Unit – 3

SAFETY PERFORMANCE
 Overview
EFFECTIVE STEPS TO IMPLEMENT  
SAFETY APPRAISAL
SAFETY PROCEDURE

STUDY OF PLANT LAYOUT PERIODIC ADVICE & CHECKING 
SAFETY PROCEDURES

PERIODIC INSPECTION CONSTANT MAINTEANCE

PROPER SELECTION AND 
REPLACMENT OF HANDLING 
EQUIPMENTS

RESPIRATORY/ 
PERSONNAL PROTECTIVE 
EYE/HAND/HEAD /BODY
EQUIPMENTS

2
 Safety Appraisal
Definition: It is a tool for developing as well as assessing safety awareness and
performance at workplace.

Safety Appraisal significance:

1. The competence and commitment to manage safety.

2. The appropriate safety management systems in place.

3. Demonstrated the effective implementation of their health and safety management

systems.

4. The necessary competence to carry out the required work.

5. The ability and willingness to allocate adequate resources to the project.

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Example

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Positive Safety Appraisal Negative Safety Appraisal Indicators
Indicators
1. The employee consistently  1. An employee is careless, and must be 
follows standard operating  corrected or counseled concerning 
procedures, job safety  adherence to safety standards, 
procedures, standards, and  programs, procedures, or policies.
general employee safety  2. An employee contributes to or 
responsibilities. experiences an accident which results in 
2. An employee prevents an  injury to the employee or another 
accident by removing a hazard person, or property damage or 
from the workplace or reports a  destruction. Subsequent accident 
hazard to proper authorities. review determines that the employee 
3. The employee participates in  purposely ignored procedures.
safety and health programs,  3. An employee contributes to or 
and/or serves on safety‐related  experiences a non‐injury producing
committees and work groups. accident which may or may not involve 
4. An employee or an entire work  property damage or destruction. A 
group remains accident‐free over  subsequent accident review determines 
an extended period of time. that the employee purposely ignored 
5. A supervisor or manager actively procedures.
supports and implements safety 
programs, training and safe 
performance of tasks by 
employees

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 Contents
EFFECTIVE STEPS TO IMPLEMENT  
SAFETY APPRAISAL
SAFETY PROCEDURE

STUDY OF PLANT LAYOUT PERIODIC ADVICE & CHECKING 
SAFETY PROCEDURES

PERIODIC INSPECTION CONSTANT MAINTEANCE

PROPER SELECTION AND 
REPLACMENT OF HANDLING 
EQUIPMENTS

RESPIRATORY/ 
PERSONNAL PROTECTIVE 
EYE/HAND/HEAD /BODY
EQUIPMENTS

6
 Implement Safety procedure
Safety procedure: provides guidelines, documentation or practices for to
perform any task safely and training, evaluation of contractors and
performance review through job observations.

Implementation Steps:

1. Management’s Commitment

2. Employee Involvement

3. Written procedures and practises

4. Controlling & Monitoring Hazards

5. Training

6. Incident Reporting & Analysis

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 Implement Safety procedure
Step 1:- Management’s Commitment:
a) The allocating or budgeting of money for safety manpower.
b) Management’s commitment is to provide motivating force and resources for
organizing and controlling activities.
c) Regular visible involvement and establishing a written safety and health policy
that’s signed, dated and posted for everyone to see.
d) Conduct an assessment or review process.

Step 2:- Employee Involvement: There are many opportunities for employees to
participate in the safety and health program, that include,
1. Safety committees
2. Incident investigations
3. Inspections
4. Emergency response teams
5. Development of operating procedures
6. Job Safety Analyses (JSAs)
7. Presentations of training topics

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 Implement Safety procedure
Step 3:- Written Procedures and practises: Written safety process should
include:
a) Proper meeting and control of safety and health hazards
b) Training
c) Incident reporting
d) Emergency programs and procedures
e) Division of responsibility and accountability
Step 4:- Controlling & Monitoring Hazards: Proactive tools for maintaining safe
working conditions include,
1. Mechanical integrity
2. Industrial hygiene and exposure assessment
3. Housekeeping inspections
4. Corrective action systems
5. Design concepts
6. Operating procedures
7. Safe work practices and Site safety and health procedures

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 Implement Safety procedure
Step 5:- Training:
a) Safety philosophy and Safety practices.
b) Operating procedures
c) Hazcom, respiratory protection, hearing conservation, lockout/tagout, confined
space entry, powered industrial truck and fire extinguisher
d) Permit system and communication during emergency
e) Contractors training.

