equipment, building etc., a near miss, loss to the
company, or any combination of these effects.
• An accident is an unplanned, not necessarily injurious or damaging event that interrupts
the completion of an activity. It is invariably preceded by an unsafe act or an unsafe
condition or their combination.
• An industrial (occupational) accident is also defined a san undesirable event that result in
a certain length of disability and stoppage of work and time loss due to the effect of a
production-related dangerous factor or a combination of such factors.
• An occupational accident is presently regarded as an index or a symptom of dysfunction
in a system formed by a production unit, such as a factory, a workshop, a shift or a
workplace.
• Occupational accident is also defined as “any organic or functional injury or damage to
body, limbs or health or psychic disorder due to an external, sudden or violent cause

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

occurring during work or due to work itself and resulting in death or total or partial,
permanent or temporary incapacity for work” Fata accident or death from accident is an
accident that results in one or more deaths within one year from the date of accident.
Philosophy of accident: it should be noted from above definitions of ‘accident’ that
• In accident phenomenon, which includes event and its effect, ‘event’ is more important
than its ‘event’ Event or consequence may or may not be there. For example, a person
getting chemical splash (exposure), struck by falling body, falling by striking against
object, falling from height, getting electric shock or meeting with road accident may not
get any injury or his normal activity may not be interrupted. Here event has taken place
but it has not a notable effect. Even then this is an accident for the purpose of finding the
‘cause’ of event and remedial measures to prevent its recurrence.
• Event may be one or more. One thing falls or may things fall one by one, only fire takes
place or explosion follows the fire, events of primary and secondary explosion, collision
of many vehicles, one persons die or more persons die in a sequence or due to different
injuries in one accident may constitute one accident.
• Idea of ‘accident by chance’ is not acceptable in safety philosophy. Each accident has its
‘cause’ or ‘cause’ that need inquiry, investigation and efforts to remove them.
Considering accident as chance or fate does not help to prevent the accident and may
result in another accident. Even if it is considered as chance, the ‘causes’ of that chance
occurrence are important.
• There may not be immediacy between event and effect. For example, pain or symptom
may appear after repeated actions or few hours or days after the accident, cancer may
occur after years from the exposure of a toxic substance. This delay or latency period’
hides the effect for some time. However such accident of delayed effect may prove most
serious and needs thought investigation and effective control measures viz. pesticide
poisoning and control.
• Duration or span of event may be short or long Span of event should be considered from
its beginning to the end of the effect or consequence. Therefore when effect occurs just
after the event begins, duration of event is short and when effect occurs after a long time
(i.e. delayed effect) from the beginning of the event duration of the event is long.
Therefore in definition of accident, immediate or delayed, both the effects are included.
Chronic disease (effect) requires events of long duration.
• Legal definition of ‘non fatal injury accident’ or ‘dangerous occurrence’ makes it
reportable after the duration of 48 hours from the time of accident. Thus legal definition
of accident has considered 48 hours duration of event to notice any harmful effect.
Accident causing death or possibility of death is to be reported immediately (Sec. 88 &
88A, the Factories Act).

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Injury: (Injury & Accident are two different things & Injury is a consequence of the
Accident)
• To injury means 'to hurt' and an injury means harm’. In legal terms injury may be to a
person or property or both and compensation (damages) can be awarded to the injured
person for the loss he has suffered and may continue to suffer. Punitive damages can be
awarded for grave injury.
• An injury could be psychological also and not necessarily a physical condition resulting
from a mechanical, electrical, chemical or radiological accident. A heart attack resulted
from unusual mental stress from the work is injury for which compensation is payable.
But natural death or heart attack during normal activities may not be considered as an
injury from accident.
• Injuries are not considered resulting from an accident where willful death, self-inflicted
intentional injury, intoxication and undue alteration by the person injured are involved.
• There are two types of injuries. Minor injury generally means that having no permanent
effect and leading to less than three days off work. Major injury generally means that
leading to more than three days off work. The major injury may be fatal (death) or
serious. A fatal injury is a great loss to the worker, his family society and the employer.
• An injury is an external damage to the human body; disturbance or dysfunction resulted
from an accident.
• By cause, injuries may be mechanical (bruise, cuts, tissue ruptures, breakage etc.),
thermal (shock, burn, frost-bite), chemical (bum, acute intoxication and poisoning),
radiated (tissue regeneration, changes in the hematopoietic system), or combined (the
effect of more than one causative factor with various consequences). The result of
accidents (which may cause serious, minor or no injury) may be temporary or permanent
disablement or a fatality (injury).
• The term "accidental injury" denotes an injury to a workman due to an accident. It does
not include an injury to a worker's health unless it results directly from an accident, as for
example, a poisoning due to toxic chemical.
• "Serious bodily injury" as defined in section 92 of the Factories Act means "An injury
which involves, or in all probability will involve, the permanent loss of the use of, or
permanent injury to, any limb or the permanent loss of, or injury to, sight or hearing, or
the fracture of any bone, but shall not include, the fracture of bone or joint (not being
fracture of more than one bone or joint) of any phalanxes of the hand or foot".
• An injury is merely the result of an accident: An accident is controllable, but, when it
occurs, it is difficult to control the resulting injury. The severity of accident depends upon

