Reduction of Un-safe Work Practices by Enhancing Shop floor Safety– A case study

Dr. B P Mahesh et al. Int. Journal of Engineering Research and Applications www.ijera.com
ISSN: 2248-9622, Vol. 5, Issue 12, (Part - 4) December 2015, pp.58-66
www.ijera.com 58|P a g e
Reduction of Un-safe Work Practices by Enhancing Shop floor
Safety– A case study
Dr. B P Mahesh*, Vanishree Beloor*, K. Arpitha***, N Naveen***
Professor*, Assistant Professor **, Research Scholar***
Department of Industrial Engineering & Management JSS Academy of Technical Education, Bangalore
ABSTRACT
Industrial safety is of utmost important in the present industrial scenario in order to protect employees, plant and
environment. The present study is carried out in a machine tool manufacturing company. The initial study
revealed several problems with respect to industrial safety and productivity. Keeping these problems in view,
the aim of the present study was to analyse the existing layout and designing the new layout to improve the
productivity by ensuring safety in the shop floor according to the standards.The existing problems were
analysed systematically and solved by adopting andimplementing DuPont Safety Model. The implementation
resulted in increasing the safety and productivity in the organization.
Key words: Layout, Productivity, safety, DuPont Safety Model.
I. INTRODUCTION
1.1 Industrial Safety
Industrial safety refers to the operations which
are carried out by the management are within
theworkplace in order to safe guard organizations,
employees and assetsthereby minimizing near miss
incidents and fatal accidents. Any system related to
safety will be an important countermeasurewithin the
workplace. Priorities are given to safety measures in
order to safe guard workers and assets in case of
emergency. Industrial safety includessolving number
of issues which affects safety of worker and assets in
any organisation or industry. There are various
industrial safety causes in the following areas like:
Process and Production SafetyGeneral Safety,Fire
Safety, OSH- Occupational Safety and Health,
Workplace Safety, Material Safety ,Electrical Safety,
Environmental Safety .
1.2 Objectives of Safety
 To minimize hazards that can help in preventing
accidents.
 To eliminate the accident caused due to Work
stoppage and loss of production.
 To prevent permanent disability, fatality of
worker.
 To Train workers on safe work place and good
working condition that helps to evaluate
employee’s morale.
 To educate all employees about safety in the
organization to ensure continuous state of safety
and also to supervise about competent and safety
rules.
1.3 Hazards
Hazard is termed as a condition, substance,
behaviour or practice that can cause injury, illness or
damage to the property.
The nature of hazards are as follows: Safety
hazards , Chemical exposure, Heat stress, Fire and
explosion, Ionizing radiation, Electrical hazards,
Cold exposure, Noise, Biologic hazards.
1.4 Safe Work Practices
A safe work practice is a series of processes
which allows employees to work safely by ensuring
safe working procedure which are associated with a
particular task.
In situations where a safety is required, a task is
not needed, a safe work practices is sufficient.
However, it is more complex or high-hazard
situation, when it is often necessary to use safe
operating procedure more precisely.
1.5Benefits of Safe Work Practices
 Ensuring safe working which provides standards
for completing work activities safely
 Safe work affects quality, safety, productivity
and efficiency
 potential hazards caused due to injury and illness
will be eliminated
 Focuses on training and information sharing to
all grade of employees
 Fulfils legal requirements
1.6 Steps for Developing Safe Work
Practices
Step1: Job Inventory
Step2: Complete Job Hazard Analysis
RESEARCH ARTICLE OPEN ACCESS