Step 6:- Incident Reporting and Analysis:

Any incident should be viewed as an opportunity to better the safety and health
process. Inline

1. Written incident reporting system and agency involved for analysis

2. Determines corrective action and track them for completion
3. Analysis finding to be communicate to employees

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 Contents
EFFECTIVE STEPS TO IMPLEMENT  
SAFETY APPRAISAL
SAFETY PROCEDURE

STUDY OF PLANT LAYOUT PERIODIC ADVICE & CHECKING 
SAFETY PROCEDURES

PERIODIC INSPECTION CONSTANT MAINTEANCE

PROPER SELECTION AND 
REPLACMENT OF HANDLING 
EQUIPMENTS

RESPIRATORY/ 
PERSONNAL PROTECTIVE 
EYE/HAND/HEAD /BODY
EQUIPMENTS

11
 Periodic advice to follow safety
Workplace safety procedures are necessary for the well-being of both employers
and employees.

Safety Procedures may not be followed for a variety of reasons, some are:
1. Procedures are not correct or out-of-date;
2. Procedures are difficult to use or follow;
3. Procedures are not readily available/portable;
4. There are easier ways of performing the task;
5. Pressure from peers;
6. A failure to understand the risks;
7. Perceived pressure from management to ‘get the job done’.

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 Periodic advice to follow safety
Encourage compliance with procedures:

1. Design the job or task so that the correct procedure is hard to avoid (e.g.
through equipment design or programmable logic controllers);

2. An informal procedure that is quicker/easier and these methods should be

incorporated into the formal procedure (as long as safety/quality issues are
not compromised).

3. Identify incentives to take short cuts (such as work pressures) and address
these directly;
4. Adopt a control and review process to keep procedures relevant and up-to-
date.

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 Periodic checking to follow safety

Safety Audit:
1) Audit is a systematic and, wherever possible, independent examination to
determine
 whether activities and related results conform to planned
arrangements.
 and whether these arrangements are implemented effectively.
 and are suitable to achieve the organization's policy and objectives.

2) Auditing examines each stages in the H&S management system by

measuring compliance with the controls the organisation has developed,
with the ultimate aim of assessing their effectiveness and their validity for
the future

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 Periodic checking to follow safety

Types of Safety Audit: SIX types

1. Health and safety audits

2. "Walk around audit"

3. Health and safety management audit

4. Project Health, Safety & Environmental (HSE) auditing

5. Process safety audit

6. Product safety audit

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 Safety Audit

1. Health and safety audits:

Objectives of this type of safety auditing are to inform the company:

How well it is performing in H&S

Whether managers and others are meeting the standards which

the company has set itself

Whether the company is complying with the H&S laws which

affect its business

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 Safety Audit

2. Walk around Audit:

A " walk around audit" is to determine whether the health and

safety policies of the company are being properly implemented
and to identify areas in which policy effectiveness needs to be
improved.

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 Safety Audit
1. Health and Safety Management Audits:

H&S Management audits look into the following areas:

–adequate procedures for identifying H&S requirements.
–procedures followed and are responsibilities set out clearly and
understood.
–adequate procedures for identifying hazards which exists at the
workplace, and for assessing regularly the risks to employees
–Are adequate risk assessment procedures also set out for hazards of
products and /or services.
–setting, reviewing and revising as necessary its health and safety
standards.
–adequate procedures for planning, implementing, controlling, monitoring
and reviewing the measures.
–adequate procedures for carrying out H&S audits.

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 Safety Audit
4. Project Health, Safety & Environmental (HSE) auditing

It provides the method for monitoring and controlling HSE activities and
procedures throughout the life of the project. It comprises of,
–Formal audits
–Regular and ad-hoc inspections

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 Safety Audit
1. Process safety audit

It is a self-evaluation audit which aims at:

- gather all relevant documentation covering process safety management

requirements at a specific facility

– determine the program's implementation and effectiveness by following

up on their application to one or more selected processes.

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 Safety Audit
PRODUCT SAFETY AUDIT

Safety Audit is important in the product design and development stages.

It is to ensure that the company had adequately protected the user of a
product from hazards that it did not know existed. This type of audit is to,

–Identify and classify hazards associated with the product i.e.

catastrophic, critical, occasional, remote, or improbable
–Develop a hazard risk index and priority setting
–Get employee to present design alternatives and to review for feasibility

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 Contents
EFFECTIVE STEPS TO IMPLEMENT  
SAFETY APPRAISAL
SAFETY PROCEDURE

STUDY OF PLANT LAYOUT PERIODIC ADVICE & CHECKING 
SAFETY PROCEDURES

PERIODIC INSPECTION CONSTANT MAINTEANCE

PROPER SELECTION AND 
REPLACMENT OF HANDLING 
EQUIPMENTS

RESPIRATORY/ 
PERSONNAL PROTECTIVE 
EYE/HAND/HEAD /BODY
EQUIPMENTS

22
 Plant Layout
Definition:
Plant Layout is the physical arrangement of equipment and facilities
within a Plant.
Optimizing the Layout of a Plant can improve productivity, safety and
quality of Products.

