Safety Excellence ULTRATECH CEMENT LIMITEDqcfihyderabad.com/cementconclave2018/wp-content/uploads/2018/10/Ultratech-Anatapur...Safety KPI for every employee in order to achieve H&S

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ULTRATECH CEMENT LIMITEDAndhra Pradesh Cement Works, Tadipatri

Safety Excellence


Unit Vision & Mission

Vision 2020

To be a Model Cement Plant by 2020 with a clear focus on Safety, Environment,

Quality, Cost, Productivity, Delivery, Employee & Societal Satisfaction.

Mission 2020To deliver superior value to our customers, shareholders, employees and society at largewith Systems & Team based, Safe & Environment friendly work culture throughInnovation, Skill up-gradation, Conservation and Technological up-gradation adheringto Aditya Birla Group Values.


HSE Policy

Andhra Pradesh Cement Works has a separate written safety and health policy duly signed / approved by Occupier

Andhra Pradesh Cement Works (APCW) 4

EHS Policy Deployment Methodology

EHS POLICY

UTCL safety Apex Board

UTCL Safety sub committee

APCW Site Safety Sub committee

s

Statutory Safety

Committee

Environ-ment cell

Health (Hospital)

Safety Departme

nt

WCM EHS Sub

committee

APCW Safety Apex

Board

Sustainability cell

HSE Policy objectives

Implementation

Compliance

SystemStandards

SMPSWP

Standardoperating

procedures

RulesandProcedures

Method of deploying H&S objective


Mode of HSE Policy communications

The policy is made to know to all levels of employeesCategory Mode of Communication

Visitor Safety & Health Policy boards are displayed at all the office buildings in plant area and also displayed at guest houses / visitor safety orientation.

Company Employees

Safety & Health Policy is briefed to all employees as part of induction training. Each policy point is explained for clear understanding & compliance.

Safety & Health boards displayed in plant at all office areas and at shop floor. Posters are displayed at prominent locations of the plant

Safety & Health policy is also printed in safety standards pocket book and distributed to all employeesPocket size Safety & Health policy cards are distributed to all of employees for ready reference & reminder.Safety & Health policy is uploaded in our intranet portal for accessing by our employees

Contractors & their employees

Safety & Health policy is printed in the contractor safety manual / plan and issued to them. Safety Policy by major contractors is also prepared, displayed & followed.

Vendors & Suppliers

Safety & Health Policy is uploaded in UltraTech Business website for reference / access suppliers and vendors. Policy is also printed in the contractor safety plan / manual. They are also communicated in the periodic vendors meet.


Safety Standards & ProceduresSafety Standards

1. HIRA/JSA2. Confined Space Entry 3. Excavation4. Working at height5. Scaffolding6. Electrical safety 7. LOTOTO8. Incident Investigation9. Road safety 10. Rail safety 11. HEMM12. Handling of load by Mobile Crane &Lifting Tackles 13. Hot Work14. PPE – Selection, use and maintenance15. Storage, Transportation & Handling of Explosives16. Dump Management17. Drilling Standard18. Ripping & Dozing19. Loading & Rock Breaking20. Transportation in Mines21. Fire Risk Management

Safety Procedures 1. On-site Contractor Safety Management(CSM)2. Training & Capability Building3. Permit to Work4. Machine Guarding5. Heavy Earth Moving Machinery / Equipment Operation 6. First Party Safety Audit7. Corporate Safety Audit8. Multiple Agency Working9. Floor Hole Cover10. Job Cycle Checks11. Silo Cleaning12. Management of Change13. Progressive consequence management


HSE Organization structure

• The HSE organization is well structured in such a waythat almost all line managers are responsible /accountable for safety in respective departments / sectionacross plant.

• HSE policy is implemented by setting periodical objectives& targets, which are reviewed in the monthly Safety apexmeetings.

• Line managers right from top management i.e. from UnitHead to the FLE’s/FLO’s (front line engineers / front lineofficers) are accountable/responsible to ensure & achievethe HSE objectives & targets.

