How Can Tracking Near Misses and Incidents Help Prevent Workplace Accidents?

Dear Sir,

Thank you, and I am happy to see more participants joining in this discussion on Safety & Health.

One important aspect of safety is to prevent accidents. By following Nature's advice, we can surely prevent accidents. Accidents never come all of a sudden. According to Heinrich's theory, accidents precede incidents and near misses. However, there is no mechanism in the organization to collect details of Near Misses and Incidents.

If we can collect this information and conduct root cause analysis as we do in accident investigations, taking remedial measures, then accidents can be prevented. I have analyzed the incidents from the occupational health center registers myself, proving Heinrich's theory, which states that for every 29 incidents, one accident occurs. The analysis demonstrated that for every 27 to 29 reported incidents, there is one accident.

Let us prioritize incidents and near misses more, so the cost of accidents can be reduced.

Regards,
T.S. SRINIVASAN

Dear TSS,

You have nicely emphasized the importance of taking all incidents and near misses seriously. Your highlighting of the significance of root cause analysis, including the reference to Heinrich, is commendable.

Could you please share a case study from your experience illustrating how the investigation and root cause analysis were conducted, along with your recommendations on executing these findings? This would provide valuable insights for others.

Additionally, could you clarify Heinrich's accident ratio? Is it:
- 1 accident to 29 incidents
- 1 fatal accident for every 29 major injuries or 300 first aid cases
- 1 major injury for every 29 minor injuries or 300 near misses

Have you ever considered why the ratio of 1 accident to 29 incidents has remained unchanged since Heinrich's time? I hope you can shed more light on this issue!

Regards,
Kesava Pillai

Dear Sir,

In the Incidents Pyramid to which I refer, it states the following: Fatal incidents are at the top of the pyramid.

1 = Fatal
30 = Lost Time Incident
300 = First Aid Cases
3000 = Near Miss
30000 = Unsafe Act and Condition

Is this the same concept that Heinrich pointed out years ago? If so, why have these figures remained unchanged?

Please provide your valuable comments on this matter.

Dear Boarders,

I have come across many such postings pertaining to preventing accidents and studying the causes of accidents. It's great to read and participate in such discussions. One contributor has mentioned Heinrich's formula and questioned why accidents continue to increase despite it.

Here are a few vital facts that are highly applicable to the Indian scenario. One of the key reasons for the rising number of accidents is the lackadaisical attitude towards adopting safety measures and guidelines. Organizations often pretend to be safety-conscious, but audits and research reveal that many Indian companies use substandard safety equipment. A significant uproar occurs when accidents happen.

While safety norms exist, the prevailing Indian mindset often adopts a casual "Chalta hai" approach, leading employees to take shortcuts with safety measures. Regular safety training programs should be conducted, followed by rigorous mock drills to ensure everyone understands how to prevent accidents and avoid fatalities.

In reality, many companies only seek safety training for audit purposes, often opting for cheaper quotes without ensuring quality training. With over 1.2 billion people in the country and flexible laws, there is a prevalent lack of strict adherence to safety guidelines.

Safety officers frequently skip safety training sessions, assuming they know everything and are exempt from the rules. It's crucial for safety officers to stay updated on changing safety guidelines to effectively implement them.

Organizations may possess sophisticated equipment, but a common issue arises when employees lack knowledge of operating such equipment during emergencies. Increasing awareness about First Aid and conducting regular exercises can boost confidence among employees.

Murphy's Law holds true, emphasizing the importance of knowing how to reduce the severity of accidents should they occur. Employees are the most valuable assets of any organization, and minimizing their fatalities should be the primary goal of safety measures.

Dear Sir,

A near miss is one where no injury has occurred. This can involve one individual or may be indicative of a broader issue involving others.

Incidents of this nature are often classified as minor accidents, where individuals receive first aid or treatment at an occupational health center before promptly returning to their duties.

I have examined this aspect by analyzing approximately 20 years of data that we have collected for discussion within our safety committee.

The data revealed that following every 27 to 29 minor accidents, a major reportable accident occurred.

Our safety performance has seen improvements as a result of investigating these minor accidents and implementing necessary corrective measures.

Typically, organizations only conduct investigations for reportable accidents, which are mandated.

