Need for safety

To gain knowledge on
1. Different aspects of engineering systems safety
2. Focusing on tools, techniques and methodologies needed for prevention of
occurrences of unsafe operations and accidents
3. Concepts of engineering safety systems
4. Safety design and analysis
5. Design and control for engineering safety
6. Integration of safety with other operational goals such as quality and reliability
Safety and Productivity
1. Safety and productivity are interdependent—when the workplace is safe, operations
run smoothly without accidents or disruptions.
2. When workers feel safe, they are more focused, confident, and efficient in their tasks,
leading to higher productivity.
3. Safe practices reduce incidents, minimizing equipment damage, medical leave, and
production halts.
4. Fewer accidents mean lower costs for repairs, compensation, and legal issues,
contributing to overall productivity.
5. A safe and healthy environment increases employee morale, motivation, and
retention, which directly enhances output.
Productivity:
1. Increased Performance: Higher productivity leads to faster, more efficient
completion of tasks with better quality.
2. Improved Employee Engagement: Efficient and effective productivity in the
workplace encourages employees to be more involved in their work
3. Greater Fulfilment: When productivity is high, employees experience a sense of
achievement and job satisfaction.
4. Promotes Healthy Work Culture: Productive environments encourage teamwork,
discipline, and a positive mindset.
5. Better Revenue Generation: Long-term productivity in the workplace can maximize
company profits

Accident
• An accident is an unexpected /unintentionally-caused event that results in serious injury or
illness of an employee and may also result in property damage.
• Accidents which take place in the workplace are referred to as occupational accidents.
• Workplace accidents include events that damage property, inhibit a particular workplace
function, or cause harm to a person located in the workplace.
• Occupational accidents are also referred to as work-related accidents, and the personal harm
they cause may be referred to as an “occupational injury” or “occupational death” specifies
that the cause of the harm was occupational in nature.
• Work-related accidents impose significant costs to the economy including direct costs due
to property damage and lost worker hours, as well as indirect costs, such as due to a decrease
in productivity from an accident-related decline in worker morale.
• Businesses may also be forced to pay compensation costs, fines, and increased insurance
premiums
if they are held to be liable or responsible for the accident.
• Accidents that do not cause harm to any person but which have the potential to do so are
referred to as a “near miss."
• A situation which could lead to injurious or fatal accidents is referred to as an “undesired
circumstance,” “unsafe condition,” or “unsafe act.”

Accidents can be caused by

Human (behavioural) factors:
 Unsafe conduct
 Inattention
 Negligence
 Improper training
 Inexperience
 Drowsiness, fatigue, or illness
Environmental and workplace design factors:
 Unsafe working conditions
 Unsafe workplace design
 Substandard safety controls
 Inclement weather

Injury
• An injury or illness is an abnormal condition or disorder.
• It is any physiological damage to the human body caused by immediate physical stress.
• It refers to harm caused by accidents, falls, hits, weapons, and more.
• This includes cases such as a cut, fracture, or sprain and also both acute and chronic
illnesses, such as a skin disease, respiratory disorder, or poisoning.
• It refers to physical or mental harm to an employee due to an accident or illness, including
damage to artificial members, dental appliances, teeth, hearing aids, or eyeglasses.
However, compensation for hearing aids or eyeglasses is given only if the accident also
caused a personal injury.
• An injury can occur intentionally or unintentionally and may be caused by blunt trauma,
penetrating trauma, burning, toxic exposure, or overexertion.
• Several major health organizations have established systems for the classification and
description of injuries.
• Injuries can occur in any part of the body, and different symptoms are associated with
different injuries.
• Treatment of an injury is typically carried out by a health professional and varies greatly
depending on the nature of the injury.
• Injuries are distinct from chronic conditions, psychological trauma, infections, or medical
procedures, though injury can be a contributing factor to any of these.