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

the material causing injury, energy released, body part being injured and the physical or
mental condition of the person being injured. As accident precedes injury, attention
should be paid to prevent the accident.
H.W. Heinrich estimates that in a unit group of 330 accidents of the same kind and involving
the same person, considering average of averages, 300 results in no injuries, 29 in minor
injuries and I in a major lost-time injury. It indicates an ample opportunity to prevent any
injury by efforts during 300 no-injury or warning accidents. This foundation of a major injury
is shown in Fig.
Major Injury
1
Minor
29

No injury
300

Fig.: Foundation of a major injury

Dangerous Occurrences: (Dangerous Occurrence means an unplanned, an uncontrolled
event, like fire, collapse of structure, bursting of pressure vessel, spill, leak etc. which results
in damage to plant or equipment or loss of material without causing any injury to persons.)
U/s 88A of the Factories Act and u/r 103 of the Gujarat Factories Rules, the following
occurrences are prescribed as dangerous and they are reportable in Form No. 21 (for bodily
injury or death) & 21A (for no bodily injury, property damage may or may not be resulted):
• Bursting of a steam plant under pressure.
• Collapse or failure of lifting appliances or overturning of a crane.
• Fire, explosion, escape of molten metal, hot liquor, gas etc.
• Explosion of a pressure vessel.
• Collapse or subsidence of a structure.
Unsafe Act: (Unsafe Act is an Act performed by an individual or individuals by deviation of
Standard Safety Rules, Procedures & Practices which may lead to an injury &/or property
damage)
• It means either a positive act i.e. commission of an act or a negative act i.e. omission or
failure to perform an act which a prudent man should not have done and which results
in hazard, accident or injury.
• The unsafe act might be deliberate (mischief, sabotage etc.) or committed due to
absence knowledge, ignorance or through forgetfulness (human error, mistake etc.).
• The unsafe act may be the sole accident cause or one of several causes. Examples are
standing under suspended load, design mistake, starting machine without authority or

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warning, removal of safeguard, chance taking, wrong interpretation of safety rule, not
following the safety precaution, poor vision or judgement etc.
• Unsafe act is concerned with the human being and can be corrected by the action of the
human being only.
• Training plays an important role. Even if the condition is fully safe, an accident may
happen because of the unsafe act.
• At the root of creation of unsafe condition, many times the underlying cause is unsafe
act i.e. human failure somewhere, which can be detected and corrected.
• According to H.W. Heinrich, @ 88% accidents are due to unsafe acts. He considered
unsafe acts responsible for most of the unsafe conditions.
Unsafe Condition:(It is a situation which has got potential to lead to an injury unless
corrected by someone)
• It means existence of a mechanical, physical, chemical or environmental condition,
situation or state of affairs, which may cause hazard or accident.
• The unsafe condition might be the result of any unsafe act (human failure) or accidental
failure or alteration of the safe condition.
• The unsafe condition may be the sole accident cause or one of several causes. Examples
are, wrong design, no guard on dangerous part, no control of chemical process, no
provisions of safety devices, poor light, poor ventilation, confined space, high noise etc.
• Unsafe condition is concerned with the position, situation, existence or accidental
alteration of the safe condition into such position, situation, existence or state of affairs
leading to the causation of any hazard or accident.
• Such condition may be because of any unsafe act or not. Acts of God are unsafe
condition.
• Unsafe condition can be rectified, repaired or made safe mostly by engineering controls.

Hazards:
• Hazard means existing unsafe condition or action or situation or event or their
combination which has potential to cause accident.
• Thus hazard can become a cause of accident or risk and it can exist without accident or
risk.
• When due to hazard, accident happens, it is converted into accident.
• If hazard still exists, accident may happen again, viz. flammable atmosphere.
• The causes of accidents generally remain latent for some time before an accident occurs.

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• These latent or potential causes are hazards. Hazards are sometimes referred to
synonymously with accident causes, but there is a clear distinction that a hazard can exist
without an accident whereas an accident cause without an accident is an absurdity.
• Hazard recognition, diagnosis and elimination are essential to any successful safety
programme.
• Hazard is an inherent property of a substance, agent, a source of energy or situation
having the potential of causing undesirable consequences.
• Hazard means an intrinsic capacity associated with an agent or process capable of causing
harm.
• Hazard is defined as, 'any event with the potential to cause harm, ill health, injury,
damage to property, plant, products or the environment, production losses or increased
liabilities.'
• Hazard is a condition with the potential of causing injury to personnel, damage to
equipment or structures, loss of material, or lessening of the ability to perform a
prescribed function. When hazard is present, the possibility exists of these adverse effects
occurring.
• Chemical Hazard is a hazard due to chemical (including its property, storage, process,
handling, effect etc.) and it is realized by fire, explosion, toxicity, corrosion, radiation etc.
• Major Hazard is a large-scale chemical hazard, especially one, which may be realised
through an acute even.
For Major Accident Hazard (MAH) see part 3.55 following.
• Occupational hazards are the hazards arising in course of and out of occupation or
employment.
• They include physical, chemical, biological, mechanical, electrical, psychological and all
occupational health hazards, diseases and poisoning.
• Rapid ranking method is a means of classifying the hazards of separate elements of plant
within an industrial complex, to enable areas for priority attention to be quickly
established.