Organizational set up and responsibilities at various levels and arrangements for implementation of H&S policy

HSE Organization chart


HSE Organization

H&S OrganogramV. Ganesan

Unit HeadAPCW, Tadipatri

P.Ganapati Raju

DH-QC & Envt.

R. Nithianandan

SH-Envt.

Vinod Kumar

Officer-Envt.

MSRK Prasad

FH-HR,P&A

Dr.Babu Prasanna

CMO (Health)

Dr.Manohar

Medical Officer

Dr.Swarnalatha

Lady Doctor

S.Umar Farooq

DH- Safety .

B.Hari Prasad

SH-Safety

Dada peer saheb

SH-Safety

B.Sanjeeva RajuSafety engineer


HSE Organization

Safety KPI for every employee in order to achieve H&S Objective

• Accountability is fixed for the individual for achieving safetyperformance and 15% weightage is given for advancement.

• Promotions of managers are delayed in case of fatal / seriouspotential incidents in their respective supervision/areas.

• Progressive consequence management is implemented to takedisciplinary actions for violation of life saving rulespertaining to – work at height, hot work, PTW, LOTO,Confined space entry, Non-reporting of incidents, condoningany of these.

• Cash Awards & appreciation letters given to employees /contractors for identifying / preventing fatal /serious potentialincidents.

Safety KPIs

Safety inspection and Audits

Reduction in no.of

incidents

Standard compliance

Monthly Schedule of

Safety Observation

Round

Reduction in unsafe

behaviors

Reporting Near Miss

Cases

Compliance to

recommendations


Review of HSE performance by top management

Review report on H&S performance

HSE performance of all the units of UltraTech Cement Business is reviewed in themonthly UTCL Safety & Sustainability Board meeting.

Ten subcommittees including Off the Job Safety subcommittee Chaired supportingthe UTCL OH&S Board, reviews the core performance of all the UTCL plants in theirmonthly meetings conducted by respective Chairman.

HSE performance of the unit is reviewed in the monthly site apex safety meeting Chaired by Unit Head, as well as the six safety subcommittees.

Monthly safety report & Cement Sustainability Initiative (CSI) report detailing plantsafety performance is sent to our Corporate - Safety Head and CMO/DMD.

A copy of Safety performance indicating brief report on injuries & CSI(CementSustainable Initiatives) ,leading &lagging indicator report submitted monthly to thecorporate safety board

Safety performance indicating brief report on injuries & CSI(Cement Sustainable Initiatives) report


Review of HSE performance by top management

Organization is certified OHSMS under Indian Standards.


HSE TrainingsIdentification of training Needs for employees and contractors• Line managers identify & ensure safety training needs (TNI) of the employees / contractors working under them and training is

arranged / conducted through trained trainers on each safety standard / procedure.Training matrix for Employees & Contractors (Trade Wise)

Trade Wise Contract employees Training Matrix

TradeCSM Working

at Height ScaffoldingLifting and

Supporting of Loads

Hot work

Confined Space Entry

Machine Guarding LOTOTO HEMM HIRA/JSA Electrical

Safety Excavation Road Safety Standard

Hot Work Standard

Mine Safety Rail Safety

Technical

Mines

Technical

Mines

Technical Mines Technic

al MinesTechnical

Mines

Technical Mines Tech

nicalMine

sTechnical

Mines

Technical

Mines

Technical

Mines

Technical

Mines

Technical

Mines

Technical

Mines

Technical

Mines

Technical

Mines

Technical

Mines

Contractor Supervisor √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ × √ √ √ √ √ √ √ √ √ √ √ × √ √ √

Technician × × √ × √ √ √ √ √ √ √ × √ √ √ √ × √ √ √ √ √ √ √ × × × × × √ √ ×Driller/Helper × × × × × × × × √ √ × × √ √ × × × √ √ √ × × × × × × × × × √ × ×Electrician × × √ × × × × × √ × √ × √ √ √ √ × √ √ √ √ √ × × × × × × × √ √ ×Wireman × × √ × × × × × × × √ × √ √ √ √ × × √ √ √ √ × × × × × × × × × ×Fitter × × √ × √ √ √ √ × × √ × √ √ √ √ × √ √ √ √ √ × × × × √ √ × √ √ √

