Steps to Prevent work place accident...
1. identify the hazards,
by means of inspection, audit, discussion wit workers of the specific task, by reviewing your accident history,
or by using hazard id tools like JHA,hazap study, job safety survey.
then make a list of high risk areas/activities according to its rank and severity.
note: include long term hazard to health also like noise level, viberation, illumination, exposure to hazardous substance like dust , fumes , etc.
2. try to eliminate the identified hazard totally by design itself,
like revised design, substution for hazardous material .
then, ensure the reliabality of the activity , its not that much reliable imply early failure identification techniques and continuously moniter it to identify the symptoms of failure as early.
refer same type of operation in various plant to what are the majour causes for failure of the equipment / design etc.
some hazards are resedual or un avoidable for the operation according to its necessity.
in this case
3. limit the hazard level by engg control, admin control or by means of ppe
like using automatic pressure relif valve, forced ventilation.
then
4. isolate hazard form workers
by isolating explosive material, storage tank or fuel source for furnace in designated area.
isolate man machine contact by using machine guard, distance machine guard, interlocks etc.
isolate man machine and operation by using lockins/lockouts and tagouts while maintaneance or when & wher ever necessary. ( rate of accident takes place when maintaneance is more ).
5. useing fully automated fail safe desigh ( resonabely applicable )
by implementing fail passive arrangement , fail active arrangement/fail operational arrangement.
like circuit breakers, battery operated sprinkler device, fusible links in fire door etc.
6. minimize the causes for failure that lead to accident.
by design or equipe the machineary / plant for more strength than its actual requirement.
reduce the failures
by periodic / predictive proactive maintaneance.
by properly monitering the activity/operation etc like parameter monitering and buddy system ( confined space , hot work )
7 . provide proper warning system ( alert the worker )
by visual means like place caution, warning sign boards, highlight hazordous area by yellow paint like that spot light or proper illumination for high risk activity.
by sound , like siren, beep sound when an malfunction starts , by hearing the warning the operator wil get alert and do proper remidial action.
by smell like using odarant to refined natural gas, over heating of a machine.
8, each and every operator should know about the safe operating procedure / emergency shutdown procedure and other manditary things given in manufacturer operation manual.
this very much helps to prevent the incedent before getting serious .
9.provide proper backout and recovery plan and allot ther responsibilities for workers.
10. in worst case the accident may happen( because of man machine interaction)
so be prepare for that also to minimize the impact of the accident to the person / property /environment.
by physicel isolstion, ppe, crewting weaklinks. escape and survival equipment and procedure, resque equipment and procedure...
ALL ACCIDENT ARE PREVENTABLE
BY, CREATING WEL DESERVED SAFETY POLICY , IMPLIMENTING IT, PRACTCEING IT AND REVIEW IT WHEN EVER NECESSARY.
IMPLIEMENT ALL FACTORYS ACT / OSHA / ECT RULES AND REGULATIONS AND FOLLOW IT .
CREATING VERY GOOD SAFETY CULTURE .
PROVIDE PROPER TRAINING AND AWARENESS TO WORKERS.
USE COMPOTENT PERSONS ACCORDING TO JOB REQUIREMENT.
USE LOTO PROPERLY
ENCORPORATE PROPER WORK PERMIT SYSTED.
PLACE RIGHT PERSON FOR RIGHT JOB.
ALWAYS FOLLOW SAFE WORKING PROCEDURE.
MAINTAIN ALL MACHINES/EQUIPMENT IN PROPER WORKING CONDITION.
CREATE A CULTURE AMONG THE WORKERS FOR PRE WORK AND POST WORK VISUAL INSPECTION AND REPORT IT PROPERLY TO IDENTIFY UNSAFE CONDITION.
PROVIDE PROPER PPE ACCORDING TO THEIR FIT.
AVOID CONTINUOUS SHIFTS OF WORK TO WORKERS.
EDUCATE ABOUT ALL THE CONSEQUENCES OF ACCIDENTS.
HIGH LEVEL OF SUPERVAITION IS REQUIRED TO PREVENT ACCIDENT.