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Error:
• Errors are of different types, viz. human error, design error; planning, production,
operation and maintenance error etc.
• Human error can be defined as a human's action, which differs from or is inconsistent
with prescribed or established behaviors or procedures. It may be of two types:
predictable or random.
• Predictable error occurs under similar conditions and can be foreseen because it has
occurred more than once.
• Random error is non-predictable and unique in nature. For example, all of a sudden a fly
or insect enters in eye due to which a worker may throw away a tool or lose his balance
and cause error. But if flies become common phenomena i.e. predictable, the error
becomes predictable one and remedial measures are required.
• Human error takes place due to omission (failure to perform a required function) or
commission (performing a function not required), failure to recognize hazard, poor
response, poor timing, wrong decision, sudden disturbance etc.
Oversight:
• Oversight means overlooking of something, error or supervision. When there are more
switches side by side and looking identical, an operator may operate a wrong switch by
oversight.
• While counting many things, by oversight, someone may make mistake. Thus oversight
denotes a state of mind by which error or mistake is possible due to lack of concentration
or attention. Result of oversight is mistake or error.
• Oversight leads to unsafe action and that may result in accident.
• The words - error, mistake and oversight - have thin difference, all leading to the
causation of hazard or accident and concern with the state of mind or human behavior.
Mistake:
• Mistake, in the sense of safety, can be defined as an act of wrong opinion, judgment about
a thing or situation which results in hazard or harm to a person, property or environment.
• It means to have wrong, perception about danger or to understand it wrongly so that it
may cause hazard.
• Like error, as explained earlier, it is an act of omission or commission resulting in hazard
or hazardous situation.
• Mistakes may be committed by men or machines and can be classified as personal
mistake, mechanical mistake, technical mistake, historical mistake etc. It may be small or
big. A gross mistake is called blunder.

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• Examples of mistake are wrong judgment of the speed of a vehicle, falling body or a
moving machine, to perceive blue as black, to press 'start' button instead of 'stop' button,
to press clutch or accelerator instead of brake etc.
Difference between 'error' and 'mistake' is thin and may be understood
interchangeably.
Theories of Accident Prevention: H.W. Heinrich estimates that in a unit group of 330
accidents of the same kind and involving the same person, considering average of averages,
300 result in no injuries, 29 in minor injuries and I in a major lost-time injury. It indicates an
ample opportunity to prevent any injury by efforts during 300 no-injury or warning accidents.
This foundation of a major injury is shown in Fig.

Major Injury
1
Minor
29

No injury
300

Fig.: Foundation of a major injury

6.2 Accident Prevention:
THEORIES OF ACCIDENT CAUSATION: Various theories are developed to explain the
phenomena of accident causation as under. They are useful to understand the methods of
prevention also.
Heinrich's Theory: H.W. Heinrich, a pioneer in safety philosophy, first published his work.
Industrial Accident Prevention, in 1931. Many of his principles and basic philosophy of
accident causation and prevention are confirmed by time and application, but, some are also
questioned and criticized. His philosophy is based on his 10 axioms (self evident-truths) as
follows.
Ten Axioms of Industrial Safety:
1. The occurrence of an injury invariably results from a completed sequence of factors - the
last one of these being the accident itself. The accident in turn is invariably caused or
permitted directly by the unsafe act of a person and/or a mechanical or physical hazard.
2.The unsafe acts of persons are responsible for a majority of accidents.
3. The person who suffers a disabling injury caused by an unsafe act, in the average case has
had over 300 narrow escapes from serious injury as a result of committing the very same

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unsafe act (see fig. 4.2). Likewise, persons are exposed to mechanical hazards hundreds of
times before they suffer injury.
4. The severity of an injury is largely fortuitous the occurrence of the accident that results in
injury is largely preventable.
5. The four basic motives or reasons for the occurrence of unsafe acts provide a guide to the
selection of appropriate corrective measures. These are: Improper attitude. Lack of
knowledge or skill, Physical unsuitability and Improper mechanical or physical environment.
6. Four basic methods are available for preventing accidents. These are Engineering revision,
Persuasion and appeal. Personnel adjustment and Discipline.
7. Methods of most value in accident prevention are analogous with the methods required for
the control of the 'quality, cost and quantity of production.
8. Management has the best opportunity and ability to initiate the work of prevention,
therefore it should assume the responsibility.
9. The supervisor or foreman is the key man in individual accident prevention. His
application of the art of supervision for the control of work performance is the factor of
greatest influence in successful accident prevention. It can be expressed and taught as a
simple four step formula - Identify the problem, find and verify the reason for the existence
of the problem, select the appropriate remedy and apply the remedy.
The humanitarian incentive for preventing accidental injury is supplemented by two powerful
economic factors: (1) The safe establishment is efficiently productive and the unsafe
establishment is inefficient (2) The These axioms were the first set of principles or guidelines
ever set before in industrial safety and it has guided all safety activity till today. During the
passage of 75 years, some of his axioms are questioned and disbelieved as truths, but, most of
them are still true and deal with the important areas of safety, viz. accident causation and
prevention, reasons of unsafe acts and conditions, management control functions,
responsibility of organization, costs of accident, safety and productivity etc.
H. W. Heinrich’s Accident Sequence:

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The five factors .in accident occurrence series in chronological order are:
a) Ancestry and social environment.
b) Fault of person.
c) Unsafe act and/or mechanical or physical hazard.
d) Accident and
e) Injury
One factor is dependent on another and one follows because of another, thus
constituting a sequence that may be compared with a row of dominoes placed on end and in
such alignment in relation to one another that the fall of the first domino precipitates the fall
of the entire row. An accident is merely one factor in the sequence. If this series is interrupted
by the elimination or withdrawal of even one of the five factors that comprise it, the injury
can possibly be prevented. See Fig.

