Professional Documents
Culture Documents
A Project Report on
Effectiveness of Safety Training
At
Damodhar Cement works of ACC Ltd.
By
Chitritak Mukherjee
From
International Business School,Kolkata
Enrollment No.EIILMU/09/S0069
ACKNOWLEDGEMENT
Chitritak Mukherjee
DECLARATION
I hereby declare that all the information and facts produced here are based
on my own findings and studies at ACC Limited, Damodhar Cement
Works are original in nature. The contents of report are a true expression
of my efforts on the said topic.
Chitritak
Mukherjee
MBA – 2009-2010
International Business
School, Kolkata
Page No.
Introduction 5-6
History 7
Plants and their Capacity 8
Milestones of ACC Ltd. 9-13
Achievements of ACC Ltd. 14-16
Awards and Accolades 17-18
Present Employee status 19
Corporate Social Responsibility 20
Social Program and Entertainment Program 21
Objective of the project 22
Scope of the Project 23
Holcim Pyramid 24
Analysis 25-35
Cardinal rules of DCW,ACC 36
Safety Policies 37-39
Need Assessment 40
Safety Topics and Suggestions 41
Made Safety team in plant adjoining township 42
Vehicle and Training safety 43
Training on Mental Strength 44
Training on machine guarding 45
Fire fighting 46-47
Conclusion 48
“To be safe is to be human”-but contrary to popular belief, most big accidents or
disasters have in fact taken place due to seemingly human beings to play safe,
whereas it is lack of wisdom that induces a man to adopt calculated risk i.e. unsafe
practices. Though data & information regarding life build up instinct, environmental
situations sometimes predominated over instinct when lack of judgment overrules
wisdom-resulting in danger. In order to react correctly in such situation, both instinct
& wisdom require to appear at surface.
Keeping in mind that safety engineering has become one of the most complexes of
engineering discipline, certain commandment learnt from experience need to be
enforced as far as industrial safety is concerned. It is also true that, strict adherence to
military discipline & commandments may convert human beings to virtual robots
when they fail to rise or act when demanded by extraordinary situation.
The above mentioned factors may be sub-dived into different categories if we intend
to arrive at a solution to our presentation to our present day problems. Some of the
factors like lack of knowledge & error of judgment are outcome of basic ignorance
which includes lack of experience as well as lack of aptitude for the job. It is possible
to overcome these factors only through proper coordination & empathy of all around
besides training & increased scope of acquaintance with the system.
Certain other governing factors like negligence, folly, sheer indifference and
absentmindedness are primarily the results of basic human nature. Social
environmental constraints also add to these factors. In order to overrule these a careful
study of the individual and development of mutual trust along with increased
accountability are of foremost importance.
widely with the physical and mental capability and limitations of the individual. It
calls for an in-depth study of system as well as human involvement.
A scrutiny of the last two year’s accident cases in a utility organization like ours
reveals that apart factors like absentmindedness, casual approach and irrational
emotive behavior, etc, most, of the incidents were caused due to communication gap
and lack of interdepartmental coordination,
Ashoka Cement Ltd. later disinvested its entire holdings in DCSL to WBIDC
in May 1981 and subsequently WBIDC and Cement Corporation of India Ltd.
(CCI) executed a joint venture agreement in July 1983. From October 1990 it
started its commercial production.
In September 1996 The Associated Cement Cos. Ltd. (ACC) took over the
management of the Company and it became a subsidiary of The ACC Ltd.
with WBIDC as a partner.
In the year of 1998 after taken up by Acc capacity enhancement from 2.72 to
5.25 LTPA.
1936 First Board Meeting of The Associated Cement Companies Limited held at
Esplanade House, Mumbai on November 10, 1936.
1937 With the transfer of the 10th company to ACC, viz. Dewarkhand Cement
Company, the formation of ACC is complete on October 23, 1937.
1955 Sindri cement works used the waste product calcium carbonate sludge from
fertilizer factory at Sindri.
1961 Blast furnace slag from TISCO used at the Chaibasa Unit to manufacture
Portland Slag Cement for the first time in India.
1961 Manufacture of Accocid Cement, which resists the corrosive action of acids
and chemicals.
YEAR
ACC Cement:
ACC’s brand name is synonymous with cement . its marketing, sales and
distribution processes are industry standards. The brand building
approach to marketing cement which was first adopted by ACC has
proved to be exceptionally successful in respect of blended cements in
terms of providing more effective communication with customers and
has been emulated by other companies in the industry.
ACC is the only cement producer in India with its own in-house Research
and Development facility. The sprawling Research and Consultancy
Directorate
(RCD) complex at Thane near Mumbai has a unique track record of
innovative research and specialized technological services.
