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Trusted Technology – Solid Strength

SAFETY AT

VASAVADATTA CEMENT

SAFETY DEPT-ORGANIZATION CHART

Plant Head

GM-Safety

VC-Safety Steward (8 Nos)

Dept –Nominated Safety Officer (15 Nos)

Manager-Safety

Contractor Safety steward (15 Nos)

Sr.Engineer-Safety

Trusted Technology - Solid Strength

SAFETY POLICY Trusted Technology - Solid Strength

Safety Statistic / Key Indicators Trusted Technology - Solid Strength

Sl No Audit Team 2016-17 2017-18

1 No of Fatals 00 00

2 No of Reportable Accidents 00 00

3 No Of First Aid Injury 09 07

4 No of Near Miss 13 10

5 No of Tool Box Talk 17998 19483

6 No of Task Observations 4479 4189

7 No of Dangerous Occurrences 00 00

8 No of Suggestion Received Form Employees 1361 915

9 Training Imparted to Employees 2075 2101

10 Frequency Rate 00 00

11 Severity Rate 00 00

12 Incident Rate 00 00

13 Longest Safe Mendays 712115 974915

LEGAL COMPLAINCES


Integrated Management System Certifications ISO 14001- Environmental Management Systems ISO 9001 - Quality Management Systems ISO 50001:2011 - Energy Management System OHSAS 18001 – Occupational Health & Safety Management Systems Under which Risk assessments have been done for all task which involves risk and may cause Injury or leads to occupational decease and also made Safe Operating Procedure for each task and are displayed at work site in local , Hindi and English languages. Comprehensive Internal / External Safety Audit inviting experts From various organisation Viz, National Safety Council, M/s Green circle,CII, M/s Reliance Insurance Mumbai, BIS Etc.

Sl No

Audit Team No of

Observation No of Observation

Implemented Pending / Not

Feasible

1 M/s National safety Council Karnataka chapter

193 193 00

2 M/s National safety Council Mumbai

56 56 00

3 M/s Reliance Insurance 29 29 00

4 M/s Green Circle Inc Gujarat 138 135 03 (NF)

Sl No No of Risk Assessment No of Safe Operating

Procedure (SOP)

1 246 136


LEGAL COMPLAINCES

We comply with all statutory requirement as per Karnataka Factories Rules 1969 / Factories Act,1948. We do Mock drill once in every quarter on Height Rescue Drill and Fire Fighting Demonstration Etc and separate emergency manual being made and circulated among all and respective team will response during emergency .

Inspection of All Tools, Tackles, Pressure Vessels & Passenger Lifts by Competent Person As per Rule 63 & 65 of

Karnataka Factories Rules 1969

Central Safety Committee being formed which includes 101 members and chaired by plant head and committee will meet once in quarter and all safety issues will be addressed and decided by committee members

Central Safety Committee Inspection Of Lifting Tools By Competent Person

Mock Drill

Directional Board & Traffic Mirror Installed At Plant Premises


safe access with platform to eliminate risk of fall of person from tanker top while

opening / closing top doors


Safe Over Head Platform

Vehicle Speed Check and Safety Talk To Truck Drivers



Training to All Staff / Workmen / Contract work men By M/s Road Safety Foundation On “Defensive Driving Training’ “-23rd Dec 2017

Training on Defensive Driving to Truck Drivers On the view of Road Safety Week Celebration

Safety Suggestion & Near Miss Reporting


Boxes are kept at convenient locations with reporting format A single form developed which includes Near Miss, Safety Suggestion, Unsafe Act & Unsafe Condition Weekly Forms are segregated in above four Categories Reward for reporting a near miss incident, a safety suggestion and at least 05 unsafe condition Monthly Awards distributed during Safety Gate Meeting holds on “No vehicle Day” Whats App Safety group has been formed to report Safety Suggestions/ Unsafe Conditions/ Unsafe Acts

With advance Information-To check the Safety knowledge and competency level of person Without Information-To monitor the Safe behaviors and attitude of person