1 2 3 4 5

Ancestry & Social environment Fault of a Person (undesirable traits)

Unsafe act or /and condition Accident Injury
Fig.: Five Factors in Accident Sequence
In above dominos, social environment includes family and surrounding atmosphere in which
a person is born and brought up. This is the origin or root cause of behavioural development
as per H. W. Heinrich.
• Undesirable traits include unsafe behaviour, negligence, lack of knowledge, violent
temper, nervousness, recklessness etc.
• Unsafe act or conditions are the results of undesirable traits.

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• Accident is caused because of unsafe act or condition both. Injury is the result of
accident.
This suggests the steps of management controls as under:
Unsafe Mechanical, Chemical, Physical
Unsafe Acts of Persons (88%) Conditions (10%)
1. Operating without authority or clearance, 1. Unguarded, absence of required guards.
failure to secure or warn. 2. Inadequate support or guards, guards of
2. Operating or working at unsafe speed. improper height, strength, mesh etc.
3. Making Safety devices inoperative. 3. Defective, rough, sharp, slippery, decayed,
4. Using unsafe or defective equipment or cracked surfaces etc.
equipment unsafely or improperly. 4. Unsafe design of machines, tools, plant,
5. Unsafe loading, placing, mixing, equipment or supplies.
combining, etc. 5. Unsafely arranged, poor housekeeping,
6. Taking unsafe position or posture. congestion, blocked exists, etc.
7. Working on moving or dangerous 6. Inadequately lighted, sources of glare etc.
equipment. 7. Inadequately ventilated, impure air source
8. Distracting, teasing, abusing, startling etc.
horseplay etc. 8. Unsafely clothed, no goggles, gloves or
9. Failure to use safe affair or personal masks, wearing high heels etc.
protective equipment or devices. 9. Unsafe processes, mechanical, chemical,
10. Failure to warn co-workers or to secure electrical, nuclear hazards etc.
equipment. 10. Inadequate warning systems.
11. Improper lifting. 11. Fire & Explosion hazards.
12. Servicing equipment in motion. 12. High noise or vibration.
13. Use of drugs or alcohol. 13.Hazardous dusts, gases, fumes vapours
etc.

This supports Heinrich's conclusion that human failure is the predominant cause of accidents.
However, this is not necessarily applicable to all or majority of the industrial accidents as per
other theories.

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Criticism of Heinrich's Theory and His Reply:H.W. Heinrich's ratio theory (fact finding
from a study of 75000 accident cases) that 88% accidents are due to unsafe acts, 10% due to
unsafe conditions and 2% unpreventable is criticised as follows:
Heinrich made his analysis from reports submitted to insurers by the managers of the
companies at which the accidents happened. No manager would want to indicate to the
insurer or to the safety authority or agency that the company had been at fault and that
hazards existed in the workplace under his control. Such a statement may sound harsh but is
borne by known practices, which also distort statistical data.
This ratio idea is fallacious because it rests on a false assumption that accidents are
result of either unsafe acts or unsafe conditions. Actually there are multiple (combined)
factors as supported by the results stated below.
A study conducted by the National Safety Council (USA) yielded the following conclusions:
18% injuries due to mechanical causes.
19% injuries due to personal causes.
63% due to a combination of both causes.
A study by the Department of Labour and Industry of the State of Pennsylvania yielded the
following:
3% "due to mechanical causes.
2% due to unsafe acts.
95% due to a combination of both causes.

The ratio idea had done much harm and many employers still say, 'Why should first of all we
spend a lot of money on only 10% mechanical causes? We will start after 88% personal
causes are removed by the employees'.. Such concept is damaging. There are two essentials
in every case of injury - there must be some degree, of hazard and there must also b~ faulty
behaviour by someone. If the factor of hazard is properly detected and eliminated, there could
be no injury. Similarly, if behaviour could be made and kept perfect, the result would be the
same. Both these are the duties of every management It must try collectively to combat the
combined causes of accident and should not separate the unsafe acts as employee's
responsibility only. Law always stresses for employer's responsibility first. Why? Because the
primary duty, money and ultimate control lie with the management to detect and remove

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unsafe conditions actions and to give necessary training to the workers. This is the only safe
and healthy approach.

Heinrich is aware about the public debate and criticism of his 88-10-2% ratio in accident
causation stated above and its wide spread that may influence people to ignore the machine
guarding and to take the assumedly easier path of issuing instructions. In reply, he states his
belief that the accident-prevention fraternity, like almost all professional groups, want all the
pertinent facts and he has more faith in-their good judgement than to fear that they will ignore
the very first common-sense step of safeguarding mechanical environment. The machine is
dangerous as man makes it so. It's man's use of the machine - more correctly, his abuse of it -
that creates danger.

