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INTRODUCTION
For achieving maximum output and high productivity, safety of men, machines
and materials in industry is very important. The advent of Industrial Revolution
gave rise to invention of many numbers of machines which gave a spirit to the
productive capacity.
However, since these machines were full of hazards and risks, there had been a
heavy tool of accidents disabling the workers. Gradually, due to the promulgation
of Factories Act 1948 and its subsequent amendments by the Government
stipulating the minimum safety measures and condition to be provided, the
accident prevention work gained momentum.
The recent amendment in 1987 has got its own significance in the sense that
many radical changes have been made in the provision of the Factories Act Safety
measure have been tightened with a view minimize the industrial accidents.
1
IMPORTANCE OF ACCIDENT PREVENTION
When an employee gets injured, he suffers pain and agony and in case of
permanent disablement he is abandoned unless to do his normal work and there by
experienced worker is lost to the industry. His family a also gets affected by his
disablement. By loss of his earning capacity he becomes more or less a burden to
the society. A certain amount of inhibition sets in among the co-workers there by
regarding their productive capacity. Hence, the causation of a single accident
resulting in a injury sets a chain of reactions ultimately affecting the nation’s
economic and social advancement.
The industry also suffers monetary loss due compensation payable to the
injured employee, medical attendance, interruption of work and the fear set in
among the fellow-workers after occurrence of an accident. Therefore, a study on
industrial in modern industrial society.
In this project, a similar study has been undertaken in a leading (public sector)
industrial establishment in this town namely Trichy steel Rolling Mills Ltd., Trichy
(hereafter mentioned as TSRM Ltd.,)
TSRM Ltd., belongs to the basic industry and it is engaged in forging and
fabricating iron road and parts which are ultimately made use of in construction
and other industries.
4
This study has been designed with the following objectives:
5
METHODOLOGY
(a)Collection of data
To collect primary data, random sampling method was adopted with the help
of an interview schedule. This sample comprised of 100 works of the study unit.
This schedule was supplied to these 100 employees.
The secondary data were collected from the records and reports available in
the personal Department of TSRM Ltd., Besides, books, journals and magazines
discussions and reports were also used for gathering related information required
for the study.
The collected data were suitable arranged and tabulated for the purpose of
the study, percentage method was adopted, wherever necessary, in order to derive
results. Diagrams and charts were also drawn.
6
LIMITATIONS OF THE STUDY
The collection of primary data required for the study was a difficult task
and only the available information’s were used;
A sample on only 100 workers is selected from among 484 workers i.e.
10.5%
On account of shortage of time and limited resources at the disposal of
the researcher, it was not possible to interview each and every of the
organization. Hence, the findings may not be cent percent accurate.
7
CHAPTER-II
ORIGION
TSRM Ltd., is one of the major steel producers in southern region of India.
It was incorporation in the year 1961 as private company. In 1963, it was
8
converted into a public limited company and named as “Trichy steel Rolling Mills
Limited”.
In the same year, the company started its commercial production as a re-
rolling mill. The licensed and installed capacity then was 15,000 tones. In the year
1974-75, they are Furnace and the Structural Rolling Mill were installed with the
manufacturing capacity of 26,032 tones of mild steel ingots and casting and 8,000
tones of Structural.
The present licensed and installed capacity of the company is 57,300 tones
per year, the company was started with a paid-up capital of 35 lakhs. The present
equity capital is raised to Rs.55, 50,000 including 1, 85,000 equity shares of
Rs.10/- each issued fully paid –up bonus shares by capitalizations of reserves.
The authorized capital of the company consist of Rs.1 crore divided into 9
lakhs share of Rs.10/- each and 10,000, 10% redeemable cumulative preference
shares of Rs.100/- each.
EXPANSION OF BUSINESS
At present, the company has land around 35 acres for factory. The company
has got additional power in the Senthannirpuram factory and based on post
performance, it is eligible for double the steel making capacity. And application
had been made to the Government of India for substantial expansion. The
company’s production of steel was affected from 1st February 1988 due to power
cut. After the power cut has been removed, the extra power of 1950 KVA was fully
exploited by the company. The company is very thankful to the Tamil nadu
Electricity Broad for having given additional supply of power in 1988.