Step3: Implement Safe work practices and
procedures
Step4: To follow and sustain Safe work procedures
and practices
Step5: Evaluates Safe work
1.7 Incident & Accident Investigation and
Reporting
Any Accident/Incident (including near miss)
involving acute injury, illness to personnel, loss of
revenue or damage to company property or personal
property while working must be reported by an
employee to Safety Management Department as soon
as possible or within 24 hours. Every accident that
causes or may cause death of a worker or that
requires a worker to be admitted to a hospital as an
in-patient for a period of 24 hours or more must be
investigated as soon as possible. Immediate reporting
is also required when a worker is aware of a
condition that may cause a work-related incident.
The incident must be documented and forwarded
to Industrial Scale within a reasonable period of time
(7 days maximum).
Any Near Misses that occur during company
time must be reported in the form of documentation
to the Top Management.
A worker (Owner/Manager or a Supervisor) who
is qualified and competent in investigation techniques
must investigate all Incidents or Accidents. Company
should provide training on the investigation
techniques to be used during an incident investigation
(if no qualified investigator is available, the company
shall use a third party trained investigator).
These investigations must be completed as early
as possible so that all evidence can be preserved.
Once an incident or accident has been investigated,
the investigator must make a written report to be
placed in file in the office. If the incident or accident
still poses a hazard for employees, Management must
ensure all employees are immediately informed of the
hazard. If the incident, accident, or near miss does
not pose a hazard to workers at current time, the
Safety Committee should discuss regarding these
investigations to each member or the supervisor to
ensure that all workers are made aware of the
situation.
1.8 Shop Floor Layout
The shop floor layout design helps to achieve
small product life cycles, higher varieties of product
with smaller lead times in assembly shops which are
dedicated to all individual assembly lines. Shop floor
layout improvement is the tool in order to increase
Productivity. The design of a shop floor layout plays
a vital role on basis of today’s workstations which
influence many parts of work efficiency. It requires
arranging the machines and positioning employees,
materials and other manufacturing supports to create
the most effective shop floor layout.
Shop floor layout is designed in every
organisation to minimize the number of
transportation, motions and waiting in order to
increase the productivity. Productivity is illustrated as
a method to analyse the performance or efficiency in
the industry, organisation or factory. The
improvement of productivity is done by modifying
the design of shop floor layout, supporting multi-
machine operating and streamlining the material flow
between the machines or workstations.
1.9 Types of Shop Floor Layouts
Shop Floor layouts are broadly classified into
following five categories:
 Process
 Product
 Cellular Manufacturing(CM)
 Fixed Position
 Hybrid Layouts
II. LITERATURE SURVEY
2.1 GEOCEL- Unorganized and Unsafe Working
Environment
Geocel was one of the leading Plymouth
Company who was suppliers of sealants and
adhesive. This company was facing lot of problems
with unorganized and unsafe working environment
which included lot of safety and health issues and
also there were more number of accidents that
happened on the shop floor which in turn involved
more reduction in sales and increase in manual tasks.
The members of company decided to hire a safety
adviser to resolve the issues and also to take workers
suggestions regarding the positions of machinery and
gangwaysalong with the ergonomically designed
plant layout which helped workers to work easily.
Training was given based on safety and health which
gave huge benefits to the company in the reduction of
accidents and lost time. Installing heavy machinery
also was not a problem as there were high safety
levels on the shop floor and working environment
was also very safe and organised as there were health
safety committee which was formed in each
department to control and ensure safety in the shop
floor. [5]
Tata steel company had around 15000 workers
working every day at their industrial site in
Jamshedpur, unlike other companies even they
experienced safety issues in terms of increasing
fatalities in their 80 other sites. So ensuring safety to
its workers became the biggest challenge for
company and hence they implemented DuPont safety
approach to overcome their safety problems.[6]
Tats steel firstly encountered the total number of
safety incidents occurring in their project sites and