He points out that judgement must be used in selecting the major cause when a mechanical
hazard and an unsafe act both contribute to accident occurrence. Personal judgement may
lead to error, but it is defensible and in the majority of cases results in fair conclusions.
The 300-29-1 Ratio (Foundation of lost-time accident - Explaining the foundation of
a major injury, Heinrich estimates that in a unit group of 330 accidents of the same kind and
involving the same person, 300 result in no injuries, 29 in minor injuries and I in a major lost-
time injury. See Fig. 4.2. He explains this 300-29-1 ratio as an aid in accident prevention,
because, it vividly emphasises preventive opportunity, when an employee, either because of
his repeated unsafe action or repeated exposure to an unsafe mechanical condition, suffers
300 no-injury accidents (actual events such as slips and falls but fortunately not causing
injury) surely there can be no lack of opportunity in preventive effort.
Replying misunderstanding and misquotation of this ratio, he states that this ratio is an
average. Sometimes a major or serious injury occurs the very first time a person acts unsafely
or is exposed to mechanical hazard – in other cases he is so endangered hundreds or
thousands of times and may slip or fall many times before injury is sustained. In industry,
where, employees are under supervision, these unsafe practices, conditions and the resulting
narrow escapes from actual injury (events-accidents) are tangible and visible. They can and

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should be controlled long before one of the 300 no-injury accidents ultimately causes an
injury.
In above ratio - cases, a major injury is any case that is reported to insurance office or to the
State Compensation Commissioner. A minor injury is a scratch, bruise, or laceration such as
is commonly termed a first-aid case. A no-injury accident is an unplanned event involving the
movement of a person or an object, ray, or substance (slip, fall, flying object, inhalation etc.),
having the probability of causing personal injury or property damage but not resulted in
injury (near miss).

Hepburn's Theory
H.A. Hepburn amplified the above Heinrich's theory and arrived at the principle that an injury
accident is the result of the convergence at the same point of time of 4 factors (1) Unsafe
actionable (2) Unsafe conditional (3) Proximate casual and (4) Personal.

Unsafe Actionable

Personal Accident Unsafe

conditional
Proximate casual

Here unsafe actionable and conditional factors are as usual Personal factor means person
injured or likely to be injured by an accident and die person causing the accident. The
proximate factor is that immediate causative factor such as failure of a brake, sudden
exposure to gas etc., which by its reaction causes a sudden closing together or convenience of
all the four factors to cause an injury accident He emphasises that lie four factors are
complementary to one another m causation of any injury-accident such that, if any one or
more can be withdrawn by any means during or just before convergence, an injury accident
can be prevented. The event of an accident will not be prevented by efforts to control any one
of the factors to the exclusion of the others. Remedial measures must be adopted for each of
the factors. Like Heinrich he also suggested planning and organizing to prevent unsafe
actions and remove unsafe mechanical or physical conditions.

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V.L. Grose's Multiple Causation Theory:

As per this theory many contributing factors combine together UK random fashion, causing
accidents. Such factors should be identified. As shown in figure 4.6, mostly man, machine
and media interact with each other to generate causes for accident and management has to
identify them and provide necessary safety measures.

MANAGEMENT

MAN MACHINE

MEDIA

Fig.: Multiple intersecting cause

In this theory
1. Man includes- workers, public etc.
2. Machine includes- equipment, vehicle etc.
3. Media includes- environment, weather, roadways etc.
4. Management means within which above three parameters operate i.e. to be controlled by
the management.

Characteristics of –
1. Man includes- age, sex, height, skill level, training, motivation etc.
2. Machine includes- size, weight, speed, shape, material of constriction, energy etc.
3. Media includes- pressure, temperature, content, contaminants, obstruction on road etc.
4. Management includes- structure, style, policy,
5. procedure, communication etc.

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Simple example of this theory is a man slipping due to walking on a banana skin lying on .the
road. Here main contributing factors are as under:
Man - A man walking on the road.
Machine or object or vehicle - Slippery banana skin.
Media - Hard road.
As per the multiple causation theory some of the contributing factors surrounding this
accident can be found out by asking :
1. Why was the defect in ladder not found in normal (past) inspections?
2. Why did the supervisor allow its use? Why did he not get it repaired urgently?
3. Didn't the injured worker know he shouldn't use it?
4. Was he properly trained or not?
5. Was he reminded or cautioned?
6. Did and do the supervisor examine the job first?

The answers to these and similar questions would suggest the following measures:

1. An improved inspection procedure.

2. Repairing the ladder (machine-tool, job etc.) immediately i.e. not waiting for an accident.
3. Improved training and supervision.
4. Better fixation of responsibilities.
5. Pre job planning and checking by supervisors.

Systems Model Theory :Similar to V.L. Grose's multiple causation theory, Bob Firenze
developed a system model theory as under:
Here interaction between man, machine and environment (basic pre-elements for any
accident) leads to an accident if the information available to the important element of the
system is inadequate. If the risk is high and the decisions based on information are illogical
and unsound, an accident occurs resulting into incompletion of the task.