9
2.3 DEPARTMENTS
1. Production Department
2. Maintenance Department
3. Electrical Department
4. Stock-Yard Department
5. Laboratory Department
6. Billet Casting Machines Department
1. Personal Department
2. Account Department
3. Commercial Department
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4. Material Department
5. Administration Department
6. Mill (Productive) Department
7. Maintenance Department
8. Stock-Yard Department
9. Electrical Department
10.Security Department
PRODUCTS
TSRM Ltd., meet almost all the requirements of Bars and Roads, of 8mm to
25mm thickness which are essentially useful for building constructions and
railways. The products are produced by melting iron scrap. The scrap material and
were fed into furnace for melting.
WORKING RESULTS
The working results of the Company for the past five years are shown with a
view to known its performance.
6 EMPLOYEE’S UNION
All the employees are members in these unions. In these unions the
president, vice president and secretary are among the employees expert the TSRM
Labour Progressive Front. In TSRM Labour Progressive Front Union, the president
is an outsider and other positions are filled up by the union. All these unions were
started in the same year.
ORGANIZATION STRUCTURE
D.K.Adikesalavalu - Chairman
Sri.A.Arunachalam - Director
Sri.R.Subramaniyan - Director
Sri.C.D.K.Reddy - Director
Sri.D.A.Sinivas - Director
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Sri.Aravind Nandagopal - Director
CHAPTER-III
INTRODUCTION
The occupational safety and health of workers are basically and essentially
the responsibilities of management, as in the matter of quality and production.
When the management ensures proper safety arrangements in its premises, the
workers are motivated well towards the performance of their jobs. It should also
aim at minimizing deterioration and losses of precious resources of man, machines,
materials and money.
13
prevent the hands against acids explosive materials, safety shoes, skin guards,
safety apparel for protection of the body, etc., are provided for the use or workers.
SAFTEY COLOURS
As an aid to safety, colours are used to identify and mark-out the dangerous
parts of machines. According to jucious, yellow or orange colours are used to
indicate dangerous materials or part of a machine; blue of protective materials and
red for fire-fighting and fire protection material and equipments.
Safety education for all levels of management personnel and for worker is
vital for any successful safety programme, The aim of safety education is to
develop safety consciousness among the employees and to ensure safe work
performance on the part of each employee be developing his skills in the use of use
and operating of safety equipment.
Accidents occur due to two basic factors; (1) Technical and (2) Human.
Technical factors include all engineering deficiencies related to plant, tools,
materials and the general working condition. Thus for example, improper lighting,
inadequate ventilation, poor machine guarding are some hazards which may cause
accidents.
2. INVESTIGATION OF ASSOCIATION
The company under the study is covered by “The Factories Act 1948” Thus
the following are provided as per this Act:
15
In every factory, a suitable striking gear or the efficient mechanical
appliance shall be provided and maintained. Driving belts, when not in use, shall
not be allowed to rest or on a shaft in motion. Suitable devices for cutting off
power in an emergency shall be provided and maintained in every work room.
When a device, which is likely to be provided and maintained in from the “off” to
the “on” position, there shall be provided in a factory to cut off power.
Arrangements should be made to lock it in a safe position with view to prevent any
accident.
All machine driven by power installed in any factory, every set screw, bolt
or key on any revolving shift, spindle, wheel shall be so sunk, encased or otherwise
effectively guarded, as to prevent danger casing of machinery is duly complied
with in the unit.
No women or child shall be employed in any part of factory near the cotton
openers.
16
6. HOISTS AND LIFTS (SECTION 28)
(SECTION 29)
In every factory, lifting machines, tackles, chains and ropes shall be of good
constriction and of sound material. They shall be free from defects and strong
enough to carry the necessary loads.
All doors steps, stairs, passages and gangways shall be of sound construction
and shall be free of obstruction. No substance which is likely near them.
17
In every factory, every fixed vessel, tank, pit or opening in the floor. Which
may be source of danger, shall be securely covered or securely fenced.