when the number of safety incidents increased they
adopted the six step process from DuPont; this
process helped them to develop a clear and well
defined safety roadmap for their improvement in
safety issues. The focus on training and competency
building in the six step process raised a benchmark in
the industry. For the implementation of DuPont
safety Model the company developed a three phase
Pronged plan to improve the safety performance. The
three phases were:
Phase 1: Containment
In this phase, the priority was to contain the
injuries and fatalities and it was achieved by
including safety audit, sharing job hazards and
preventive measures, setting standards for Personal
Protective Equipment (PPE), conduct training and
meetings to train the workers on safety measures.
Phase 2: Establishing systems and processes
The main aim of safety system is maintain the
safety measures and to reduce the injuries .The same
system was adopted by Tata steel to first ensure
safety for the contract labours and to reduce the
accidents occurring. To maintain the safety systems
some of the steps were incorporated they are:
contractor safety committees, initiating contractor
field safety audits, having safety metrics for
contactors and making contractors responsible for
safety of their people even though the final
accountability remained under Tata steel
management.
Phase 3: Sustaining the safety way
To keep motivating the employees in the
organisation, measures were taken to drive safety
culture momentum which included: operating
discipline, Rewarding and recognizing positive safety
behaviour, monitor some safety indicators and to
convey safety messages to the workers.
As a result of the implementation of DuPont
Safety measures, the company achieved no fatalities
and no injuries which made the company to create
some safety initiatives such as online incident
reporting system to capture incidents or near-misses
so that the causes could be identified and suitable
corrective and preventive measures could be
taken.[6]
2.2 DuPont’s Model
E.I DuPont the founder of the DuPont Company
which was established in the year 1802 (two
centuries ago), which laid a strong foundation for
safety precautions to be taken in a company, remains
as one of the core corporate value today. This
company was established to manufacture high quality
gun powder in United States.E.I DuPont was almost
uniquely qualified as he had done internship with one
of the famous French Chemist by name Antoine
Lavoisier, who was also the French royal powder
company chief, a manufacturer of gunpowder. While
his internship there, he recognized that everyone
should understand the hazards which occur in any
business organisation. Due to his past experience he
made a list of process hazards and established a
strong safety process in his Company. This was the
foundation for the evolution of the process hazards
and safety programmes of the current day. The
picture below shows the modern DuPont’s triangle
which has its roots to the earlier DuPont’s triangle.
[9]
III. Problem Formulation
The aim of the present study is to analyse the
existing layout and designing the new layout to
improve the productivity by ensuring safety in the
shop floor according to the standards. The following
are the some of the problems encountered:
 There was no effective utilization of the layout.
 More number of accidents occurred due to high
unsafe work practices.
 Difficulty in completion of assembly operations
within the target time.
 Fire hazards occurred due to ineffective plant
layout.
There was no proper design of the layout and
also comparitively less standardization of the process.
The assembly process adopted there was unscientific
and were carried based upon the parts available in the
shop floor and hence there was no standard safety
measures for the workers to follow.
IV. Objectives
The following are the objectives of the present study.
 To ensure Shop floor safety.
 To create efficient safety management within
the shop floor that will boost employee’s
morale to work more effectively and efficiently.
 To complete Assembly and production activity
on time.
 To increase Productivity with high safety
standards.
 To ensure Safety that creates enjoyable work
place.
 To ensure Operator’s job satisfaction.
V. METHODOLOGY
The methodology used to achieve the above
mentioned objectives were:
 Safety functional and analysis
 DuPont Safety Model
 Increased shop floor safety
 Layout redesign

VI. Data Collection
VLD SHOP FLOOR AUDIT MONITRING SHEET
S. No. Year Area Issue Rank
1 2012 Mechanical Guards were not used while grinding B
2 2012 Materials Fall of pallets while storage A
3 2012 Electrical Live wires left out on shop floor A
4 2012 Chemical Irritation and itching due paint sprays in shop floor C
5 2012 Mechanical Worker falling down while doing height works B
6 2012 Materials Hitting objects with the part of the body C
7 2012 Mechanical Hit Injury- While fillment of Accumulator C
8 2012 Mechanical Eye disorders while welding B
9 2012 Electrical Electrical Shock while operating Oven C
10 2012 Mechanical Pinch point injury: while Manual handling of parts B
11 2012 Mechanical Hand injury during filing and chipping operation B
12 2013 Mechanical
Injuries to nerves and spinal cord while fillment of
accumulator
B
13 2013 Chemical Irritation and itching due paint sprays in shop floor C
14 2013 Electrical
Trip and fall due to lengthy tangled electrical wires
of the devices left on the shop floor
C
15 2013 Materials Trips and fall due to contact with materials C
16 2013 Mechanical Cut in High Pressure air hose B
17 2013 Materials
Back and Shoulder Injury while manually handling
materials
B

Rank A Impact on routine work / Fatal
Rank B Contribute to work may causes to work delay/ Incidents or Recordable injuries
Rank C Issue is their not effected to routine work/ Near Miss Accidents
Accident Trend Analysis
18 2013 Electrical Burns due to short circuit B
19 2013 Mechanical Hit by the movement of hoist A
20 2014 Materials
Worker getting injured while removing parts from
trolley
C
21 2014 Mechanical Fall from storage racking A
22 2014 Chemical Potentially contaminating scratches C
23 2014 Mechanical Fall from ladder while assembly of accumulator B
24 2014 Materials
Back and Shoulder Injury while manually handling
materials
B
25 2014 Mechanical Guards were not used while grinding B
26 2014 Mechanical
Injuries to nerves and spinal cord while fillment of
accumulator
B
27 2014 Chemical Slip due to oil sludge on the shop floor C
28 2014 Mechanical
Improper fastening of the heavy components while
lifting on crane.
B
29 2014 Electrical Electrical Shock while operating Oven C
30 2014 Chemical Potentially contaminating scratches C
31 2014 Mechanical
Machine turned on when maintenancecrew working
on the machine, Due to improper sigh boards of
maintenance.
B
32 2014 Chemical Slip due to oil sludge on the shop floor C
33 2014 Mechanical collision during machine assembly process B