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Bob Firenze's system model is shown below:

Man Unsuccessful task

feedback
Machine Stressors
Environment
Decisions
Task
Risks

Accident

Ferrell’s Human Factors Theory:

Dr. Russell Ferrell, Professor of Human Factors al the University of Arizona, gave this theory
of accident causation as shown in diagram below:

Overload Human
(load, capacity, state) error
Incompatibility
Improper activities Initiating
incidents

Accidents

Outcomes

Casual Chain

This theory states that accidents are the result of a casual chain (as in multiple causation
theory), one or more of the causes being human error, which is in turn caused by three
situations - overload, incompatibility and improper activities.

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Factors affecting these three situations are as follows :

1. Overload (A mismatch of capacity, load and a state) due to-

(a) Load Task (Physical, information processing)

Environment (Light, noise, distraction, stressors, that requires active
coping)
Internal (worry, emotional stress)
Situational (Ambiguity of goals or criteria, danger)
(b) Capacity Natural endowment, physical condition, safe of mind, training,
drugs, pollutants, pressure, fatigue, stressors that impair ability to
respond.
(c) State Motivational level and arousal level.

2. Incompatibility (incorrect response or mismatch) due to -

(a) Stimulus – Response Due to control – display
(b) Stimulus – Stimulus Due to inconsistent display types
(c) Response – Response Due to inconsistent control types or locations.
(d) Work station Size, force, reach, feel

3. Improper Activities due to

(a) The worker did not know how to do it.
(b) He deliberately took risk due to
— low perceived probability of accident
— low perceived cost of accident
Since this is basically human factor model, greater emphasis is placed on the first two causes
of human error, overload and incompatibility.
Petersen's Accident – Incident Causation Theory:
Overload, human error and /or system failure may directly cause accident or may cause
system failure which may cause accident resulting in injury or loss as shown below:

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Overload Human error

Traps
Decision to err
Accident or
incident

System failure Injury or loss

System failure is due to error in policy, responsibility, authority, accountability,

measurement, inspection, correction, investigation, orientation, training, selection, safe
operating procedure, standards, hazard recognition, records, medical and others.

Epidemiological Theory:
Suchman stated definition of accident as "An unexpected; unavoidable, unintentional act
resulting from the interaction of host (accident victim), agent (injury deliverer) and
environmental factors within situations which involve risk taking and perception of danger".
His model is shown below:
This originated from the study of epidemics. Casual association between diseases or other
biological processes (accidents) and specific environment are studied. A classic example of
epidemiological method was given by Snow who discovered that persons using a particular
water supply had a higher death rate from cholera than others. Gordon and McFarland
supported that accidental injuries could be studied with the same techniques.
Surry’s Decision Theory:
Jean Surry developed this theory stemming from .the epidemiological model of Suchman. It
assumes that by a person's action or inaction, danger occurs to the person. If any negative
responses to the question are shown during the danger build-up cycle, the danger becomes
imminent. If all replies' are positive, the danger diminishes. A negative response to one of the
questions will lead to inevitable injury. An accident can be the result of many different routes
through the model (20 routes). There are fewer routes leading to no-injury situations.
Energy (Release) Theory :
Dr. Leslie Ball, former Director of Safety for NASA, introduced a causation theory. His
thesis is that all accidents are caused by hazard, and all hazards involve energy, either due to

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involvement with destructive energy sources or due to a lack of critical energy needs. This
model is most useful to identify hazards and to understand system safety.
Gibson noted that injury to a living organism can be only by some energy
interchange. Hence it was suggested that the energy exchange should be considered as the
injury agent. The energy exchange resulting in an injury could be mechanical, chemical,
thermal, electrical etc. This concept is useful in understanding the way injury is caused and
examining the solutions. When a grinding wheel is in stop-position it does not make
accident, but if it runs and fingers trapped, it makes accident because of its kinetic energy.
William Hadden, m 1970, explained 'energy transfer or release' as the main factor for
accident causation and said that accidents and injuries are caused because of transfer or
release of energy between objects, events or environment interacting with people.

Ten strategies were suggested by Hadden to prevent or reduce losses as under:

1. Prevent the transfer or origin of energy, e.g. safe substitution - using toluene instead of
benzene, not keeping the car running, dipping instead of spraying, shot blasting instead of
sand blasting.

2. Reduce the amount of energy trailer, i.e. drive vehicle or machine at slow speed, reduce
quantity or concentration 'of hazardous chemicals.
3. Prevent release of energy, e.g. flameproof electric fitting in flammable area, fall arrester
device, dyke to stop spread of .chemical, safe overflow pipe or level cut off device.

4. Change the rate of release or distribution of released energy, e.g. reduce the road slope,
use inhibitor to reduce rate of reaction, sprinkler to reduce rate of burning, scrubber to scrub
toxic gas, condenser to liquefy organic vapour.

5. Divert (separate) the energy released in time or space, e.g. separate paths for vehicles and
pedestrian traffic, keep electric wiring or pesticide out of reach, discharge gases at height

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6. Provide barrier between the energy released and a structure or a person likely to be
affected, eg. guards on machines, radiation shield, filter, safety goggles, earplugs, insulation
on hot surface, blast wall against explosion energy.
7. Make the surfaces of structure safe. e.g. rounded corners, blunt objects, big handles of
tools and no sharp edges.
8. Strengthen the structure or person susceptible to damage, e.g. fire resistant wall, training
to workers and vaccination for disease.
9. Early detection ,of damage and actuate counter effect, e.g. fire detectors with sprinklers,
high level alarm and tripping of feed pump, temperature alarm and starting of cooling system.
10. Speedy measures to restore normal condition, e.g. rehabilitation of injured worker,
repairing of a damaged machine or vehicle.