If any factory (i) No portable electric light or any other electric appliance of
a voltage exceeding 24 volts shall be permitted for use inside any chamber, tank,
vat, pit, flue or confined place. No lamp or light other than the one which is flame-
proof shall be permitted to be used therein.
The following activities of the TSRM Ltd are listed as the safety
promotional efforts.
1) Every month, the top executive of the Mill in the “Shop out turn meeting”
reviews the reasons for the increase or decrease in the number of accidents
occurred in the shops during the particular month. This meeting is attended by all
shop supervisors. They use to take decisions about the measures that may reduce or
eliminate the incidence of accidents in future.
2) A “Safety week” is being observed once in every year. All the supervisors of the
TSRM Ltd are required to wear the “Safety Badges” during the working hours of
the entire safety week.
3) Safety posters of different types have been exhibited in each shop for creating
safety awareness among the workers and supervisors.
19
SAFETY COMMITTEE
One copy is kept with the department and one is send to inspector of
Factories directly. One of the 3 copies send with the injury person is send to ESI
Local officer filling the particulars regarding location and nature of injury. Another
copy with the same particulars will be send to welfare Department. And one will
be kept with the Medical Department.
ACCIDENT INVESTICATION
20
CELEBRATION OF SAFTEY DAY
“Safety Day” is observed in TSRM Ltd. On 4th March of every year. One
that, day worker uses to take some safety oath.
CHAPTER-IV
After having explained the existing safety measures statutory and voluntary-
in TSRM Ltd., It is proper to evaluate the effectiveness of such safety measures.
Hence, this chapter earmarks to such critical evaluation.
Here, the reported and recorded accidents in TSRM Ltd., are analysed. The
accident frequency rate and severity are computed and interpreted for the purpose
of evaluating the performance of the management in terms of accident prevention.
The accidents frequency rate refers to the number of disabling accidents per
10 lakhs man-hours worked. The frequency rate is calculated by the following
formula.
No. of accidents
F.R.= X 10,00,000
No. of man- hours Worked
21
STARTUTORY PROVISIONS AS PER THE FACTORIES ACT 1948
FENCING OF MACHINERY
22
TABLE.1
INFERENCE
Reveals that the option of 41% of the respondents was good, 39% of them
was satisfactory and only20% of them was not satisfactory about this provisions
made to them.
23
CHART. 1
45
41
39
40
35
30
25 20
20
15
10
0
Percentage
24
PROHIBITION OF WORK ON OR NEAR MACHINERY IN MOTION
The management of the company takes care in respect of the above measure
sincerely as per Section 22. The opinion of the sample workers regarding the
above provision made is as follows:
TABLE 2
Satisfactory 34 34.0
INFERENCE
The above table shows that 39% of the respondents had good opinion 34%
of them had satisfactory opinion and 27% of them had not satisfactory with the
above provision made to them.
Hence, majority of the workers (39%) had good opinion on the prohibition
of work on or near machinery in motion provided by the company.
25
CHART – 2
27
39
34
26
TABLE - 3
Satisfactory 30 30.0
INFERENCE
Indicates that 45% of the respondents was good, 30% of then expressed
satisfactory and 25% of the expressed not satisfactory about this provision made to
them.
CHART – 3
27
STRIKING GEAR OR DEVICE FOR CUTTING OFF POWER
45 45
40
30
35
30 25
25
20
15
10
0
Good Satisfactory Not satisfactory
TABLE - 4
INFERENCE
From the above table, it is indicated that 45% of the sample workers
opinioned that the safety of self-acting machinery was good, 35% of them
opinioned that is was satisfactory 20%of them opinioned that it was not
satisfactory.
Therefore, most of the workers (45%) opinioned that the safety of self-acting
machinery provided by the company.
CHART – 4
29
20%
45%
35%
TABLE - 5
30
Opinion No of Percentage
Respondents
Good 49 49.0
Satisfactory 30 30.0
Not satisfactory 21 21.0
Total 100 100
INFERENCE
The above table, shows that 49% of the respondents were on good opinion,
30% of them were on satisfactory opinion and 21% of them were on not
satisfactory opinion about his measure provided to them.