VII. Root Cause Analysis &Solution
Implementations
7.1 Problems Encountered
In Vertical Lathe Division of BFW they
assemble the Vertical CNC machines, this division
does not have any standardized process which is
being followed. While assembly parts from the
supplier are delivered directly to shop floor and
quality check is done at the shop floor only. The flow
process of the assembly operations is followed as
given in the below figure 5.2. The process of the
assembly operations were not followed as given due
to many problems. Some of the most bottle neck
problems were:
 Ineffective utilization of plant layout.
 There are no safety concerns for the workers.
 Accidents due to improper storage of pallets
were occurring
 Fire hazards occurred due to ineffective plant
layout
 Accidents were occurring while movement of
hoist as there were no safety signals.
Fig.6.2. Flow Process Chart of VLD

7.2 Analysis of the Problems
Fig.6.3. Fish bone analysis of problem
7.3 Implementation of Corrective Actions
7.3.1 Elimination of Pallet Collapsing
During Stacking Process
Problem Root Cause
1) Accessing the pallet is difficult for the forklift
operator
2) Safety is not ensured while stacking the pallets
3) Chances of pallet falling are more due to
improper stacking
4) More movement of forklift to ensure proper
stacking.
Countermeasure Taken
Forklift operator can easily access & stack the pallets
1. Safety is ensured while stacking the pallets &
Chances of pallet falling is eliminated
2. Less movement of forklift to ensure proper
stacking
Elimination of Fire Hazard by Redesigning
the Layout
 Countermeasure Taken
1) U-type layout is designed to separate oil storage
area & oven
2) Flammable materials are avoided that are
coming in contact with fire from oven
3) High level of safety is ensured.
4) Chances of fire hazards is totally eliminated.
Elimination of Worker Injury during Part
Loading Process
 Problem Root Cause
1) Cherry picker is used to carry out height work
2) Chances of worker falling from top resulting in
fatal accident
3) There is more unsafe condition, unsafe act
practiced in the shop floor
4) Cherry picker has to be rented from an outside
contractor
5) Rent cost of cherry picker is more
6) One worker to operate cherry picker and the
same worker has to carry out height related
works which is very unsafe.
7) Chances of Man & machine and Machine &
machine collision is more within the shop floor.
 Countermeasure Taken
1) In house height work pallet is fabricated to carry
out height related works within the shop floor
2) Fatal accident of worker falling from height is
completely eliminated as more safety is ensured.
3) Double locking is ensured to eliminate un safe
act and un safe condition.
4) Easily available and no need to depend on the
contractor for cherry picker.
5) Rent cost is saved to the company as usage of
cherry picker is eliminated.
6) Chances of Man & machine and machine &
machine are eliminated and thus safety is
ensured in the shop floor.