PRINCIPLES OF ACCIDENT PREVENTION:

After understanding the causation of accidents, it is obviously essential to understand the
principles and techniques of accident prevention. But before that we will see the types of
accidents first.
Types of Accidents:
a) First Aid: Injured Person is fit to work after giving First Aid Treatment
b) Minor or Non-Reportable: Injured Person is disabled for 48 hours or less after the
Accident
c) Major or Reportable: Injured Person is disabled for more than 48 hours after the
Accident
d) Fatal: Injured person dies after the Accident or as a consequence of the Accident
e) Near miss: Incident occur without injury
f) Disaster: Incident where there is extensive loss of property & /or life
• Fundamentals of Accident Prevention: As explained by Heinrich, accident
prevention is both, science and art. It represents control of performance of man,
machine and physical environment (Ventilation, Light and Storage).The word 'control'
includes prevention as well as correction of unsafe conditions and actions. Prevention
is the first or initial part of 'control' which if practiced, subsequent control for

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

consequence or effect may not be needed. Thus accident control is a vital factor in
every industry, which if ignored or practised unskillfully, leads to needless human
suffering and business bankruptcy.
The accident-prevention task requires both, the short term approach (direct control of
personal performance and environment) and the long-term approach of instruction, training
and education. This task must be performed before an accident and injury occur. Subsequent
efforts after accidents are also necessary.
Thus accident prevention may be defined as an integrated programme, a series of co-
ordinated activities, directed to the control of unsafe acts and unsafe conditions and based on
knowledge, attitude and ability for safety. It aims to serve industry, country and humanity.
Five basic or fundamental steps for accident prevention (safe and efficient production),
suggested by H.W. Heinrich, are:
1. Organization. (Policy & Safety Structure)
2. Fact finding.(Investigation)
3. Analysis of the facts found (for immediate cause & Root cause)
4. Selection of remedy and (Corrective & Preventive action)
5. Application of the remedy (Actual Implementation for closure)
Sixth step of 'Monitoring' (i.e. measurement o: result, assessment i.e. comparison with legal
criteria or standard, feedback and further improvement) is also suggested. Such review is
necessary after all safety progrmmes.
SAFETY
5 Application of remedy
4 Selection of remedy
3 Analysis

2 Fact finding

1 Organisation

Steps of Accident Prevention

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

ACCIDENT COST TO THE INJURED PERSON AND HIS FAMILY .

Wage loss if not covered by insurance scheme.
Medical cost of medical expenses, transport, fruits, food etc.
If he suffers permanent disablement, he loses his earning capacity for life.
Even after return to duty, he is unable to perform his normal work for many days and
therefore may lose incentive and overtime wages during that period.
Example :
Let us take an example of a worker who meets with an accident at his age of 20 years and
loses his total earning capacity. His monthly wage is Rs. 1500/-.
As per Workmen's Compensation Act, he will get (60% of 1500) x the relevant factor
= 900 x 224 = 201600, or Rs. 90000/- whichever is more, thus he will get the compensation
of Rs. 201600/-.
If the accident would not have happened, he would have worked for another 40 years and
would have earned as follows : 1500 p.m. wage x 12 months x 40 years = 720000.
Considering yearly increment of Rs. 50 throughout the span of 40 years, i.e. increasing Rs. 50
x 12 = 600 each year for 40 years (wage ceiling is not considered because of the periodical
wage rise), further earning
= (600 x 1) + (600 x 2) + (600 x 3)+.... (600 x 40)
= 600 (1+2+3+......+40) = 600 x 820 =492000
Therefore total earning = 720000 + 492000 = 1212000.
Thus against Rs. 1212000 he gets only Rs. 201600 which seems much less.
Suppose, he would have died, his family gets (50% of 1500) x the relevant factor = 750 x 224
= 168000, or Rs. 80,000 whichever is more, i.e. Rs. 168000 a still less amount than the
compensation for permanent total disablement.
ACCIDENT COST TO THE MANAGEMENT:
Direct or Insured or Tangible Costs:
This includes the compensation paid to the injured person, or insurance premium, medical
and hospital charges, transport charges directly paid by the employer.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

Direct costs are easy to calculate as their money value is directly available. Workers' legal
compensation or accident insurance premiums (net premiums after deducting refund if any),
medical expenses of doctors' bills, medicine bills, hospital/ dispensary charges etc., extra
compensation paid to the injured worker or his family and all other direct
expenses/expenditures paid, by the employer due to the accident, constitute direct costs.
If hospital charges' doctor's bill, medicine bill or other expenditure is paid by insurance
company, only premium cost should be considered. Direct cost includes insured expenditure
and direct payment only.
Indirect Costs Uninsured or Intangible (hidden):Indirect costs are of many types
and need careful consideration to determine their 'equivalent money value'. Use of cost data
sheets and other methods have been developed to calculate indirect costs. They include
following
1. Cost of wages paid for working time lost by insured workers, other than workers'
compensation payments.
2. Cost of wages paid for working time lost by workers, other than the injured worker(s).
3. The net cost to repair, or replace material or equipment that was damaged in accident.
4. Extra cost due to overtime work necessitated by accident.
5. Cost of wages paid to supervisors for their time required for activities necessitated by
accident.
6. Wage cost due to decreased output of injured worker after return to work.
7. Cost of learning period and preparation of new worker(s).
8. Uninsured medical cost borne by the company.
9. Cost of time spent by higher officers, outsiders and clerical workers on investigations
or in restarting the production or in processing compensation application, procedure
and other administration.
10. Cost of work interruption due to idle machine, work stoppage or spoilage.
11. Cost of property (including material and equipment) damage due to accident.
12. Uninsured other costs and the miscellaneous unusual costs.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