By investigating minor accidents or incidents, safety performance can be enhanced.

The Heinrich theory has been substantiated.

Nature provides us with ample warnings.

If 300 near misses occur and no action is taken, incidents are likely to follow. Failure to address issues after 29 incidents may result in a major accident. This theory remains valid based on my verification.

Regards,

T.S. SRINIVASAN

@ravelove

Nice to go through your write-up.

As you said, Indian industries do have a "Chalta hai" attitude when it comes to safety. However, the scenario is changing, albeit very slowly.

Nowadays, corporate companies realize the value of safety and are giving it utmost care. It's not only for conducting a successful safety audit but also for implementing it on a sustainable basis.

Moreover, nowadays, the concept of safety is spreading widely in such a way that even market investors, before buying shares, compare all aspects of the company, including safety. Therefore, things will definitely improve.

Just hope for the best and prepare for the worst. The only thing is to do our part sincerely for the sake of this divine career.

Hope to have your continuous participation in the forum discussions.

@ T.S Srinivasan

Thanks for your explanations regarding the incident pyramid and the Heinrich theory.

Let's keep up the pace and participate in the discussions, sharing your expertise with us.

Dear Boarders,

It's pertaining to my write-up on this discussion and subsequent replies by fellows. It's right, and I am also experiencing the same - that awareness towards safety is increasing among the masses. The need of the hour is to analyze why there are a large number of accidents occurring every year in the industrial scenario, and despite so many efforts, we are still not able to check the fatalities. Here comes what I mentioned in my earlier note: we have to do introspection, and surely we will find that it's not the equipment, it's not the infrastructure, but it is the mindset and our poor approach that causes the majority of accidents. Additionally, poor planning leads to fatalities.

Whatever I am quoting here is based on my research, and I have myself witnessed it almost every time I go to industries and take sessions there. There are safety plans, evacuation plans, emergency preparedness drills, and safety equipment in place. However, the irony is that when I ask the employees, most of the time, I get a blank response from them. At the time of accidents, what actions are to be taken by employees, even people do not know where the emergency exit routes exist. As I have mentioned, people just say, "I will try to call a doctor in case of an accident," but they themselves do not know that their efforts are more vital for saving the life of the injured.

It's all about learning and bringing this learning into behavior. The perception and attitude of employees can be molded according to the organizational requirements since every individual has to adopt the organizational culture.

Learning can take place in many ways, and when we want to achieve that the behavioral change should take place, then it can best be done by repetition and reinforcement. Trial and error is also a way for learning, but industries cannot afford it, and sometimes the nature of work in the industries can cause a catastrophe if we apply the trial and error way.

So the moral is we must plan the training and ensure the training program in such a way that the positive presence of key employees is there, and soon after the training, there should be repetitive sessions and case discussions with mock drills to be conducted, and we can reduce accidents. Mock drills are very essential, and they should be treated as a real-case scenario with the active participation of employees, just like defense forces carry out drills.

Thanks & Regards,
RP Singh
Basic and Advanced Cardiac Life Support Trainer (American Heart Association), First Aid Trainer
Safepro.co.in
76209582102

@RP Singh

I agree with your point emphasizing the need for imparting quality training. This is one of the key areas that will help in the reduction of accidents.

When it comes to Mock Drills, what comes to my mind is "NATO" - No Actions, Talk Only. Everything seems to be 100% on paper. This situation really needs improvement. Even though Mock Drills are being conducted, the frequency is very low.

Let's each do our part sincerely. Keep sharing your expertise with us.

@RP Singh

Very nice to see people like you coming forward with a helping and sharing mentality. As you pointed out that the discussions which are going on are monotonous, I am just bringing a new topic.

What are all the health hazards that can occur in a dry cement manufacturing plant? I am looking forward to hearing in detail with any write-up or presentation about the health hazards and their precautionary measures. What health checkups are mandatory as well?

Also, if you can, please participate in the thread below and share your expertise with us. I am not sure about the answer, hence not commenting on this thread:

https://www.citehr.com/297287-pre-em...nt-checks.html

Looking forward to hearing from you soon.

Have a look at the link below, which is available in this forum itself. It contains a good write-up and presentation regarding first aid.

https://www.citehr.com/213437-first-...#axzz16NPbTGHt

If you need more information, please let me know. I will be happy to help.