TASK OBSERVATION

CATEGORY-A CATEGORY-B

CATEGORY-C

CATEGORY-D

CATEGORY-E

CATEGORY-F

PPE POSITIONS OF

PEOPLE ERGONOMICS

TOOLS AND

EQUIPMENT PROCEDURES

HOUSEKEEPING

SERVICES

•Eyes and face

•Ears

•Head

•Hands and arms

•Feet and legs

•Respiratory system

•Striking against •Struck by

•Caught between

•Falling

•Temp. Extremes

•Elec. current •Inhaling •Absorbing •Swallowing

•Posture

•Type and number of motions

•Load handled •Work area design •Tools and grips •Vibration

•Temperature

•Lighting •Noise

•Right for job

•Used correctly In safe condition. •Leads tagged Ladders/work Platforms (height) •Crane operation •Electrical protection

•Scaffold •Mobile equipment

•Is standard pract. adequate for job

•Is standard practice Established? •Is standard practice Being maintained?

•Permit

•Isolation

•Risk Assessment

•Tidy workplace

•First aid boxes

•Emergency exit signage/clear passages

•Fire protection •Emergency Lighting • Quality of Air/Potable water •Hygiene

Done for individual or group of people

Done with or without information

Skill and Behavioral Observation is made

Done by Section Engineer/ Officer

FACTORS CONSIDER FOR CARRYING TASK OBSERVATION

SAFETY REGISTER


Sl. No

Date

Work Description / Location

PPE’s T

O

O

L

B

O

X

T

A

L

K

S

A

F

E

T

Y

P

E

R

M

I

T

All tools /Tackles Etc Inspected

Other Appliances Provided Viz, Safety Net, Life Line, FBA, ELCB Etc

Signature R

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m

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k

s

S

H

O

E

S

H

E

L

M

E

T

H

A

N

D

G

L

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V

E

S

G

O

G

G

L

E

E

A

R

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P

L

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G

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A

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T

Y

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S

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r

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2

It is to ensure all required PPE’s are available with all worker.

Prior to work commencement all the safety requirements are cross checked by section engineer.

Unless the register is cross checked and signed by safety officer work cannot be started.

Applicable for working at height, scaffolding work, confined space work

Work Permit System

This is one of the most effective safety system which ensures that all control and precautionary

measures are at place to carry out critical task without any accident.

We have following work permit system and are rigidly followed by all concerned

A)-Permit to work in confined space.

B)-Permit to work at height

C)-Scaffolding work permit.

D)-Hot work Permit

E)-Excavation work permit

F)-Radiation work permit.

G)-Line Clearance permit.


LOTO

Height work Permit

SCAR-Safety Corrective Action Request


Planning is done for the month

Done by Safety Officer and Section Manager.

Entire plant is covered in a month

Mostly Unsafe Conditions are Reported

Observation are recorded with photographs 1300

1320

1340

1360

1380

2014 2015 2016 2017

1380

1329

1380 1370

SCAR

Procedure for Addressing Unsafe Condition

Specific

Location:

Wagon tippler-I, beside Control room

Comments/ Recommendation: Toe guard

found missing.

Responsible dept.: Mechanical

Reply Date: 15-02-2018

Reply: Toe guard fixed to festoon

platform.

SAFETY CODE OF CONDUCT FOR CONTRACTOR

Total 56 Safety points defined under six main clauses.

Every contractor shall have at least one Safety Co-ordinator at site. Wherever the number of workmen to be engaged is more than 50, a qualified safety officer shall be appointed by the contractor.

Job specific PPE (Personal Protective Equipment) such as Hand Protection, Respiratory Protection, Full body protection.etc shall be used as per IS standards.

Safety Code of Conduct is incorporated with work order. The contract is only awarded to contractor who agreed to adopt and adhere VC safety rules and standards.


Contractor Evaluation Trusted Technology - Solid Strength

CONTRACTOR’S PERFORAMANCE EVALUATION 1 Department

2 Name of the contractor

3 Work Order Reference

4 Work Order Date

5 Validity of order From : To:

6 Period under evaluation From : To:

OCCUPATIONAL H&S AND HOUSEKEEPING (To be filled in consultation with Safety Manager)

Statistics on Safety Performance of Contractor - Inputs for evaluation on H&S performance