VIII. Calculations
Additional Benefits of Safety Height Work Pallet Fabrication
Total Usage Hours= 38.5/Month
Division Monthly Required
Usage Hours
Fuel Consumption/
Hours
Cost of Fuel
VLD 9 10.5 1944
MFD 2 9 432
MLD 0.5 2.25 108
HLD 4 18 864
CNC 3 13.5 648
KAIZEN 6 27 1296
Fabrication 3 13.5 648
Foundry 9 40.5 1944
Stores 1 4.5 216
Dispatch 1 4.5 216
TOTAL 38.5 173.25 8316
 Cherry Picker Rent Data& Calculation:
Cherry Picker Rent consumption for one hour=
`1500/1hour
Total Cherry Picker Usage in VLD (9hours*1500)=
`13500/Month i.e. `162000/Year
Total cherry Picker Usage in the company
(38.5hours*1500) =`57750/Month i.e. `69300/Year
 Cherry Picker Fuel Consumption Data&
Calculation:
Cherry Picker diesel consumption for One Hour use=
4.5Lit/ Hour
Total Cherry Picker usage in VLD = 9hours*4.5=
40.5/Month i.e. 486/Year
Total Cherry Picker Usage in the Company=
38.5hours*4.5= 173.25/Month i.e. 2079/ Year
 Cherry Picker Fuel Cost Consumption Data
& Calculation:
Cherry Picker diesel cost consumption for one litre=`
48/lit
Total Cherry Picker Fuel Cost Consumption in VLD
(48*40.5) =` 1944/Month i.e.` 23328/Year
Total Cherry Picker Fuel Cost Consumption in the
Company (48*176.25) =` 8316/Month i.e.`
99729/Year
 Total Cost Saved in Rupees:
Total Cherry Picker Rent Cost + Total Cherry Picker
Fuel Cost
At VLD, ` 13500+` 1944=` 15444/Month i.e. `
185328/Year
For the Company, ` 57750+` 8316= ` 66066/Month
i.e. ` 792792/ Year
 COLLISION & NEAR MISS ACCIDENTS
AT VLD
Before machine to machine collision =16times/ hour
Before machine to machine collision=16*9=
144time/ Month
After machine to machine collision= 3*9= 27 time/
Month
Total Collision Avoid= Before Collision- After
Collision
Before man to machine collision= 8time/Hour
Before man to machine collision= 8*9 = 72 time/
Month
After man to machine collision= 2*9=
18Time/Month
Total Man to Machine collision avoid= 72-18= 54
collision/Month i.e. 648 collision/Year
Total Machine to Machine collision avoid= 144-
27=117 collision/Month i.e. 1404 collision /Year
IX. CONCLUSIONS
General Conclusions
1. By implementing the DuPont’s Model, the
organisation could change the mindset and
behaviour of the workers by training them about
the safety measures and its importance.
2. DuPont’s safety model helps the organisations to
categorise their past accidents and to reduce the
cost involved in the compensation given to the
employees for which the root cause was not
adopting the safety measures in the shop floor.
3. Implementing sign boards showing movement in
the shop floor will avoid fatal accidents.
4. Identification of specific areas in the shop floor
where the high speed cutting tools and
equipments are to be kept and usedwhich will
increase the safety of the employees on the shop
floor.
5. Proposal of safety audits within the shop floor
helps the organisations to monitor on every small
injury that take place.

6. Efficient safety management within the shop
floor will boost the employee’s morale to work
more effectively and efficiently.
Specific Conclusions
1. High level of safety standards were implemented
which increased productivity and also the safety
of workers.
2. Implementation of proper design for storage of
pallets helped the organisation in reduction of the
fatal accidents.
3. Reduction of cost by implementing the basic
safety standards within the shop floor.
4. Redesign of shop floor layout avoided the
occurrence of the fire hazards.
5. Elimination of the worker injury during part
loading process ensures the safety of the
workers.
6. Quality check of the material in the stores helps
in the effective utilization of the layout as idle
time is reduced.
7. The implementation of signals while the
movement hoist or heavy fork lift prevents
workers from being injured.
8. By the implementation of safety management in
the shop floor, the secondary benefits such as
equipment movement became easy and safe,
standard storage location was developed and
high rejection rate were eliminated.
REFERENCES
[1.] Occupational Health & Safety Program for
Department of Transportation and Works
Government of Newfoundland and Labrador
[2.] Industrial Scale Safety Manual prepared by
workforce compliance safety limited, Rev 3,
18.3.2012
[3.] uotechnology.edu.iq/depproduction/industria
l_lec/1st_class/Lecture (7)
[4.] Layout%20for%20manufacturing%20faciliti
es.doc- Links
[5.] www.bfwindia.com- Links
[6.] www.hse.gov.uk/involvement/geocel.pdf-
Geocel case study
[7.] A Safety culture beyond employee
protection- A Proven System for Effective
Contractor Safety- Tata Steel Limited case
study
[8.] Lean Applications in Shop Floor Layout
Design at Sanmina-SciFactory, Authors:
JanneRoslof, D.Sc. Marja-LeenaSuomi,
Lic.Sc.
[9.] http://www.hse.gov.uk/involvement/doyour
bit/case-study-john-smiths.html- Links
[10.] Two Centuries of Process Safety at DuPont,
Authors: James A. Klein, E. I. du Pont de
Nemours and Company
[11.] http://www.yourarticlelibrary.com/industries
/industrial-accidents-types-and-causes-of-
accidents-explai ned-with-diagram/35400
[12.] www.powershow.com/view/3df81aNz5Y/sa
fety_Managament_powerpoint_ppt_presenta
tion

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