Hence most of the workers (49%) were on satisfactory opinion about the
provision of casing of new machinery by the company.
CHART – 5
31
50
49
45
40
35 30
30
25 21
20
15
10
0
Good Satisfactory Not satisfactory
TABLE - 6
32
Opinion No of Percentage
Respondents
Good 40 40.0
Satisfactory 39 39.0
Not satisfactory 21 21.0
INFERENCE
Gives that 40% of the respondents were good 39% of them were satisfied
and 21% of them were not satisfied with the hoists and lifts facilities provided to
them.
Therefore, majority of the workers (40%) were satisfied with the provision
of hoists and lifts facilities made by the company.
CHART – 6
33
40 40 39
35
30
25
21
20
15
10
0
Good Satisfactory Not satisfactory
TABLE .7
Opinion No of Percentage
34
Respondents
Good 55 55.0
Satisfactory 29 29.0
Not satisfactory 16 16.0
Total 100 100
INFERENCE
It is understood from the above table that 55% of the sample workers
expressed good, 29% of them expressed satisfactory and 16% of them expressed
not satisfactory opinion about these facilities provided to them.
Thus, most of the workers (55%) expressed good opinion about the lifting
machines, tackles, chains and ropes provided by the company.
CHART - 7
35
60 55
50
40
29
30
20 16
10
0
Good Satisfactory Not satisfactory
TABLE - 8
Opinion No of Percentage
Respondents
Good 57 57.0
Satisfactory 28 28.0
36
Not satisfactory 15 15.0
Total 100 100
INFERENCE
The above table presents that 57% of the respondents had good opinion,
28% of them had satisfactory opinion and 15% of them has not satisfactory opinion
about the safety of revolving machinery maintained to them.
Therefore, majority of the workers (57%) had satisfactory opinion about the
safety of revolving machinery maintained by the Company.
CHART - 8
37
15%
28% 57%
TABLE - 9
38
Opinion No of Percentage
Respondents
Good 65 65.0
Satisfactory 20 20.0
Not satisfactory 15 15.0
Total 100 100
INFERENCE
CHART – 9
39
15
20
65
TABLE - 10
40
Opinion No of Percentage
Respondents
Good 42 42.0
Satisfactory 34 34.0
Not satisfactory 24 24.0
Total 100 100
INFERENCE
From the above table, it is known that 42%f the respondents were of good
position,3% of them were satisfied and 24%f them were not satisfied with the
provision of floors and stairs made to them.
Therefore, majority of the workers (42) were satisfied with the provision of
floors and stairs made by the company.
CHART - 10
41
42
34
24
TABLE - 11
42
Opinion No of Percentage
Respondents
Good 58 58.0
Satisfactory 24 24.0
Not satisfactory 18 18.0
Total 100 100
INFERENCE
Shows that 58% of the respondents has good opinion,24% of them had
satisfactory opinion and 18% of them had not satisfactory opinion about this
measure provided there.
Thus, most of the workers (58%) had good opinion about the protection of
pits and opining in floor made by the company.
EXCESSIVE WEIGHT
This provision is not applicable to the study unit as per section 34 as this
unit has been using mechanical devices for moving materials, and so it to be
explained
CHART - 11
43
18%
58%
24%
TABLE 12
44
Opinion No of Percentage
Respondents
Good 44 44.0
Satisfactory 36 36.0
Not satisfactory 20 20.0
INFERENCE
The above table highlights that 44% of the sample workers were in good
opinion 36% of them were satisfied and 20% of them were not satisfied with the
safety measure for protection of eyes provided to them.
Therefore, majority of the workers of the study unit (44%) were in good
position with this safety measure for protection of eyes provided by the company.
CHART - 12
45
45 44
40 36
35
30
25
20
20
15
10
0
Good Satisfactory Not satisfactory
TABLE - 13
Opinion No of Percentage
46
Respondents
Good 54 54.0
Satisfactory 22 22.0
Not satisfactory 24 24.0
Total 100 100
From the table given above, it is mentioned that 54% of the sample workers
expressed good, 22% of them expressed satisfactory and 24% of them expressed
not satisfactory opinion about the precautions taken against dangerous fumes.