The important factors of plant layout as far as safety aspects are

concerned are those to:
1.Prevent, limit and/or mitigate escalation of adjacent events (domino);
2.Ensure safety within on-site occupied buildings;
3.Control access of unauthorised personnel;
4.Facilitate access for emergency services.

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 Plant Layout
Based on factors :
1.New site development or addition to previously developed site.
2.Type and quantity of products to be produced,
3.Possible future expansion,
4.Operational convenience and accessibility,
5.Type of process and product control,
6.Economic distribution of utilities and services,
7.Type of building and building code requirements,
8.Guidelines related to health and safety,
9.Waste-disposable problems,
10.Space available and space requirement,
11.Auxiliary equipment, and
12.Roads and railroad.

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 Criteria for good Plant Layout
1.Maximum flexibility: A good layout will be one which can be rapidly modified to
meet changing circumstances.

2. Maximum co-ordination: Entry into, and disposal from, any

department or functional area should be in such a manner that it is must convenient
to the issuing or receiving departments.

3. Maximum use of volume: Facilities should be considered as cubic devices and

maximum use made of the volume available.
4. Maximum visibility: All the people and materials should be readily observable at
all the time; there should be no ‘hidden places’ into which goods or information can
get mislaid.

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 Criteria for good Plant Layout
5. Maximum accessibility: All servicing and maintenance points should be readily
accessible.
6. Minimum distance: All movements should be both necessary and direct.
7. Minimum handling: The best handling of material and information is no handling.
8. Minimum discomfort: poor lighting, excessive sunlight, heat, noise, vibration and
smells should be minimized
9. Inherent safety
10. Maximum security
11. Efficient process flow

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 Plant Layout

Types of Layout

•Process
•Product
•Cellular
•Fixed position
•Hybrid (mixed)

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 Types of Plant Layout
1.Process type Layout:
o Used when the operations system must handle a wide variety of products in
relatively small volumes (i.e., flexibility is necessary)
•Designed to facilitate processing items or providing services that present a variety
of processing requirements.
•The layouts include departments or other functional groupings in which similar
kinds of activities are performed.
•A manufacturing example of a process layout is the machine shop, which has
separate departments for milling, grinding, drilling, and so on.

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Process type Layout:

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 Types of Plant Layout

2.Product (Assembly type) Layout:

•A job is divided into a series of standardized tasks, permitting specialization
of both labour and equipment.
•The large volumes handled by these systems usually make it economical to
invest huge amount of money in equipment and job design.
•Operations are arranged in the sequence required to make the product. For
instance, if a portion of a manufacturing operation required the sequence of
cutting, polishing, and painting, the appropriate pieces of equipment would
be arranged in that sequence.
•Product layouts are used to achieve a smooth and rapid flow of large
volumes of products or customers through a system.
•Product layouts achieve a high degree of labor and equipment utilization.

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Product type Layout:

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3.Cellular Manufacturing (CM) Layout

• Cellular manufacturing is a type of layout in which machines are grouped into what
is referred to as a cell.
• Groupings are determined by the operations needed to perform work for a set of
similar items, or part families that require similar processing.
• Cellular layout provides faster processing time, less material
handling, less work-in-process inventory, and reduced setup time.
• Used when the operations system must handle a moderate variety of products in
moderate volumes

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3.Cellular Manufacturing Layout

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 Types of Plant Layout
Fixed Position Layout
• In fixed-position layouts, the materials or major components remain in a
fixed position, and workers, materials, and equipment are moved as needed.

• Fixed-position layout is used when product is very bulky, heavy or fragile

• Fixed-position layouts are used in large construction projects (buildings,

power plants, and dams), shipbuilding, and production of large aircraft and
space mission rockets.

• Fixed-position layouts are widely used for farming, firefighting, roadbuilding,

home building, remodeling and repair.

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 Types of Plant Layout
5.Hybrid (mixed) Layout

• Actually, most manufacturing facilities use a combination of layout types.

• An example of a hybrid layout is where departments are arranged according to the

types of processes but the products flow through on a product layout.

• For instance, supermarket layouts are fundamentally of a process nature, and

however we find most use fixed-path material-handling devices such as roller-type
conveyors both in the stockroom and at checkouts, and belt-type conveyors at the
cash registers.

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 Contents
EFFECTIVE STEPS TO IMPLEMENT  
SAFETY APPRAISAL
SAFETY PROCEDURE

STUDY OF PLANT LAYOUT PERIODIC ADVICE & CHECKING 
SAFETY PROCEDURES

PERIODIC INSPECTION CONSTANT MAINTEANCE

PROPER SELECTION AND 
REPLACMENT OF HANDLING 
EQUIPMENTS

RESPIRATORY/ 
PERSONNAL PROTECTIVE 
EYE/HAND/HEAD /BODY
EQUIPMENTS

36
Personal Protective Equipment, Not Including Respirators

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Chemical Plant Control Techniques

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