The ratio 4 to 1 : In 1927, H. W. Heinrich presented a paper at the National Safety Congress
(USA), and placed the indirect cost as an average 4 times the direct cost. This was the origin
of much discussed and controversial 4 to I ratio.

Fig.: Bird's Iceberg concept

Part A : Insured costs

1. Medical 2. Compensation
Part- B : Uninsured costs
1. Building damage
2. Tool & equipment damage
3. Product & material damage
4. Production delays & interruptions
5. Many items such as hiring & training, investigation time etc.

Bird and Germain, however consider this revised concept, an ineffective tool in safety
motivation and they suggested, a ledger-costs concept that appear on department ledgers. The
main factors considered in accident cost-accounting are -
1. Workers:
(a) Total cost of workers' compensation benefits.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

(b) Wages and medical costs paid during disability in addition to (a) above.
(c) Cost of time lost on day of accident and on subsequent days.
(d) Cost of time spent on light work or reduced output.

2. Machinery, Material, Equipment :

(a) Cost of repairing damage or cost of replacement.
(b) Cost of lost production time,

Factors of Indirect (Hidden) Accident Cost:

The list given by Heinrich is as under :
1. Cost of time lost by injured employee.
2. Cost of time lost by other employees who stop work.
3. Cost of time lost by foremen, supervisors or other executives as follows:
• Assisting injured employee.
• Investigating the cause of the accident.
• Arranging for the injured employee's production to be continued by some other
employee.
• Selecting, training, or breaking in a new employee to replace the injured employee.
• Preparing statutory accident reports, or attending hearings before Govt. officials.

4. Cost of time spent on the case by first-aid attendant and hospital department staff, when
not paid for by the insurance carrier.
5. Cost due to damage to the machine, tools, or. other property or to the spoilage of material.
6. Incidental cost due to interference with production, failure to fulfill orders in time, loss of
bonuses, payment of forfeits and other similar causes.
7. Cost to employer under employee welfare and benefit systems.
8. Cost to employer in continuing the wages of the injured employee in full, after his return -
even though the services of the employee (who is not yet fully recovered) may for a time l)e
worth only about half of their normal value.
9. Cost due to the loss of profit on the injured employee's productivity and on idle machines.

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

10. Cost that occurs in consequence of the excitement or weakened morale due to the
accident. (Stoppage or slawing down of work)
11. Overhead cost per injured employee - the expense of light, heat, rent, and other such
items, which continues while the injured employee is a non-producer.
This list is not exhaustive and many points can be added to it, though it is sufficient to point
out one

Example :Let us consider an example of a worker drawing Rs. 900/- p.m. and meeting with
an accident at his age of 40 (completed) and losing three fingers of one hand (i.e. 30%
permanent partial disablement).
Direct Cost (Rs.)
1. Compensation under Workmen's Compensation Act.
From Sr. No. 8 of Part II of Schedule I,
30% of (60% of 900 x the age factor)
= 0.30 (540 x 184.17)
= 0.30 x 99451.8 = 29835
2. Medical & Hospital charges
including fees, medicines, milk, fruits etc. = 02137
3. Transportation charges = 00200
Total direct cost Rs. 32172

Indirect Cost (Rs.)

1. Cost of lost time -
A. By injured worker 1870
B. By other workers 5330
C. By Supervisors & executives 6240
D. By first-aid staff and Clerical expense 1260

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Sahyadri College of Fire Engineering & Safety Management, Nashik
Course Name & Code: Advance Diploma In Industrial Safety
Subject : Industrial safety Management (23108)

2. Cost of production loss due to -

A. Idle m/c and clean up etc. 1390
B. Damage to the machine 7310
C. Damage to tools 5650
D. Damage to materials 4620
E. Spoilage of materials 2550
3. Incidental cost due to -
A. Fulfilling order (supply) 6280
in time (worked overtime)
B. Payment of forfeits
C. Welfare & benefit system 0840
D. Less production by the injured 8560
worker after his return to work
E. Loss of profit & productivity 5356
F. Production loss by weakened 2644
morale of others

4. Overhead & Administrative expense 4800

Total indirect (uninsured) Cost 64700
Total cost of the Accident
32172 + 64700 =96872
Suppose due to a fatal accident 3500 workers do not work for one shift or day, that estimate
only would cost Rs. 3500 x 60 (daily wage) = 210000 and adding to the indirect cost, the
ratio would be 1:8.
Suppose direct cost is not born by the company which paid accident insurance amount for
that-worker as Rs. 16000, then ratio will become 16200/64700=l:4. See also Part 4 for costs
discussion.

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