RCD has helped introduce some unique special projects of immense
value to the concrete and construction sectors. These include repair
products and grouts and Ancones, a non explosive demolition agent. RCD
has developed Acc marg, a revolutionary new product and grouting
composition for the construction and repair of new roads and highways.
The services of concrete group at RCD have been utilized in the striation
of several heritage buildings across the country, such as the CST terminus
at Mumbai, churches and royal palaces in Goa, Mysore and Hyderabad.
Awards & Accolades
• IMC Ramakrishna Bajaj National Quality Award - – Gagal wins Commendation
Certificate and New Wadi Plant wins Special Award for Performance Excellence in
the Manufacturing Sector, 2007.
• FICCI Award --- for innovative measures for control of pollution, waste
management & conservation of mineral resources in mines and plant.
• Drona Trophy - By Indian Bureau Of Mines for extra ordinary efforts in protection
of Environment and mineral conservation in the large mechanized mines sector.
• Greentech Safety Gold and Silver Awards - for outstanding performance in Safety
management systems by Greentech Foundation
ACC was the first recipient of ASSOCHAM’s first ever National
Award for outstanding performance in promoting rural and
agricultural development activities in 1976.
Over the years, there have been many awards and felicitations for
achievements in Rural and community development, Safety, Health, Tree
plantation, A forestation, Clean Mining, Environment Awareness and
Protection.
Durga puja
Rural football tournament
Yoga Camp
Annual Picnic
Christmas Day celebration
Republic Day celebration & Annapurna Utsav
Film Shows
Shiva Ratri Festival
Holi Milan
Construction of new club
Safety is one of the core values of ACC.ACC aspires to have the best safety records in
the country and unwavering believe in the principals of “NO HARM TO ANYONE”.
Associated with it. To achieve these cherished goal ACC Ltd. has unleashed several
inactive involving all employees including contract employees in the past few years.
Health &
Wealth Issues
90%
Occupational Procurement Management
Rehabilitationn of Changes
88% 68% 73%
In this analysis we see that in the last 5 years fatality is only 1 which is
less than 1% and No. of non fatality is 275 which covers the remaining
area of the above pie chart.
NON-FATALITY AREAS
Here in the pie chart, each areas of non-fatality has been shown with their
percentage of happening.
From this chat e see that out of these incidents maximum no, are near
miss incidents which is 63%,then minor injury 27%,then medical
treatment like first aid come only 6%.
Here the No. of work days lost is maximum at 2007 and after that it
decreased every year. On the year 2010 till the month of May, not a single
work day lost.
NAME OF TRAINNG PROGRAM AND HOURS SPENT
FOR TRAINING-1
ACC LTD gives training employees. Some of them here shown above,
Out of these we may see that the No. of participants and hours of training
are maximum for work permit with new format and emergency
preparedness.
NAME OF TRAINNG PROGRAM AND HOURS SPENT
FOR TRAINING-2
From the above chart we see that No. of employees are more or less same
for all training programs but trining hours spent for Computer Ergonimics
is maximum.
From all the training programs we have seen that For most of the
programs average 2 hours used for an employee. But there are also
exceptions. As for Computer Ergonomics and Workshop on JSA
trainings. For Those trainings 8 hours have been spent for each employee.
From that we can understand that ACC has given more importance in
these trainings than other training programs.
Safety is a back bone of a company. If the safety procedure is well, then no accident
will be happened in a plant or a company ,so that the company run safely.
Before giving any type of safety training, the 1st step of this policy is to
find in which area, what type of safety training is needed. This process is called need
assessment process. After that a training schedule is made. This training schedule is
containing of these following things,
1) which area or department training is needed.
2) What type of training is needed.
3) Who will be conducting the training program(external or internal faculty)
4) What will be the time period of deferent training program.
After observing all the elements training program is conducted.
But sometimes it’s seen that after giving training though same type of
mistake is happening again & again.
ACC safety follows some well accepted transparent rules. As per the rules ACC
follows some steps & they also try to keep document in written form also.
For keeping this document in written form ACC use some forms. One of the form is
SAFETY OBSERVATION TOUR. This observation form have lots of heads or
column by filling up those heads the observer’s easily keep in records which he have
seen in the time of observation, Except that there is another form which called SOT
OBSERVATION TABLE. Where observer easily record the feedback about safe 7
unsafe work. There is another type of form where have space for different work(like
hot work excavation & digging, electrical work, work at a hight etc) It is compulsory
to fill-up this form. By filling-up this form it’s became clear that what types of risk
related with what types of risk is related with what types of work, How the work will
be performed.
There are lots of training program in ACC which provides for making people aware of
different types of safety, trained them against different types of unsafe work will not
happened by those people. Those training are given all the person in the category of
the contractor & the employee both.