Dear All,

Thank you for continuing the discussion. In addition to accident prevention, the aspect of health needs to be looked into. The occupational health hazards need to be looked into. In addition, pre-employment health check-ups, post-employment monitoring is necessary, especially in the areas of dust, noise, and vibration.

Organizations do conduct post-medical check-ups but on a need-based basis and they do not analyze the trends. The cause of long medical leave needs to be analyzed. Based on the cause analysis, corrective measures can be taken. For example, in the cement industry, dust is a major health hazard. The silica level in the dust needs to be monitored.

The recent air monitoring norms for industries have given importance to PM 2.5 over the earlier 10-micron estimate, emphasizing health concerning dust.

Regards,
T.S. SRINIVASAN

Dear Mr Dipil

I am posting the here the occupational health related issues in cement industries.

Health and safety in the cement industry

The main causes Health related issues are injuries:

• Injured while handling, lifting or carrying

• Slipped, tripped or fell on the same level

• Hit by moving, flying or falling object

The main causes of occupational ill health are:

• Musculoskeletal disorders (MSDs)

• Skin disease, e.g. Dermatitis

• Respiratory disease, e.g. Occupational Asthma

The main causes for respiratory and skin related problems are due to cement dust.

Even today , millions of people are working daily in a dusty environment. They are exposed to different types of health hazards such as fume, gases and dust, which are risk factors in developing occupational disease. Cement industry is involved in the development of structure of this advanced and modern world but generates dust during its production. Cement dust causes lung function impairment, chronic obstructive lung disease, restrictive lung disease, pneumoconiosis and carcinoma of the lungs, stomach and colon. Other studies have shown that cement dust may enter into the systemic circulation and thereby reach the essentially all the organs of body and affects the different tissues including heart, liver, spleen, bone, muscles and hairs and ultimately affecting their micro-structure and physiological performance.

From Medical Point of View:-

The harmful effect of cement dust upon living organisms consists in irritating, sensitizing and pneumoconiotic properties of its components. In animal studies it has been observed that cement dust induces atrophic and hypertrophic changes in nasal and pharyngeal mucosa and chronic exfoliative bronchitis ( These all symptoms bears similarity to Asthma for layman to understand) . In the lungs of experimental animals slight tissue fibrosis and some emphysema foci were found. The examination of workers exposed to cement dust has shown that disorders of the upper respiratory airways they suffer from include most often chronic rhinitis, laryngitis and pharynx catarrh. Also, it has been noticed that chronic bronchitis in the exposed workers was 1.7 times more frequent compared to those non-exposed, and that asthma was diagnosed in some of the exposed workers. Chronic bronchitis was usually characterized by the symptoms of impaired, obstructive lung ventilation. Defects in lung ventilation were strictly related to the duration of mild cases of cement pneumoconiosis diagnosed in a small percentage of workers who were exposed for at least 10 years to high dust concentrations. Long-term contact of skin with cement results in inflammatory changes or, in some cases, in chemical burns. Etiological factors of inflammatory skin changes are allergenic elements (Cr, Nr, Co) and irritating agents found in cement.

Therefore, It is mandatory for the safety officers to spread health awareness among the workers about these hazards by providing them with information regarding the hazards of cement dust.

Strict Compliance with use of PPEs.

encourage deep breathing Exercises.

Periodic health check Ups and Spirometry can rule out any presence of

Respiratory ailment.

Symptoms among the workers such as Severe cough, Weight loss should be monitored regularly.

Thanx

Ravi( RP Singh)

Dear Dipil,

Occupational health is a serious subject. The subject of occupational diseases is another. A safety man is supposed to be aware of both in general. When he is posted in a particular industry, he can very well acquaint himself with the possible occupational diseases of his industry and precautions to manage the occupational health of all his subjects.

What are the various occupational health hazards in a plant? What are the precautions?

When it is difficult to find solutions, immediately seek expert opinions.

Remember, most health hazards are common for all types of industries, whereas some are specific.

Now, check what the various hazards are in your cement plant?

Of all those hazards, except chemical hazards, others are all common for most industries. Precautions are also the same.