Unsafe act
• The unsafe act is a violation of an accepted safe procedure which could permit the
occurrence of an accident OR People make the violation of the standard rules and met with an
accident.
• 80% of all injuries on duty are the result of unsafe acts by people.
Some examples of unsafe acts are:
 Speed – operating a machine at a speed it is not designed to run at.
 Not wearing personal protective equipment (PPE) like helmets, gloves, or safety
goggles.
 Operating machinery without proper training or authorization.
 Adjusting moving machinery – lubricating bearings or changing the drive belts while
the machine is still running.
 Making safety devices inoperable or removing safety devices
 Working at heights without fall protection or harness.
 Improper handling or storage of hazardous materials.
 Running in work areas.
 Using damaged tools or equipment.
 Smoking in restricted or flammable areas.
To prevent unsafe act type accidents:
1. Plan before you start – Think about how to do the task safely before beginning.
2. Warn others – Alert coworkers about hazards like spills, wet floors, or damaged
equipment.
3. Follow rules – Always comply with safety procedures and work regulations.
4. Operate only if trained – Never use equipment unless properly trained.
5. Avoid rushing – Don’t take shortcuts or rush tasks; it increases the risk of errors.
 6. Use tools properly – Use all tools and equipment as intended (e.g., don’t use chairs as
ladders).
7. Lift safely – Use correct lifting methods or get help or use lifting devices.
8. Wear PPE – Always use appropriate personal protective equipment.
9. Correct unsafe acts – Stop and guide coworkers who are working unsafely.
10. Supervisor vigilance – Supervisors should actively monitor and correct unsafe
behaviour.

Unsafe Condition
• The unsafe condition is a hazardous physical condition or circumstance which could
directly permit the occurrence of an accident OR Working conditions/environment which
are prone to have an accident.
• A study attributes 20% of all injuries on duty to unsafe working conditions.
• They all relate to physical or mechanical defects, which can be corrected relatively
cheaply and permanently.
• It is always the first area to be tackled when working on an accident/incident reduction
programme.
Some examples of unsafe conditions are:
 Poor guarding – inadequate or inefficient
 Defective Conditions – hand tools, equipment, substances
 Poor Layout – work flow, overcrowding and congestion
 Substandard housekeeping. (A place for everything and everything in its place
always). Eg Waste bins, Aisles, Storage, signs & notices
 Loud noise – can’t hear instructions etc
 Inadequate illumination or ventilation – can’t see clearly or breathe properly
 Inadequate or improper protective equipment
 Defective tools, equipment or materials
 Congestion or restricted action
 Inadequate warning systems
 Poor housekeeping or disorderly workplace
 Hazardous environmental conditions; gases, dusts, smokes, fumes, vapours
 Noise exposures
 High or low temperature exposures

To prevent unsafe condition type accidents:

  Think about how to do the task safely prior to engaging in the work. Ensure that you
have all appropriate equipment, tools and material to safely do the job. If you don’t
have the
 correct equipment, e.g., personal protective equipment, tell your supervisor before
starting the work.
 Inspect all equipment, tools and material before use. Make certain the item is in good
working condition and is appropriate for the task.
 Make certain that you have enough space to complete the job. Many injuries are
caused
because employees didn’t have sufficient room to do a job.
 Injuries occur every day because employees choose not to say anything about known
hazards. Employees identifying unsafe conditions should cease their activity and
report the condition to their immediate supervisor for corrective action.
Dangerous Occurrence
Dangerous occurrences are certain unintended, specified events, which may not result in a
reportable injury, but which do have the potential to cause significant harm.
Dangerous occurrences usually include incidents involving:
 Lifting equipment
 Pressure systems
 Overhead electric lines
 Electrical incidents causing explosion or fire
 Explosions, biological agents
 Radiation generators and radiography
 Breathing apparatus
 Diving operations
 Collapse of scaffolding
 Train collisions
 Wells
 Pipelines or pipeline works
Theories of accident causation
1. Heinrich's Domino Theory
Heinrich’s Domino Theory explains that accidents happen in a chain, like falling dominoes. If
one event happens, it triggers the next, leading to an injury.
Heinrich found that most (88%) are caused by unsafe actions of workers, 10% by unsafe
conditions, and only 2% are unavoidable.
If we remove just one cause (like an unsafe act), we can stop the entire chain and prevent the
accident.
The five factors identified were:
  domino 1: ancestry and the worker’s social environment, which impact the worker’s
skills, beliefs and “traits of character”
 domino 2: the worker’s carelessness or personal faults, which lead them to pay
insufficient attention to the task
 domino 3: an unsafe act or a mechanical/physical hazard, such as a worker error
(standing under suspended loads, starting machinery without warning…) or a
technical equipment failure or insufficiently protected machinery
 domino 4: the accident
 domino 5: injuries or loss, the consequences of the accident
2. Human Factor Theory
The following factors together lead to human error, which can result in accidents or failures.

Overload
 Happens when a person has too many tasks, too much pressure, or not enough time or
energy.
 Causes mistakes due to mental or physical exhaustion.

Inappropriate Activities
 Performing tasks that a person is not trained or qualified for.
 Using the wrong method or tool for a job.