Sr. No. Description of incidents No. of incidents Remark

1 No of Accidents

2 No of first aid cases

3 No of danger occurrences

4 Fatal Accidents

5 No. of events of Non compliance of Safety terms &

Conditions

(A) EVALUATION PARAMETER

Sr. No. Parameter/ Description Maximum score Score on Evaluation Remark

1 Training on safety prior to start of job 100

2 Use of PPEs as per job requirement 100

3 Safety precautions taken on the job 100

4 Supervision and Monitoring w.r.t. safety compliance 100

TOTAL 400

% Total of Evaluated Score

(B) SERVICES RATING – SERVICES PROVIDED BY CONTRACTOR


1 Having proper quantity of tools as per job requirement 100

2 Having proper quality of tools as per job requirement. 100

3 Contractor has supplied proper quantity of man power as

required. 100

4 Contractor has supplied proper quality of man power as

required. 100

5 Punctuality of the manpower at their job. 100

6 Arrangement of manpower during shutdown, breakdown,

emergency or odd hours. 100

7 Understand the job & following instructions of concerned

engineer 100

8 Technical skill & ability for carrying out the assigned job 100

9 Quality of the assigned job performed 100

10 Promptness & adherence to the schedule 100

11 Compliance of housekeeping during and after of work 100

12 Services of supervision 100

TOTAL 1200


( C ) COMPLIANCE OF STATUTORY REQUIREMENTS (To be filled in consultation with HR department)


1 Timely submission of deployment / other required report/

information to HR department as per need 100

2 Compliance of statutory requirement as per acts and rules 100

3 Compliance on payment of wages as per state minimum wages 100

4 Compliance to maintain satisfactory Industrial Relation 100

TOTAL 400


SUMMARY OF CONTRACTOR’S EVALUATION/ ASSESMEMENT

Sr. No. Evaluation Parameters weightage Evaluated Scores % Signature of concerns

(A) Compliance on OH&S and Housekeeping 20%

(B) Quality of Services provided by contractor 60%

(C) Compliance on Statutory Requirement 20%

% Total of Evaluated Score 100%

OVERALL ASSESSEMENT / EVALUATION BY HODs

OVERALL ASSESSEMENT / EVALUATION BY HRD

Corrective measures, if any:

Remarks, if any:

Evaluated by

(Concerned Deptt.

Representative/

Section Incharge)

Reviewed by

Signature: Date:

Name :

Designation : HMO

EVALUATION CRITERIA/RATING

SN Score description OVERALL RATING (%)

1 Excellent. No significant faults. >95% - Excellent

2 Good. One or two minor faults. No significant faults >80% - <=95% -Very Good

3 Average. Several minor faults >60% to <=80% - Good

4 Poor. Some serious failings >40% to <=60% - Average

5 Unsatisfactory. Many potential serious failures <40% - Poor

Contractor Evaluation Trusted Technology - Solid Strength

Statistics on Safety Performance of Contractor - Inputs for evaluation on H&S performance

Sr. No. Description of incidents No. of incidents Remark

1 No of Accidents

2 No of first aid cases

3 No of danger occurrences

4 Fatal Accidents

5 No. of events of Non compliance of

Safety terms & Conditions

(A) EVALUATION PARAMETER

Sr. No. Parameter/ Description Maximum score Score on

Evaluation Remark

1 Training on safety prior to start of job 100

2 Use of PPEs as per job requirement 100

3 Safety precautions taken on the job 100

4 Supervision and Monitoring w.r.t. safety

compliance 100

TOTAL 400



Fire Fighting Measures Taken 08 numbers of trained and qualified fire men appointed. Smoke detector installed in all load Centers and CCR Fire resistance paint applied on all Power cables. CCTV cameras installed on Hot Disc Alternate fuel feeding belt. Hydrant sprinkler installed on coal handling conveyor belts. Stand by pumps/ alternate power provision is made for all Fire Pump. Apart from Disaster management plan, Emergency plan has been prepared and responsibilities have been assigned to individuals. Quarterly mock drill on Fire Emergency, Rescue etc. Hydrant System at various locations of Plant Total Hydrants Points:79 No., Dry Riser:17 No. Water Monitors :04 No. Based on the Fire Load Assessment Total 1140 no. of portable fire extinguishers have been installed at various locations including Offices, Store & all sections.