Hence, most of the workers (54%) expressed that the precautions taken by
the company against dangerous fumes were good.
CHART 13
47
54
60
50
40
22 24
30
20
10
Percentage
0
Good Satisfactory Not
satisfactory
TABLE - 14
Opinion No of Percentage
Respondents
48
Good 68 68.0
Satisfactory 20 20.0
Not satisfactory 12 12.0
INFERENCE
It is clear from the above table that 68% of the workers has good opinion
20% of them had satisfactory opinion and 12% of them had not satisfactory
opinion about the precautions against portable electric lights.
Thus, most of the workers of the company (68%) had good opinion about
the precautions against portable electric lights.
CHART - 14
49
80
70 68
60
50
40
30
20
20
12
10
0
Good Satisfactory Not satisfactory
TABLE - 15
Opinion No of Percentage
Respondents
50
Good 38 38.0
Satisfactory 52 52.0
Not satisfactory 10 10.0
INFERENCE
Furnishes that 38% of the respondents were of good, 52% of then were of
satisfactory and 10% of them were of not satisfactory opinion with regard to this.
CHART - 15
51
60 52
50
38
40
30
20
10
10
0 Percentage
Good Satisfactory Not
satisfactory
TABLE - 16
Opinion No of Percentage
Respondents
Good 38 38.0
52
Satisfactory 52 52.0
Not satisfactory 10 10.0
Total 100 100
INFERENCE
In accordance with the above table, it is noted that 36% of the respondents
opinioned good, 44% of them opinioned satisfactory and 20% of them opinioned
not satisfactory about this provision made to them.
CHART - 16
53
60
52
50
40 38
30
20
10
10
0
Good Satisfactory Not satisfactory
TABLE .17
Opinion No of Percentage
Respondents
Good 36 36.0
54
Satisfactory 48 48.0
Not satisfactory 14 14.0
Total 100 100
INFERENCE
Hence, more than half of the workers (48%) were satisfied with the safety of
building and machinery by the company.
CHART - 17
55
14
36
48
CHAPTER-V
FINDINGS
56
From the study conducted in Trichy Steel Rolling Mills Limited, the
following findings were traced.
1. The first chapter is on the design and its execution of the study.
2. The second chapter deals with the origin and growth of trichy Steel Rolling
Mills Limited.
FINDINGS
57
Most of the workers (58%) had good opinion about the protection of pits and
opining in floor made by the company.
Majority of the Workers (58%) had good opinion about the protection of
pits and opening in floor made to them by the company.
Most of the workers (54%) expressed that precautions taken by the
company against dangerous frames were good.
Most of the workers (68%) had good opinion about the precaution taken by
the company against portable electric lights.
Most of the Workers of the company (52%) were satisfactory opinion about
explosive or inflammable gas or dust.
Majority of the Workers (44%) opinioned satisfactory about the precaution
against fire taken by the company.
More than half of the workers of the company (48%) were satisfied with the
safety of the building and machinery provided to them.
SUGGESTION
58
Based on the inferences and findings of the study unit, the following
suggestions may appear to be useful to the study unit and hence the Management
of TSRM Ltd., may consider the suggestions in order to enhance the accident
preventive measures:
CONCLUSION
59
As an overall satisfaction, more than eight-tenth of the workers (53% +
32%) were satisfied with all the preventive measures adopted by the company for
the effective safety and real care of its workers. Hence, as concluding remark, it is
noted that “The accident preventive measures adopted by TSRM Ltd., were found
adequate and good from its workers point of view”.
BIBLIOGRAPHY
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BOOKS
KAPOOR .N.D., Elements of industrial Law, Sulthan Chand and Sons, New
Delhi, 1971.
KHANNA .O.P., Industrial Engineering & Management, Dhanat Raj & Sons,
Fourth Edition1985.
REPORTS:
61
INTERVIEW SCHEDULE
NAME
DESIGNATION
1. Fencing of machinery
4. Self-acting machinery
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Good Satisfactory Not Satisfactory
8. Revolving machinery
9. Pressure plant
63
16. Precautions against fire
64