Inappropriate Response
 When a person reacts wrongly to a situation (e.g., ignoring a warning signal).
 Making poor decisions due to misunderstanding or lack of information.
 3. Accident/Incident Theory
Accidents happen when people are tired, stressed, poorly trained, misjudge risks, or when
their workplace setup is bad — and when the system fails to catch or prevent these problems.
If the system or organization also has problems like:
 Poor policies
 Lack of training
 No inspections or standards
Then these errors are not caught or prevented. This is called Systems Failure.

Accidents usually happen due to human error caused by different factors.

Overload
This means someone is under too much pressure — mentally or physically — and can’t
handle the task properly.
It may be caused by:
 Too much pressure or workload
  Being tired or fatigued
 Lack of motivation
 Use of drugs or alcohol
 Too much worry or stress

Ergonomic Traps
This means there’s a bad fit between the person and their work environment.
Examples:
 The workstation is the wrong size or hard to use (e.g., chair too high, screen too far).
 The person expected the task or tools to be different than they actually are.
Decision to Err
Sometimes, people make poor decisions, either:
 They misjudge the danger
 They make mistakes without realizing
 They make a risky decision on purpose thinking it’s okay for the situation

Different ways that systems can fail, according to Petersen’s theory:

 Management does not create a proper safety policy.
 Safety roles and responsibilities are not clearly explained.
 Important safety steps like checking, correcting, and investigating are ignored.
 New employees are not given proper guidance.
 Workers do not get enough safety training.

4. Epidemiological Theory
This theory compares accidents to how diseases spread in people. Just like someone can get
sick because of a virus, a weak body, and being in a risky place, an accident can happen
because of a combination of factors: The person (host), equipment or hazard (agent), The
environment.

Two sets of factors that can either cause or prevent accidents:

Predispositional Characteristics
These are the internal or background traits of a person that make them more likely to be in an
accident. These include:
 Susceptibility of people – Some people may be more likely to get hurt due to age,
health, or physical/mental condition.
 Perceptions – How people see and understand risks or dangers. If someone doesn’t
recognize danger, they might act unsafely.
 Environmental factors – The surroundings (like noise, heat, lighting) can influence
how a person behaves or reacts.
Situational Characteristics
These are the conditions at the moment the person is doing a task. These include:
 Risk assessment by individuals – Whether a person understands how risky a task is.
 Peer pressure – When coworkers influence someone to take unsafe shortcuts or risks.
 Priorities of the supervisor – If the boss focuses only on speed or production,
workers may ignore safety rules.
 Attitude – A person’s mindset, like being careless, overconfident, or stressed, can
lead to mistakes.

5. Systems Theory
Accidents happen when people, machines, and the environment interact in an unsafe way.
If one part of this system changes (like an inexperienced worker), the chance of an
accident can increase. All parts—person, machine, environment, task, and decisions—
affect how likely an accident is.

Person, Machine, and Environment interact – The process begins with the
interaction between the worker, the machine, and the surroundings.
Collect Information – The worker gathers details about the situation to understand
what needs to be done.
Weigh Risks – The worker thinks about the possible dangers or risks involved in
doing the task.
 Make Decision – Based on the risks and information, the worker decides whether or
not to do the task.
Perform the Task – If the decision is to proceed, the task is performed, and the
outcome gives feedback for future improvements.
For example, say a machine operator is working on a rush order that is behind schedule. An
important safety device has malfunctioned on his machine. Simply taking it off will interrupt
work for only five minutes, but it will also increase the probability of an accident. However,
replacing it could take up to an hour. The operator and his supervisor may assess the situation
(collect information), weigh the risks, and make a decision to proceed. If their information
was right and their assessment of the risks accurate, the task will probably be accomplished
without an accident.
6. Combination Theory
There is often a degree of difference between any theory of accident causation and reality.
• For some accidents, a given model may be very accurate. For others, it may be less so.
Often the cause of an accident cannot be adequately explained by just one model or theory.
• Thus, according to the combination theory, the actual cause may combine parts of several
different models. Safety personnel should use these theories as appropriate both for accident
prevention and accident investigation.
• However, they should avoid the tendency to try to apply one model to all accidents
7. Behavioral Theory
The Behavioral Theory, also called Behavior-Based Safety (BBS), focuses on how a person’s
actions and behavior affect safety. It says that most accidents happen because of unsafe
behaviors, not just unsafe conditions. Experts like E. Scott Geller support this theory, using
psychology to improve safety at work. The goal is to observe, understand, and change
behavior to prevent accidents.
There are seven basic principles of BBS:
1. Intervention that is focused on employee behaviour
2. Identification of external factors that will help understand and improve employee
behaviour (from the perspective of safety in the workplace)
3. Direct behaviour with activators or events antecedent to the desired behaviour, and
motivation of the employee to behave as desired with incentives and rewards that will follow
the desired behaviour;
4. Focus on the positive consequences that will result from the desired behaviour as a way to
motivate employees
5. Application of the scientific method to improve attempts at behaviour interventions
6. Use of theory to integrate information rather than to limit possibilities
7. Planned interventions with the feelings and attitudes of the individual employee in mind.