Two Dedicated Fire Tenders for Emergency Fire Fighting

Manual Fire

Fire alarm Panel

Trail Run / Demonstration of Fire Hydrant Line At New Coal

Yard

Portable fire extinguisher installed on all gas cutting sets Portable fire extinguisher installed on all Vehicles including loco engine. Monthly inspection carried out for all fire hydrant system by Security/Safety Departments. Periodic demonstrations of portable and fixed fire fighting system are conducted. At all coal mill and transfer tower of coal conveyor belts ,dry risers have been installed.

Installation of fire extinguisher (2kg DCP type) on all cutting sets


Fire Fighting Measures Taken Portable fire extinguisher installed on all gas cutting sets Portable fire extinguisher installed on all Vehicles including loco engine. Monthly inspection carried out for all fire hydrant system by Security/Safety Departments. Periodic demonstrations of portable and fixed fire fighting system are conducted. At all coal mill and transfer tower of coal conveyor belts ,dry risers have been

installed.

Installation of fire extinguisher (2kg DCP type) on all cutting sets

Mock drill at Hot Disc belt & Railway Yard

EMERGENCY PREPAREDNESS

Disaster Management Plan approved by Director -Factories & Boilers Karnataka state.

Emergency Response manual

Team constituted for various work

Role and Responsibility fixed

Mock Drill on Regular Interval

Rescue kit is readily available to reduce response time.

Portable welding machines and a gas cutting set is kept separately for emergency situation.

Emergency contact numbers are displayed at various location.

Workers have been briefed about emergency response procedures.


PLANT HEAD DEVESH MISHRA

SAFETY & RESCUE

BISWAKARMA SINGH

RESOURCE MANAGEMENT P K JOSHI

L Vegi

FIRE COMBAT

Reji.K

ELE. ISOLATION & EMERGENCY POWER SUPPLY

R K Gupta

EVENT CONTROLLER

Mahesh Chand Gupta

FIRST AID

Dr. Jagadish Kulkarni

TYRE PRESSURE SENSOR

FLASH BACK ARRESTOR WITH FIRE EXTINGUISHER ON ALL CUTTING SET

SAFETY NET IS BEING USED FOR HEIGHT WORK


(A)-Engineering Control

ANTI NAP DEVICE FOR MINES OPERATORS


MESH GUARD PROVIDED AT EITHER SIDE OF CONVEYOR BELT

SMOKE DETECTORS INSTALLED ON HOT DISC CONVEYOR

REAR VIEW CAMERA ON TIPPERS


Note: All conveyor belts are guarded by installing mesh guard on both side of the conveyor including low speed belt Approximate length – 08 km

UNDERNEATH AREA OF TAKE UP PULLEY/COUNTER WIEGHT IS GUARDED

WATER SPRINKLER INTALLED ON HOT DISC CONVEYOR N2 AND CO2 PURGING SYSTEM AT COAL MILL



Automatic Fire Suppression System on Dumpers

Speed Governor Installed on Dumpers


(B)-Motivation & Campaigns

Safety Pledge during Monthly Safety Gate Meeting.

SHE Pillar Swatch VC Campaign

Safety Rally during National Safety Week Celebration.

Observance of National Events connected to Safety Such as Road Safety Week Fire Service Week National Safety Day National Chemical Disaster Prevention Day

Defensive driving Trainings to Lorry drivers on 24th September 2016

Fire Service Week & National Chemical Disaster Prevention Day


47th National Safety Day, Safety Gate Meeting & No-Vehicle Day Celebration on 06th March 2018

We have established system for identification of training needs of personnel and provide training as per OHSAS-FS-001 (a) (Identification of Training Needs) procedure. We conduct safety training program for Management staff and workmen including contractor laborers to create more and more safety awareness. We have following safety training ppt. modules for safety training program

Visitor safety Induction training module Electrical safety Scaffolding safety Safety while working at height Defensive driving Excavation safety Gas cutting and welding safety Rigging safety Material handling safety Chemical handling safety Principles of safety management Confined space safety Housekeeping and 5s

In addition to above modules “M/s-Dupont Safety Solution “ DVD is being used for training.


