NEBOSH_Candidates Observation Sheet_Pritesh Bare

INTERNATIONAL GENERAL CERTIFICATE (2011 specification)

Candidate’s observation sheet

IGC3 – THE HEALTH AND SAFETY PRACTICAL APPLICATION Sheet number 1 of _____ Student name

Pritesh Ramesh Bare _

Place inspected Welding Consumable Manufacturing Unit_ Observations Hazards and consequences

Student number

00196609

_

Date of inspection 07/ 09/ 2013

Control measures Immediate and longer term actions

Timescale

Wear Plate Manufacturing Plant 1.

2.

3.

4.

Overhead crane hook in loadingunloading bay no.1 doesn’t have safety latch/ pin which could result in sleep of slings from hook throat and fall of the material. It has a potential of severe head injury or fatal.

Immediate action The safety latch/pin should be put immediately and no material shall be lifted without the fixing of latch to the crane hook. Substitute bays to be use till the completion of the fixing of safety latch/pin. Longer term action Ensure that inspection of all safety devices in overhead crane are part of periodic maintenance schedule and effective monitoring of its compliance.

Plasma cutting machine no. 2 operator was handling hot cut plates with the help of cotton hand gloves, which is ineffective in protecting palms of the operator from hot surface of cut plate also has a potential to catch fire and may cause burn injury too.

Immediate action Cotton hand glove needs to be replaced with leather/ Kevlar hand gloves Longer term action Risk assessment of plasma cutting operation is to be review and monitor that it is being use effectively. Ensure that new employee should be instructed for the use of right PPE for right job.

A contract worker was carrying out painting work of air & water pipelines at the height of 5 meter by climbing on ladder and without wearing safety harness. It has potential to fall of the person from height due to slip of ladder or misbalance of the person. It may also lead to musculoskeletal disorders due to overstretching while trying to paint more area by standing of one position (ladder).

Immediate action Ladder is meant for access & egress and should not use for working. It should replace by mobile tower scaffold or scissor lift to be used. Worker should wear safety harness while working on it. Longer term action Risk assessment of painting at height work is to be review and monitor that it is being use effectively. Ensure the work permit system is being followed effectively and monitor its compliance.

One newly installed CNC welding machine was not protected with welding (Protective) screens like other machines. Its welding arc/radiations may harm eyes of other employees, visitors etc.

Immediate action Welding screens to be put immediately around the machine. Machine should not put in operation without providing protective screens. Longer term action Risk assessment of Newly installed CNC machine is to be review and monitor its compliance.

1 Hour

Monthly

½ Hour 1 Month During Induction 1 Hour

1 Month

1 Week

1 Month

5.

One welder was doing manual welding on completed wear plate as a part of rectification work inside the wear plate plant without using local exhaust ventilation which was causing generation of welding fumes/ smoke, can harm the health of the welder as well the co-workers in the plant.

Immediate action Local exhaust ventilation is to be provided for manual welding work area also change the direction of welding so welding fumes/ smoke will not spread inside the plant. Longer term action A separate welding booth/ area are to be provided with local exhaust ventilation system for any manual welding work. Risk assessment for the manual welding is to be reviewed and monitor the compliance.

6.

Each welding heads of Welding CNC machines are connected with fume extraction system followed by Air pollution control device which absorbs generated welding fumes. It get filtered through bag filters before discharging into the environment

Good Practice observed. The system is taking care of As per the employees as well as Environment. Only thing is to maintenance maintain on regular basis for better efficiency. Schedule

7.

A heap of wear plates were kept on the ground in the walkway leading to south side emergency exit. It may lead to panic due to blocked emergency route in case of emergency

Immediate action A heap of wear plates should be removed immediately and walkway needs to be clear. Longer term action A separate storage rack is to be made and as soon as plate is unloaded from CNC machine it should go to the storage rack. Ensure that no material should keep in the walkway and emergency exit is always accessible.

There were several cases of melting of safety shoe sole of CNC welding machine operators. After interviewing few of them it came to know after completion of welding on MS plate for unloading the plate from machine operator have to climb of a plate which is hot causing the melting of safety shoe sole. It might increase the consumption of safety shoes due to frequent replacement and failure to this can lead to a burn injury to the operator.

Immediate action PU sole safety shoe should immediately replace with Heat resistant Nitrile sole safety shoe. Longer term action Undertake a Wear Plate unloading risk assessment to see whether automation in the process or change in the procedure to eliminate direct human body contact to the hot plate can be done. Ensure that new employee should be instructed for the use of right PPE for right job.