There are different types of training program provided for different types of safety.
The training have given by internal & external faculties. Every training program
contains lots of thing that help to make people understand clearly about the training.
Training program contains presentation on training, practical exercise etc. After the
finishing of this training program a feedback process must be there to know how it
have helped the participants. By this feedback we can understand that it’s effective or
not.
Mother concern of ACC is Holsim. Holsim is followed their own competency module
to drive the business.
COMPETENCY;
The four bucket help to understand the business, make the people energetic for
doing their job carefully.
Each block have different part. By applying those part or process work become
easy & transparent to perform. One of the main think is to assume about the result.
If we can measure the out comes then it will good for the company.
Holsim is followed a triangle about safety. In this triangle the lower base is
minimal injury & top place is fatality.
1
Fata
lity
30
Loss time injury
300
Medical treatment injury
3000
Near Miss
30000
UN Safe act
Beside the objective one of the vital things before starting the project is is need
assessment. By this we can understand the particular reason behind doing this
project.
The things which observed at need assessment are as follows;
- 1) the organizational goals and its effectiveness in
Reaching the goals.
I have chosen some of the field in safety department & on those things I want 2 give
safety suggestions.
RISK ASSESSMENT
My first chosen topic is risk assessment. Why I have chosen risk assessment as my
first topic for safety I want to clarify it.
We need safety because we want to save ourselves from risk or any danger’s. First I
have to identify which type of risk is waiting for us. The process of identify is called
risk assessment. So how we identify the risk, which type of training is given for the
risk assessment, which type of more training we can able to give them those are my
discussing thing.
For that RISK ASSESSMENT ACC provides lots of internal training. Those help to
improve employees ability in risk assessment. We think those type is very much
needed for the employees.
But we know after getting those type of training though lots of accident are on in the
factory. After assuming the risk lots of accident is happening in the factories. So I
want 2 give some suggestion.
• If some type of accident have happened in any where then collect the picture
of that accident place from all location,& show the people who are involving
in risk assessment. By that they can get an idea that what type of accident had
happened & they have 2 take what type of precaution is needed there.
• They have to give lots of case studies on those accident & want lots of
innovative idea from them to prevent those types of accident.
• We can also arrange a competition on the innovative idea of the employees for
prevention of accident. We must give the person a lucrative prize who gives
best innovative idea. It will encourage them.
• Proper checking of work permit form which help them to know that all the
possible risk have been written on the form or not. By checking it properly
they can assess the risk .
• Must keep the records of previous mistakes which stop them to repeat it once
again.
• Regular meeting with efficient person & try to work in a team help them in
risk assessment.
If our home is not safe then we are most unsafe animal on this earth. So make our
home safe is our first & foremost duty. At the same time Plant adjoining town-ship or
colony is the home for plant employee.
If they do not safely live at their or do not keep their family in a safe place then they
will not able to concentrate in their work & can’t give their 100% in it.
Colony is vast place. N So it’s not possible for one person to manage the
whole safety of the colony. So we need to make a organized team out of
efficient people from the colony for the safety of the colony.
First we have to choose suitable person from the colony. We can choose a old
& retired person as a leader. Because he have the experience, knowledge & the
main thing is all obey & respect him or her.
We have to try to involve the house wives also in the safety team.
Then we have to make a plan through meeting that what type of safety is
needed for the colony like safety for children, safety for their home, proper
maintenance of the surroundings area of their quarter which can safe them
from snake & insects, uncovered water resources will be covered properly etc.
Must talk with the colony gate keeper or guard for stop trespassing. When
anybody want to meet with colony person, then gate keeper must talk with him
or her over phone before allowing the unknown person.
Must make a program of a entire colony checking my distributing duties on
many people,
Must make every colony people aware about one or more number which help
them in risky situation. Like make people aware about number for fire
prevention, health center, ambulance etc.
In every month try 2 arrange a cultural program to make people aware about
safety.
Arrange monthly medical check-up camp for every people of the colony for
health safety.
Must be aware about the unlikely incident that happened in that colony or
other colony before n stop the repetition of the same incident.
Transport n traveling is one of the main part of a plant n it’s adjoining colony.
Inside. The colony or town ship & just out side of both the place lots of
vehicles are moving from here & there. So we have to be safe from that too.
In the factory lots of outsiders & in the colony too lots of outsider moving here
& there everyday. Some are good driver some are not, so know the inside
road properly & some are not. Some factory driver also need more training
with the outsider driver & guard who help them to move vehicles insides.
Lots of internal trainings have given on that but I want to more suggestion;
Have to keep proper gate keeper or guard in the gate from where the vehicles
are come in & out in the plant & colony. One thing have to remember that the
person who is at vehicle gate he/she must have little knowledge about
vehicles.