Coming to chemical hazards; find all the raw materials, additives, and by-products in your plant. Draw precautions within your capacity. If you still have doubts, better seek expert opinion.

If you have ever done the above exercise and found it difficult, posting the query will be justified too.

I would only appreciate it if you can post specific issues seeking a solution in this forum.

In my view, this is the only way of doing things in a professional manner.

Regards,

Kesava Pillai

Dear Mr. Keshav Pillai,

Thank you for your candid comment. Firstly, I apologize for presenting a generic question. However, there are several reasons behind this.

Industrial Health and Illness are topics that I have just begun to explore. I do not have much knowledge about them yet. As I have not encountered any cases of occupational illness in my company over the past three years, I have not delved deeper into the subject. Recently, I was given the opportunity to join the newly established EHS committee at our plant. Our Medical Officer also lacks prior experience in industrial settings, resulting in limited knowledge on the topic. Nevertheless, we have devised a plan and created a leaflet in Hindi to distribute among all employees and workers at the plant concerning Industrial Hygiene and Health. I do not have it with me presently, but I will share it tomorrow for your feedback.

I will follow the guidance you have provided. I have not yet considered aspects such as raw materials and by-products. I suspect that my Medical Officer may also be unfamiliar with these details. I will attempt to gather information with the assistance of our process personnel here. Rest assured, I will reach out to you if I encounter any obstacles.

Furthermore, I would like to request your recommendations for any books on Industrial Health, Hygiene, and Occupational Illness that can provide me with the fundamental knowledge I require.

Thank you, Mr. R.P Singh, for your response. It is greatly appreciated.

Best regards

Dear All,

I am attaching a draft Health Awareness Pamphlet. Please go through it and give me your valuable suggestions. What points can I add further or modify any present point? It's mainly focusing on the workers. Please guide me, even with English write up, which I can further convert into Hindi. I would like to make only a two-sided pamphlet.

Looking forward to hearing from you all.

Thanks in advance.

The noise level for continuous exposure for 8 hours is often thought to be 90 dB, whereas it is actually only 85 dB. I have attached the different noise level exposure limits herewith.

Regards,
T.S. SRINIVASAN

@TS Srinivasan,

The document which you attached gives me new information. I was also aware that 90 dB for 8 hours exposure is the standard. However, I have checked the same with the Three State Factories Rules in Kerala, Maharashtra, and Punjab, and in all three states, it is still 90 dB.

I wonder why it remains the same. Could it be that the information is outdated? If so, how can we confidently refer to the State Factories Rules when they provide incorrect information?

Frankly, in my plant, we have even displayed warnings for heavy noise areas where the levels reach 90dB and higher, urging the use of ear protectors. Once I obtain convincing details regarding the queries above, I will consider changing the 90 dB limit to 85dB.

I look forward to hearing all of your comments regarding this matter.

Thanks in advance.

Dear TS Srinivasan,

A few more observations from the attachment:

1. On the third page, Singapore is mentioned. This indicates that it is not from India but from Singapore.

2. It mentions chapter 104, whereas our Indian Factories Act of 1948 has only 11 chapters.

Please provide your comments on the above.

Thank you.

Dear,

Please provide me with information about the following points:

1) Workers' Compensation Experience Modification Rate (EMR) Data.
2) Total OSHA Recordable Injury and Illness Rate.
3) OSHA Severity Rate.
4) What do you mean by "Citations"?
5) Do I have a written SHE program?
6) I have the required written programs for Hearing Conservation, Respiratory Protection, Hazard Communication, OSHA Process, and Spill Prevention.
7) I have the necessary Safety, Health, and Environmental Documentation.

Kindly assist me in obtaining information on the above points.

With Warm Regards,
Sandip
9552507006

Dear Dipil,

What you have observed is correct. I went to the Singapore government website to check the same, and your observation is accurate. Due to oversight, I made this mistake. The Factories Act is common for all the states ruled by the British. The name "Factories Act" misled me. Thank you for correcting me. One must be doubly cautious when citing examples. However, I had an opportunity to correct myself. In this process, I had a chance to learn more about Singapore regulations on medical check-ups, crane safety, etc.