8.

1 hour

3 Months

1 hour

6 Months

1 Week

1 Month During Induction

INTERNATIONAL GENERAL CERTIFICATE (2011 specification)

Candidate’s observation sheet

IGC3 – THE HEALTH AND SAFETY PRACTICAL APPLICATION Sheet number 1 of _____ Student name

Pritesh Ramesh Bare _

Place inspected Welding Consumable Manufacturing Unit_ Observations Hazards and consequences

Student number

00196609

_

Date of inspection 07/ 09/ 2013

Control measures Immediate and longer term actions

Timescale

Teromatec (Flux cored wire) manufacturing Plant 1.

2.

Single Head Draw Bench machine have inadequate fixed guard which is ineffective to protect a person from the impact of rotating wire in case of breakage also have chances to get caught in between the pinch points of the rotating parts of the equipment. It may lead to severe injury due to impact of rotating wire and crush injury due to caught in between.

Immediate action Prohibit the use of machine until the proper cage type fixed guard installed. Inform the supervisor for present hazard and instruct for safe operation. Longer term action Ensure that inspection of all machine guards is part of the maintenance schedule and effective monitoring of its compliance. Review the risk assessment to see whether fixed guard can be replaced with Interlocking guard for better protection and control on process.

During Blending of metal powders by ‘Y’ Blender it is observed that while loading and removing of blended powder fine dust is generating and spread over nearby floor as well as in the workplace environment. It may lead to slip of the person due to slippery floor and sever health hazards like damage to the lungs.

Immediate action Floor need to be clean on regular basis to avoid accumulation of dust and workers who are handling powders should wear adequate respiratory protection. Longer term action ‘Y’ Blending operation should not carry out in the workplace with other operations. It should be done in an isolated area with all necessary protections like dust absorption & removal system, workplace exhausts, antislippery floors, provision of regular dust removal & Personal Protective Equipment’s like dust masks etc.

2 Hours

1 Week 1 Month

Immediate

6 Months

Stick Electrode Manufacturing Plant 3.

Heavy oil leakage observed below Extrusion press no.3 which may lead to an injury due to slip of a person. It also has potential of fire as it is readily available fuel for fire.

Immediate action Spilled oil should be immediately wipe out with the help of saw dust or cotton waste and keep a tray below the leakage. Oil soaked cotton/dust should be kept in hazardous waste bin to avoid contamination. Longer term action Review of maintenance schedule and monitor its compliance. If required increase the frequency of preventive maintenance. Encourage operators to report such issues in future. Supervisor should inspect the machine prior to use.

1 Hour

15 Days

4.

5.

6.

7.

While extruding electrode from hydraulic extrusion press, the electrode is coming out with pressure and hitting the guide disk to rest on the belt conveyor during this the parts of wet flux also comes out with pressure which may cause eye injury due to flying particles/ foreign object.

Immediate action All the persons working nearby extrusion presses should were Transparent Safety Goggle. Longer term action A barrier screen is to be provided opposite to extrusion press hydraulic cylinder. Risk assessment of Stick electrode extrusion activity is to review and monitor the implementation.

Near binder preparation area 2 Workers were handling heavy (approx. 100kg) binder drum manually from trolley to weighing machine which may cause them back injuries, bruises and abrasions etc.

Immediate action It is to be lifted by forklift with proper drum lifting arrangement. Longer term action Elimination of manual handling with installation of required capacity overhead crane with drum lifting arrangements above the weighing machine which will lift the binder drum from trolley and keep on the weighing machine. Train the supervisor for proper manual handling and ensure the maximum use of mechanical assistance.

Workers who are working at last position on a continuous stick electrode manufacturing lines they were lifting extruded stick electrodes from conveyor and arranging in trays. Due to repetitive movement of body there are chances that they may suffer from work related upper limb disorders (WRULDs)

Immediate action Give the breaks in between the shifts. Job rotation amongst the extrusion team. Longer term action Undertake a Stick Electrode extrusion risk assessment to see is there any scope for change in workstation design or any ergonomic improvement can be done

Generation of noise is quite high in wire cutting machine area, though operators are wearing proper Ear Muff/ Plugs long exposure may cause hearing problems.

Immediate action Scheduled Job rotation amongst the department. Break in between the work. Longer term action Review of wire cutting operation risk assessment to see whether any chances of isolation of process or isolation of operators can be done.