Welder × × √ × √ √ × × √ √ √ × √ √ √ √ × √ √ √ √ √ × × × × √ √ × √ √ √

Rigger × × √ × √ √ √ √ √ √ √ × √ √ × × × √ √ √ √ √ × × × × √ √ × √ √ √

Operator / Attendant × × √ × √ √ √ √ √ √ √ × √ √ √ √ × √ √ √ √ √ × × × × × × × √ √ ×HEO/Loco/Crane Operator × × × × × × √ √ × × × × √ √ √ √ × √ √ √ √ √ √ √ √ √ × × × √ √ √

Mechinist/Turner × × × × × × × × × × × × √ √ × × × × √ √ × × × × × × × × × × × ×Instrument Tech × × √ × × × × × × × √ × √ √ √ √ × × √ √ √ √ √ √ × × × × × × √ ×Electrical Helper × × √ × × × × × √ √ √ × √ √ √ √ × √ √ √ √ √ √ √ × × × × × √ √ ×Khalasi / Mech helper × × √ × √ √ √ √ √ √ √ × √ √ × × × √ √ √ √ √ × × × × × × × √ √ √

Sampling boy × × √ × × × × × × × √ × √ √ × × × √ √ √ × × × × × × × × × √ √ ×Lab helper × × √ × × × × × × × × × × × × × × × √ √ × × × × × × × × × × × ×Blaster /Helper × × × × × × × × × × × × × × × × × √ √ √ √ √ × × × × × × × × × ×Housekeeping by broom (General Area) × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × √ ×Housekeeping Mines × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × ×


HSE Trainings

Induction method followed for employees, contract workforce, experts, Govt. Officials and others

• safety induction training to new employee (Company &Contractual) who joins the Organization• Safety Orientation to visitors who ever visits the plant at the entrance gate before issuing visitor gate pass

Organization Structure Safety Message by business head Life saving rules Company health and safety

policy

Plant layout and process outline

Hazard and risk inherent in cement manufacturing process

Safety Observation Incident Reporting & Investigation

General overview on Emergency Procedure PPEs and its use Fire Protection & Fighting Vehicular / Traffic Safety

Contents of Safety Induction Training

• pre and posttest for each classroom safety training through which safety training effectiveness of employees is being measured.• Similarly there is also pre and post test is available for on line safety training in which participant must achieve 80% to pass the post

test.

Measurement of Training effectiveness through feedback


HSE Training


HSE TrainingsIndividual training records

• Employee – Trg. details is recorded against each employeewhich is maintained by Training

• Contractors- training passport system in which all trainingsattended with signature of trainer is available and thispassport book will be lying with contractor workman.

CONTRACTOR SAFETY TRAINING PASSPORT

Drivers (Internal& External Vehicles) training• Training and awareness on defensive driving is given to drivers (internal& external).

Training is given in following waysClass room training by internal trainersDistribution of pamphlets and road safety pocket book Playing of audio safety instructions on road safety at the entrance of gateDefensive driving campaign at truck yard and material loading/unloading point Training on defensive driving by external expertsTraining on personal health& hygiene by medical officer


HSE Trainings

Training Particulars

Sr. No. Trainings 2016-17 2017-18

1 Internal Trainings 82 76

2 External Trainings 04 02

3 Training Participants Company 580 558

4 Training Participants Contractors 1700 1785

5 Total Training Hours 27824 26270

6 Training Hr. individual per employee per annum 12.8 8.8

7 Training Hr. Contractor individual per employee per annum 12 10.4

8 % covered Employees 96% 93.9%

9 % Covered Contract workforce 85% 88%


Mock Drills

Mock drill

Sr. NO Description 2016-17 2017-18

1 Fire in cable cellar and technician injured 02 012 Fire in empty bag godown 00 013 Fire in transformer 00 01

4 Fire at coal yard 01 00


Accident/Incidents Reporting

The method of reporting system

• Employees - All incidents reported promptly(within a shift) by concerned employee through mysetu portal .