Must check the driving license of the driver regularly.
Before entering the gate have to check the tire & the break properly.
Must give proper road direction board in every turn or suitable places. That
helps the driver in guiding.
Made foot road for waking & road for vehicles.
In front of the colony school or play ground or other places we should keep a
guard to manage the vehicles.
Have to post proper guard in proper places for give instruction to the driver in
moving vehicle.
We can use lighted signal & lock gate too for more safety from the vehicle.
If any accident happened then should contact with police & hospital. do not
take any risk.
Taking feedback everyday that any person or driver, insider or outsider is
doing any type of reckless driving or something like that. Then must take
possible action.
Head & mind is our main part of our body. We drive by our mind & brain. Mind
makes them decide that which path is proper for us & by taking which path we can
easily able 2 reach our goal.
After getting some type of shock or some unforgettable or terrible incident made our
mind weak. For that we lost our confidence to do any type of work.
To rebuild the confidence & made our minds strong we can apply some process.
Those are as follows;
o First have to find out that why one person became weak. What is the cause
behind his weakness,
o Arrange a psychiatrist for the person.
o Keep a look on the person that he/she is listening the or following the
psychiatrist or not.
o Make him understand what had happened, that had happened that will not
happen again.
o Show him/her some motivational movie.
o Arrange some yoga n meditation program for them.
o Do not behave badly with him/her.
o Make him/her feel that they can able to do lots of work still now.
Guard means something which use for protection. Machine guarding means
cover the unsafe portion of the machine. Like covering the sharp edge of the
machine, covering the blades of the machine, properly keeping the relate
electrical wars in proper way, installing the machine in proper place, after
using the machine covered the machine properly.
So machine guarding is a vital thing to prevent the accident in the plant. But
after happening lots of accident again & again though this issue is neglected.
So our duty is to make the labourer, contractor, HOD, employees aware about
the matter. I also want to add some suggestion on this issue.
Fire made every one so much scared. So when fire broke out inside the
industry or at township then a massive lose have happened. Peoples are
running helplessly from here to there.
Fire can be occurred for lots of causes inside the factory or town ship.
Some of the causes behind the fire broke out is are follows;
• Fire can be broke out from short-circuit. It can be happened inside the
plant as well as inside the colony.
• Fire can be broke out for some type of fuel that are using for run a
machinery. Except that lots of vehicles are moving & also parked
inside the factory, So the fire can be broke out from the fuel of the
vehicle.
• Lots of fire work is going on inside the factor .So fire can be broke out
from those types of elements.
• In town-ship fire can be broke out from the kitchen of the quarter.
• If some inflammable material is stored in warehouse then if short-
circuit happened then fire can be broke-out.
• If small fire is ignored then it will transformed into a massive fire.
• Lack of security arrangement can cause behind a fire that have set by
some cruel people means external source.
1. First identify which place is very much fire prone by the help of
efficient person.
2. Have to make a fire fighting training schedule.
3. As per the training schedule we need faculty. For that we need
external faculty or external organization.
4. We can contact some of the x-fire men for conducting this training.
5. We must show some videos on fire fighting, some still pictures etc., to
the people.
6. We must give participants some cases on fire fighting & want
suggestion about prevent the fire, Those innovative ideas help them in
real scenario.
7. Give the person a mental training to remove the fear from their mind
about fire. Psychiatrist can be appointed for that.
8. Made a fire fighting team for the plant & township also. Team is
containing with x-fire person,& brave, trained & efficient person.
9. Have to bought a fire engine made a office for fire fighter. The office
should have one or two phone numbers. The phone numbers have to
inform to everyone properly by add or leaflets etc. There will be a
telephone attender every time to attend the call. He inform these to
fire fighting team for quick action.
10. Fire fighting office is a proper place from where the fire fighting engine
can move very fast to the any place inside town-ship or plant.
11. Eire fighting team a engine must be for 24 hrs service.
12. Inside the plant or township there must be the proper recourse of
water.
13. Fire Extinguisher will be in sufficient places inside the factory &
township. Guide line for using extinguisher is given beside the
extinguisher where it is kept.
It is concluded from the survey on “Effectiveness of Safety Training”
that training program conducted in ACC Ltd, Damodhar Cement Works
is very effective in improving the skill and knowledge of the employee to
meet the present and future requirement of the organization. It’s found
that training place a crucial role in not only the development of
employees but also in achieving the overall organizational goals.
Through the research work it was found that employees were very
satisfied by the training provided to them and strongly agreed that after
training their confidence have increased and their skill and knowledge has
also been increased and hence, their was remarkable improvement in their
performance.