Safety organization
• Safety organization can be defined as the structure and process by which groups of people
(employees) are divided into sections or departments, each section or department is assigned
specific safety function or duty.
• Authority and responsibility of everybody is clearly defined and interrelationship between
them is specified for the accomplishment of organizational safety goals.
• A large unit may have safety department which may have groups of people for division of
such safety function and responsibilities.
• But in a small unit (majority) if such division is not possible and only a few persons are
available for safety work, they will be assigned specific duty and other departmental heads
(production, purchase, personnel etc.) will be explained their role and responsibility towards
safety goals.
• All supervisors shall be integrated with safety as part of their duty. ‘Safety is everybody’s
duty’ will be explained to all with their safety duty given in writing or by displaying at their
workplaces.

Need (Significance) of Organization

Organization is the foundation or framework of the whole structure of management and
contributes greatly to success and continuity of an enterprise in the following ways
1. Facilitates administration and other functions of management process.
2. Facilitates growth and diversification.
3. Permits optimum use of technological improvements.
4. Encourages use of human beings.
5. Stimulates creativity.
6. Attains maximum efficiency with minimum costs.

Objectives of safety organization

• To prevent accidents in future
• To provide safe work environment
• Safety consciousness
• Integrate safety policies with job process
• Compliance of rules as per factory act
• Ensure and modify on identified risk
• Training to ensure safety
• Invite cooperation and suggestions from the employees
• To take measures after accident

Functions & duties of safety organization

• Monitoring implementation of all directives issued by Rly Board & HQs in matters
pertaining to safety.
• Ensuring super checks of functioning of operational & maintenance machinery on the
division.
• Super check of coaching & goods trains, conduct night inspections, joint inspections with
officers of civil, engineering, S & T, electrical & Mechanical departments.
• Implementation of safety circular & safety drives on the division.
• Co-ordination of improvement in crew & guard booking lobbies, running rooms for running
staff.
• To coordinate disaster management functions, relief, & restoration etc.
• Assisting authorities in conducting inquires in serious accidents.
• Counselling & monitoring of staff involved in maintenance & operations

Role of management in safety

• Following specific rules and regulations
• Formation of committee (safety, welfare, pollution control, canteen..)
• Appointment of medical, welfare and safety officers
• Education and training employees
•Timely payment of compensation
• Compliance of applicant
• Promote coverage of employee under act

Role of supervisor in safety

Supervisors may not set an organization’s direction but they’re the ones who are ultimately
responsible for translating a company’s policies and intentions into action.

The employer must ensure that:

• All work is carried out without undue risk of injury or industrial disease
• Machinery and equipment are capable of safely performing the functions for which they are
used
• All permanent and temporary buildings and structures are capable of withstanding any
stresses
likely to be imposed on them
• All buildings, excavation structures, machinery, equipment, tools, and places of employment
are
maintained in good condition so workers will not be endangered
• Regular inspections are made to prevent structures, grounds, excavations, tools, equipment,
machinery, and work from becoming unsafe
• Any unsafe conditions are corrected without delay
• Each worker is supplied, at no cost, with all protective safety equipment required by Work
Safe BC regulations
• All workers are instructed in the safe performance of their duties
• An accident prevention program is set up
• There is a safe means of entry to and exit from the work area
• Firefighting equipment is provided and maintained
• Workers with physical or mental impairment are not assigned to work where their
impairment
endangers themselves or others
• No one enters or remains, or is permitted to remain, on the premises of any place of
employment
while that person’s ability to work is so affected by alcohol, drugs, or other substances as to
endanger his or her health or safety, or that of any other person

As a worker, you should keep the following personal responsibilities in mind:

• You must not remove any safety equipment from machines or equipment. This includes
shields
from grinders, mixers, etc.
• You must have had adequate instruction about a piece of machinery or equipment before
you
use it.
• You must make sure that no machine, equipment, or tool is used in a way that would cause
injury to someone else.
• You must make sure that there are safe entrances to and exits from the workplace.
• You must make sure that the work area is safe for the movement of workers, equipment, and
materials.
• You must wear protective eyewear when using grinders and other equipment that may be
hazardous to the eyes.