• Contractor / Visitor - report the incident in Nearmiss card and drop the cards in Near miss boxlocated at various sections of the plant. The boxowner collects the card and reports the incident inmy setu portal.

• Initial reports should be brief and limited to a briefoutline of the known facts (date, time, place, whathappened, and immediate actions taken). Personwho reports the incident is rewarded with cashaward after checking quality

Incident reporting -Mysetu Incident reporting -card


Accident/Incidents ReportingRoot Cause Analysis on incidentsWe are following route cause analysis method to investigate all incidents as per our incident investigation procedure.

Make initial response and report

Form investigation Committee

Determine the facts

Determine the key factors

Determine the system to be strengthen

Recommend corrective actions

Document and communicate the finding

Follow Up

Incidents Team Formation Team Leader

Near miss (High Risk )

Head Of the Department


Near miss (Medium Risk )

Section Head Section Head

RWC,MTC,FAC,NMC -Minor injury


Head Of theDepartment / Section Head

LWC -Serious injury

Functional Head Functional Head /

HOD

Fatality Unit Head Unit Head

Leading the Root Cause Analysis Process8 steps of Incident investigation process.


HIRAC & SOP

HIRAC for the plant and its critical maintenances.Organization is having standard on HIRA/JSA by which weare carrying out HIRA for all activities (routine/non-routine.Detailed steps of HIRA process in flow chart is as shownbelow:

Standard Operating Procedures exist for all critical and regularactivities.

SOP is made for all critical and regular activities and which is communicated to the employees working in the particular section.

Dept. SMPs SOPs SWPsTPP 25 42 163Mines 25 179 184Production 23 41 30Mechanical 161 104 10Instrumentation 30 57 69Electrical 17 26 112Total 281 449 568


Contractors Safety Management – Contractor Selection

Evaluation of contractor’s methodUltraTech cement Limited established exclusive standard on contractor safety management and the intent of the Standard is to ensure aformal approach for the administration of Contractor Safety. The objective of this program is the development of an incident free workenvironment, by creating a systematic approach to managing contractors and making them aware of the risks associated with workingon site. This standard is a six step process.

Contractor pre-qualification

Contract preparation

Contract award

Contractor orientation and

training

Contractor work coordination and auditing

Contract evaluation


Contractors Safety ManagementFrequency of contractor’s safety performance monitoring• Contractor Field safety Audits are conducted at contractor sites.• If the observations are of severity 4&5 nature, then disciplinary action will be taken against for contractor.• Observations made are communicated to the contractor by concerned engineer for doing necessary compliance, the

status of these points are reviewed in CFSA meetings and apex safety meetings.

Deployment of qualified safety person on board as per 50:1

• Contractors who are working at site deployed qualified safety person on 50:1 ratio which is also an requirementas part of our contractor safety management procedure.

Frequently of involvement of in safety meetings

• For Regular contractor – safety meeting (once in 2 months)

• For project contractor – weekly safety review meeting


Contractors Safety Management

Method adapted to encourage contractors safety performance

We have system for rewarding contractors to motivate contractor for improving safety performance. The methods are as follows.

• Individual motivation – Contractor workmen is awarded with good citizen on every month

• Contractor motivation – Yearly rolling trophy for best safety performance of the year

Apart from the above observations related to contractor field safety audit are being shared with contractors on timely manner to improve

the performance of contractor.