Sorry and thank you,
T.S. Srinivasan

Dear Dipil Kumar,

Thank you for your response. Regarding noise levels in industries, we are discussing the noise level in noise-generating zones as per factory rules. The ambient noise level is also applicable to industries under the Environment Protection Act concerning noise pollution. The limits are as follows:

Ambient Air Quality Standards in respect of Noise
Area Code Category of Area/Zone Limits in dB(A) Leq*
Day Time Night Time
(A) Industrial area 75 70
(B) Commercial area 65 55
(C) Residential area 55 45
(D) Silence Zone 50 40

Note:
1. Daytime shall mean from 6.00 a.m. to 10.00 p.m.
2. Nighttime shall mean from 10.00 p.m. to 6.00 a.m.
3. A silence zone is defined as an area comprising not less than 100 meters around hospitals, educational institutions, and courts. The silence zones are areas declared as such by the competent authority.

Regards,
T.S. SRINIVASAN

Daer all,

HEARING PROTECTION AND NOISE CONTROL

When the daily noise exposure is composed of two or more periods of noise

exposure of different levels, the combined effects should be considered rather

than the individual effect of each. Exposure to different levels for various periods

of time shall be computed according to the following formula:

Cn = T1 /L1 + T2 /L2 + .... + T3 /L3

Where:

C = combined noise exposure factor,

T = the total time of exposure at a specified sound-pressure level (in hours),

and

L = the total time of exposure permitted at that level (in hours), from Table 5-

3.

If Cn > = 1, hearing protection is required.

PERMISSIBLE NON-DoD NOISE EXPOSURES

(Contractor)

Duration/day (hours)

Sound-pressure level dB(A) -- slow response

8 -------------- 90

6 -------------- 92

4 -------------- 95

3 -------------- 97

2 -------------- 100

1-1/2 --------------- 102

1 -------------- 105

½ -------------- 110

¼ --------------- 115

Permissible DoD Noise Exposures

Duration/day (hours) Sound-pressure level dB(A) --slow response

No limit ---------------- 80

9 ½ ----------------- 84

8 ----------------- 85

4 ¾ ----------------- 88

3 ¼ ----------------- 90

1 ½ ----------------- 95

½ ----------------- 100

¼ ---------------- 105

Dear dipil,Hansa,Srini

Thanks for ur all inputs.

Thanks & Besafe

Raghu

Good discussion. I am attaching my contribution.

Request for Explanation on DoD and Non-DoD

@ Mr. Raghu, thank you very much for your information. I am not aware of DoD or Non-DoD. Please provide a detailed explanation.

Thanks and Regards,
Srinivasa Rao. M

Can anyone comment on the Health Awareness Pamphlet I have attached? Looking forward to getting some suggestions and value additions from all of you. @Raghu & TS Sriniwasan, thanks for your inputs regarding noise level.

Thank you for your write-up. It's a great one. I have one question: which provides a higher amount of protection, earplugs or earmuffs? According to your write-up, it's earplugs. But why, considering that earmuffs cover the whole ear? I look forward to reading your comments.

Best regards,

Dear Dipil,

Thank you for your feedback.

An earplug completely closes the ear's hole, but an earmuff only covers the eardrum. Earplugs will provide higher protection than earmuffs. The disadvantage of the plugs is that they are disposable and can only be used by one person for a limited period.

Thanks and Regards,
Srinivasa Rao. M

Dear All,

What is the material used to make Ear Plugs? Should it also be made of mineral oil?

Please share your views to gain a clear understanding of ear protection, ear protectors, their selection, and proper use.

Take a moment to read this insightful piece by Sir Keshal Pillai about Ear Muffs:

"The filler material in a muff-type ear defender should apply uniform pressure on the ear's periphery to ensure a proper seal. It is crucial to prevent any leakage to the ear to guarantee complete protection. Any solid material is ineffective.

As a result, mineral oil is the recommended filler material for muff-type ear defenders. The manufacturing process of ear defenders with mineral oil as the filler material is challenging. Many manufacturers opt for rubber foam or other materials, but using such equipment only provides a false sense of protection."

For further information on this topic, please refer to: https://www.citehr.com/253014-pl-che...#axzz1711825YK

@ M.S Rao & Raghu,

Thank you for your input. Your contributions are valuable and greatly appreciated. Keep up the good work through continuous participation.

Thank you in advance.