Immediate 15 days 1 Month

Immediate 6 Months

1 week

2 Hours 2 months

15 Days 2 Months

INTERNATIONAL GENERAL CERTIFICATE (2011 specification)

Candidate’s observation sheet

IGC3 – THE HEALTH AND SAFETY PRACTICAL APPLICATION Sheet number 1 of _____ Student name

Pritesh Ramesh Bare _

Place inspected Welding Consumable Manufacturing Unit_ Observations Hazards and consequences

Student number

00196609

_

Date of inspection 07/ 09/ 2013

Control measures Immediate and longer term actions

Timescale

General Observations 1.

2.

3.

4.

The damaged web slings were using for loading 12 nos. of Wear Plate from wear plate plant to truck standing outside plant near main gate no.1 which has potential of breaking of the slings and injury due to impact from falling of the plates. IT has high potential of accident as it is near the main gate where visitor movement is maximum and chances of visitor getting exposed to such hazard is high.

Immediate action Damaged web slings should be discarded immediately by cutting it into small pieces and properly tested slings with ‘C’ clamp is to be used. Longer term action Loading-unloading of material should be done with tested lifting tools & tackles at loading-unloading bay only, with the help of overhead crane installed in the bay which will isolate the activity from visitors and risk will be reduced. Ensure that inspection of all lifting tools & tackles are part of the maintenance schedule and effective monitoring of its compliance.

Electric cable was laid loosely on ground for working on maintenance table at ground floor near goods lift no.1. It has risk to trip and fall of the person. The trailing cables also present the risk of electric shock if mechanically damaged or improper joints.

Immediate action Put a cover over cable or reroute it from overhead which will clear the walkways in front of Goods lift. Longer term action Install additional distribution board near maintenance table to eliminate the need for long trailing cable.

It was observed that during reversing of forklift the reverse horn was not worked after interviewing the forklift operator it came to know that the reverse horn is on switch which he forgot to on while reversing. It might have resulted in the severe injury to pedestrians due to struck by forklift.

Immediate action Operator is instructed to on the switch without fail before reversing the vehicle. Supervisor is made aware of hazard and asks to monitor it properly. Longer term action Reverse horn should be linked with the reverse gear and it should work automatically with gear. Separate switch is to be removed. Refresher training should be to operators for the safe operation of Forklift

Ground & First Both the manufacturing floors are equipped with HVAC system. It removes hot air with excess fumes, smoke etc. and supply fresh cool air inside the plant which helps to keep plant temperature 3 degree less than the outside temperature. It provides comfort and healthy workplace to employees.

Immediate

8 hours 1 Month

1 Hour 15 Days

Immediate

1 Month 15 Days

Good Practice observed. The system is taking care of employee’s health. It not only provides the comfort but increases the productivity. Maintenance is to be done on regular basis for better As per the efficiency. maintenance Schedule

5.

6.

List of trained First-aiders & Fire fighters are not displayed in the manufacturing plant. It may take time to avail help during the emergency

Immediate action List of trained first-aiders & fire fighters to be displayed in all prominent locations of the plant. Longer term action Maximum number of persons should be trained in first-aid and fire fighting and well communicated to everyone in the plant. It should be properly communicated to new employees during Safety Induction.

1 Day As per training Calendar

During random Circuit breaker testing it was found that two circuit breakers at ground floor (one is behind rolling machine and another is near plasma cutting machine no.1) are not working. It is very serious and may lead to death of a person due to electric shock.

Immediate action A power supply is to be disconnected for both electrical switched and a warning sign should be put. These switches should not be used until the replacement & testing of circuit breaker. Longer term action Ensure that inspection of all circuit breakers are part of Electrical maintenance schedule and effective monitoring of its compliance.

7.

No evidence of Portable electrical appliances (drill machine, grinding machine etc.) testing were found. It may cause electric shock or fires due to faulty equipment.

Immediate action Equipment should be check for PAT label and also visually Before Every inspect before use. use Longer term action Ensure that inspection of all Portable electrical appliances Monthly is part of Electrical maintenance schedule and effective monitoring of its compliance.

8.

Hazardous chemicals/ substances are stored with other material in the store which may cause harm to new employee who is unaware of the hazards related to chemicals. Also there are chances of reaction if two incompatible materials come in contact.

Immediate action Identify and labelled all the hazardous chemicals present in the store. Longer term action Review of risk assessment of hazardous chemical storage and ensure its compliance. Separate arrangement to be made for storage of hazardous chemicals with all necessary precautions like eye & body shower, Fire extinguishers etc. Information about hazardous chemicals should be well communicated to new employees during safety induction.

Immediate 2 Days Monthly

1 week 1 Month 3 Months During Induction