Safety Audits

Sl. No. Audits 2016-17 2017-18

1 Internal No of Observation 279 214Compliance % 100% 100%Variance Nil Nil

2 ExternalNo of Observation 72 NilCompliance % 100% NilVariance Nil Nil


Plant Safety Performance

Type 2016-17 2017-18Near-miss 2311 1352High Potential Near miss 10 12First – aid cases 11 9LTI ( Lost Time Incident ) 0 0Fatality 0 0Man hours lost due to LTI 0 0Severity Rate 0 0Frequency Rate 0 0No of Dangerous occurrences as per factory act 0 0

Reportable incident and Frequency Rate

The longest accident free period During the assessment period i.e. 2016-2018

From Period To Period No of Days Accident Free Million Man Hours

01.04.2016 31.03.2018 730 12.794


Occupational Health

Dedicated OHC & Dedicated Staff

Factory is having dedicated Occupational Health Centre with two ambulances to cater in case of emergency. Onechief Medical officer supported with a Medical Officer with required number of Compounders, Nurses, pathologicaltechnician, pharmacist, housekeeping employee, with availability of 10 bed hospital to take care of daily routinemedical care as well as pre-employment / periodical medical examination.

Names of Medical officer are as follows:Dr. Prasanna Kumar- CMODr. K. Manohar- Medical OfficerDr. N. Swarnalatha - Medical Officer (Lady Doctor)

Apart from the above medical doctors, specialist doctors are visiting Occupational Health Centre on regular intervals.


Occupational Health

Pre-medical check procedure for employees

Employees (Company &Contractual) who ever joins the organization, they have to undergo Pre-Medical Examinationat our Occupational Health Centre. Following are the things checked as part of Pre-Medical Examination.

Pre-medical check procedure for employees

Periodical Medical Examination for all employees is carried out once in a year where complete examination including X-Ray, Spirometry is carried out.

General Checking

Blood &Urine Examination ECG Chest X-Ray Spirometry Audiometry

Contractor workforce medical prior to deployment on job

All contractor employee who joins the organization has to undergo mandatory pre-medical examination withoutwhich entry gate pass will not be issued to any contractor workmen. Pre-Medical examination of contractor isconducted at Occupational Health Centre located at plant premises.


Health Awareness Awareness on is through Posters Mails Tool Box Talks Lectures & Interactive sessions Personal Counselling


Safety Promotional ActivitiesEncouraging employees and workforce to

follow safety practices

S.No. List of promotional activities

1 Employees Suggestion Scheme

2 Near Miss Case – reporting - cash reward scheme

3 Safe Employee of the month award scheme

4 Award Scheme for kaizen

5 Award Scheme for NMC reporting

6 Road safety week celebrations

7 National safety week celebrations

8 Good Citizen award


Awards & AccoladesSafety

Best Managed Unit (Andhra State) – 2016 awarded by A.P. Govt.

CII EHS Excellence award with 4-star rating in 2016

Best Managed Unit (Andhra State) – 2015 awarded by A.P. Govt.

Indian Bureau of Mines : Hyderabad Region – 2014

1st Prize, Overall performance in MSWC – 2016

1st Prize, Overall performance in MEMC – 2015

Greentech Safety Award – 2012

FIMI Award (Best in Environment) – 2015 NCCBM Environment Excellence Award – 2011

Environment


Awards & Rewards

Sl. No. Awards Achieved / Awarded by 2017-18

1EHS Excellence award with 4 - star rating in southern region in large mfg. sector by CII

Jan’18

Awards & Accolades


Best Practices –Safety

Rearview camera monitor in mines dumper

Proximity Limit Switch in mines dumper Traffic signal lights at junction

Smart ground detector at LDO unloading station to check grounding

Confined space temperature display for safe entry

SMS Facility in DCS for communication about plant emergency


Best Practices –Safety

Biometric entry system for authorized persons in to MCC rooms

Arc flash boundary marking in MCC rooms

Cycle helmets usage by school children

Rail skid to restrict the movement of wagons

Run over protection guard installed in hydra crane

Use of arc flash suit by electrician at MCC room


Best Practices –Safety Gallery


Thank You

Documents

Safety Excellence ULTRATECH CEMENT LIMITEDqcfihyderabad.com/cementconclave2018/wp-content/uploads/2018/10/Ultratech-Anatapur...Safety KPI for every employee in order to achieve H&S