Level of Employees

Number of

employees

covered

Frequency of training

No of training Modules covered

(Weekly/Monthly/Quarterly/Annua

lly)

Senior Management

126 Annually 2

Middle Management

486 Annually 4

Junior level Management

425 Half-

yearly 5

Supervisors 58 Quarterly 7 Workers 413 Quarterly 10 Contract Workers

768 Quarterly 12

TOTAL 2276 40

Training & Education

DEFENSIVE DRIVING


GAS CUTTING & WELDING BY M/S-MESSER’S ENG. SCAFFOLDING SAFETY BY NSC FIRST AID BY ST. JOHN AMBULANCE

(A)- Training by Outsourced Faculties

Training Programme on “Lead Acid Battery Safety” .Faculties from HBL Power Systems Limited,


On 6th Jan 2018 ‘Safety Training’ was organizes for Staffs by Shri.DC.Jagadeesh, Joint Director of Factories & Boilers-KSSI and Shri.R.K.Parthsarthy DDF Kalaburgi ,Dr.Naresh-M/s:Orient Cement Chittapur,Shri.Kalil-M/s:Rajshree

Cement,Malkhed,Shri.Durairaj-M/s:Kalaburgi Cement,Kallur


Fire Fighting & Emergency Rescue Training was conducted on 23rd & 24th June 2017 at SRC by Kalaburgi Regional Fire officer Shri.S.E.Lakkappa & Divisional Fire officer Shri.T.Parsuram,Karnataka Fire & Emergency services

Health & Welfare

Pre-employment health check up

Annual health check up

Rest room and sanitary facilities.

Creche room facility

Drinking water

First Aid box

First Aid Centre with Ambulance

Qualified doctors are appointed

Qualified and experienced paramedic and nurses


Height Pass test : For working at Height Fitness test Facility Provided at VC- OHC

FIRST AID FACILITY IN PLANT

First-aid supplies are made available in the plant at all

sections(38 First Aid Boxes)

Fully Equipped ambulance room is constructed and 24*7

services is ensured by deputing qualified paramedic staff

in all shifts.

Total 207 employees have been trained through Saint

John Ambulance and now all of them are certified first

Aiders.

AWARDS RECEIVED Trusted Technology - Solid Strength

SI.No. Year Award Received

1 2018 1) Received award for Zero Fatality in KRISC level 2) Received award for best Health, Safety & Environment Monitoing system in KRISC level 3) Received award for Longest Accident Free Man days in KRISC level

2 2017

1) Received award for best Innovative system in KRISC level 2) Received Second prize in safety skit competition at KRISC level. 3) Received third prize in Safety quiz competition at KRISC level 4) Received Unnatha Suraksha Puraskar award from NSC Karnataka Chapter.

3 2016 1)First Prize in First Aid Facility . KRISC Level 2) Second Prize in Best Safety Induction Training

4 2015 Vasavadatta received Award for ‘Best Innovative Safety Systems’ in KRISC level under the agies of Dept Factories and boilers

5 2014 Green Tech Safety Award for Best Safety Performance

6 2014 Vasavadatta won First Prize in best Engineering control System

7 2014 Vasavadatta Won First Prize In Safety Skit Competition in GRISC Level

8 2013 Vasavadatta won trophy for best innovative safety systems in GRISC level

9 2013 Vasavadatta won first prize in safety quiz at GRISC and BKRISC level


Award for Zero Fatality Award for Maximum Safe Mandays Award for Best Health, Safety &

Environment (HSE) Monitoring system

Trophy Received in KRISC Level During KRIS-Day Celebration on 28th

March 2018


Received ‘Unnatha Suraksha Puraskar’ Award from National Safety Council Karnataka Chapter on 9th Sept 2017 at Bangalore. A top most state level safety award under large scale industries category. Award was given by Honourable Directorate of Factories and Boilers (Health & Safety Department) Karnataka State, Secretary-National Safety Council-

Karnataka, Chairman-National Safety Council-Karnataka and Deputy Chairman-National Safety Council-Mumbai


We won Best Innovative System Award & Second Prize in Safety Skit competition in KRISC level function hosted by M/s: UltraTech Cement Ltd,Malkhed on 25th March 2017 under the aegis of

Deputy Director of Factories Kalaburagi Region Shri.R.K.Parthasarathy

“WORK SAFELY ALL THE WHILE, GO HOME WITH A SMILE”


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