Role of unions in safety

Labour unions play an important role in promoting industrial safety. They protect workers’
rights by ensuring safe working conditions, fair wages, and reasonable hours. Through
collective bargaining, unions negotiate with employers for better safety standards, protective
equipment, and hazard control. They also give workers the freedom to report unsafe practices
without fear of losing their jobs.
Unions can influence the safety of all workers because of two things:
1. Restriction of labour supply
2. Increase in labour demand
A study of right-to-work laws published in the BMJ Occupational & Environmental
Medicine journal found that a 1% decrease in unionization resulted in a 5% increase in
occupational fatalities.
 Labour unions ensure safe and fair working conditions for workers.
 They empower workers to raise safety issues without fear of retaliation.
 Collective bargaining gives workers a stronger voice for better safety standards.
 Studies show that decline in unionization increases workplace fatalities.
 Unionized firms, especially in construction, adopt stronger safety practices.
 Unions pressure employers to fix hazards, preventing accidents and losses.
 They set industry-wide standards that benefit even non-union workers.
 Unions balance labour supply and demand, forcing companies to negotiate.
 They continue monitoring after agreements to ensure compliance.
 Overall, unions improve workplace safety, wages, and working hours.

Safety Policy
A safety policy is a written statement of an organization’s commitment to protecting the
health and safety of its employees and the surrounding community. It often goes beyond legal
requirements and industry standards to ensure a safe working environment.

The Occupational Health and Safety Act makes it mandatory for employers to develop and
implement such a policy. For the policy to succeed, it requires commitment from employers
and active participation from employees.

There are generally three sections in a safety policy, which include:

1. Statement of the Policy – Shows the employer’s commitment to managing health

and safety and defines the goals of the policy.
2. Responsibility – Clearly states who is responsible for implementing, enacting, and
monitoring the policy.
3. Arrangements or Procedures – Provides details of how the policy will be carried
out, including hazard reduction measures.

It may also include details about the following:

 Employee safety training
 Hazard isolation, warning signs, and safety symbols
 Use of Personal Protective Equipment (PPE)
 Substitution or removal of hazardous materials
 Improved workplace lighting and environment
 Prevention of slips, trips, and falls

Safety Officer Responsibility

In every organization, many activities take place simultaneously, and all must occur in a safe
environment. A safety officer plays a key role in recognizing potential hazards, acting during
emergencies, and ensuring a safe workplace for everyone. The officer also checks whether
the company’s safety program is effective and complies with legal and organizational
requirements.

The safety officer is usually the head of the safety department and reports to higher
management. Their main goal is to prevent accidents, ensure compliance with safety rules,
and promote safe work practices across the organization.

Main Roles of a Safety Officer

1. Planning – Ensuring all necessary safety equipment, protective tools, and emergency
arrangements are available before work begins.
2. Organizing – Managing workloads and processes so that tasks are performed without
harm to people or property.
3. Supervising – Monitoring workers to ensure they follow safe work practices,
understand their roles, and perform tasks safely.

Specific Responsibilities

 Identify, assess, and control workplace hazards and risks.

 Continuously review operations to detect new risks and recommend control measures.
  Document hazards, risks, and safety measures as per procedures.
 Supervise temporary work areas and ensure safe handling, storage, and disposal of
hazardous materials.
 Conduct safety inspections of equipment and facilities.
 Investigate workplace accidents and report them to authorities.
 Ensure compliance with OSHA and other safety regulations.
 Provide or coordinate safety training for employees.
 Transition manual safety practices to digital safety management systems for better
efficiency.
 Assist with first aid and emergency response when required.

Safety Committee – Need, Types, Advantages

A safety committee is a workplace group formed with representatives from different
departments, including management, staff, and frontline workers. Its purpose is to bring
employers and employees together to discuss safety issues and build a strong safety culture
within the organization.

Need of safety committee: The main need for a safety committee is to reduce workplace
injuries and illnesses, educate employees about safety, set achievable goals, and ensure that
health and safety remain a shared responsibility.

Types of Safety Committees

1. Formal Committees – Large organizations with weekly or monthly meetings,
involving representatives from different levels.
2. Informal Committees – Smaller organizations where all staff may gather monthly or
quarterly for safety discussions.

Functions / Duties
 Develop written safety programs.
 Promote safe work practices.
 Facilitate safety training and awareness.
 Perform inspections and accident investigations.
 Act as a communication link between workers and management.
 Review injury/illness records and recommend preventive measures.

Advantages of Safety Committees

 Provide an overall picture of the organization’s safety status.
 Act as a visible body for complaints, suggestions, and feedback.
 Ensure dedicated focus on safety-related activities.
 Motivate employees to follow safety standards.
 Show organizational commitment to employee health and wellbeing.