THE RAMCO CEMENTS LIMITED JAYANTHIPURAM WORKS

Transcription

1 THE RAMCO CEMENTS LIMITED JAYANTHIPURAM WORKS

2 What we Practice at The Ramco Cements Limited

3 Management System Certificates

4 2.0 Workforce & Man hours Worked Average no. of workers in Factory. SL. NO TYPE OF WORKERS Regular Contract Total Man hours worked by all workers SL. NO TYPE OF WORKERS Regular Contract Total

5 3.0 Incident Statistics TYPE Near-miss 11 7 High Potential Near-miss 0 0 First Aid Cases LTI ( Lost Time Incident ) Nil Nil Fatality Nil Nil Man Hours Lost Due To LTI 0 0 Severity Rate 0 0 Frequency Rate 0 0 No Of Dangerous Occurrences as per Factory Act Nil Nil

6 4.0 The longest accident free period During the assessment period only i.e From Period To Period No of Days Accident Free Million Man Hours

7 5.0 HSE Policy The Ramco Cements Limited, KSR Nagar has documented, implemented & maintained the Integrated Management System policy. (QMS 9001, EMS 14001, OHSMS 18001) Annexure 5.1 Policy has been approved by Manager of the Factory. IMS Policy is displayed at Factory main gate and various locations & IMS Policy Oath will be taken by all employees daily morning prayer assembly point.

8 6.0 HSE Performance Report The Ramco Cements Limited, Jayanthipuram works, KSR Nagar Plant is certified under IS18001:2007 Annexure 6.1 Top management receives the reports on HSE performance like Daily unsafe conditions and unsafe act points, Near-miss reporting, Monthly safety committee points, Property Damage, Safety violations and Safety warning letters Annexure 6.2 Top management reviews HSE performance during safety committee meeting conducted every month and directs all the respective concern for completion of points within the target date.

9 7.0 HSE Organization

10 HSE Department SL. NO NAME REGULAR / CONTRACT 1 Dharmalingam R Regular 2 Dhineshkumar S Regular DESIGNATION Deputy Manager Safety Assistant Manager Safety 3 YLRN Murthy Contract Safety Officer 4 B Ganesh Babu Contract Safety Officer QUALIFICATION B. Tech, Master of Engineering in Industrial Safety B.E, Master of Engineering in Industrial Safety B.Tech, EOH & S B.Tech, PG Diploma in Fire & Safety WORKING SINCE July 2013 December 2016 April 2017 August 2018

11 8.0 HSE Trainings The organization is identifying the training needs (TNI) for both employees and contractors in coordination with line managers and top management. Annexure 8.1 The effectiveness of training is evaluated through training feedback form. Annexure 8.3 Induction method for Employees and Contract workmen: - Classroom training. - On the Job orientation. - Regular pep-talk. Visitors, Experts, Govt. Officials: Safety, Health and Environment Instructions for Visitors is attached as Annexure 8.4

12 Training Records SL. NO. TRAININGS Internal Trainings External Trainings Training Participants Company Training Participants Contractors Total Training Hours Training Hr. individual per employee per annum 7 Training Hr. Contractor individual per employee per annum 8 % covered Employees % Covered Contract workforce

13 Internal & External Vehicles Drivers Training Being Conducted the Road Safety Awareness and Defense Training programme among the Company, Contract Drivers and Transporter truck Drivers. Faculty : Sub-Inspector, Chillakallu Apart from this, internally monthly once refresher training being conducted to our Mines drivers at Mines Group Vocational Training Centre.

14 9.0 Mock Drills As a part of Emergency Preparedness & response planning an emergency drill was conducted as per Factories Act/Law. Totally in our plant, 20 areas are identified as potential emergency areas like HSD Storage, HFO Storage, Coal Storage, Gas Cylinders Storage, Magazines, etc. SL. NO 1 DESCRIPTION Assuming, Coal handling H Conveyor counter weight area got fire and damaged the property Magazine-2 got fire and explosion Boiler 1 got fire and explosion Sliding of dumps at ML - 8 back filling area

15 Mock drill photos

16 Safety Control Measures Provided The flammable storage areas are fenced at specified safe distance. 400 Nos. of suitable fire extinguishers and fire buckets are provided in entire plant premises. Fire hydrant lines are provided in entire plant premises. DSPA (Dry Sprinkler Powder Aerosol) is installed in Fine Coal Bin to control the fire, once temp. reaches 90 O C it will activate and extinguish the fire. Smoke detectors are installed at all Buildings and Underground Cable tunnels & alarms will be displayed at CCR for continuous monitoring. CCTVs are installed at all the Coal hoppers top & Coal Mill Bag house top for continuous monitoring.

17 10.0 Accident / Incidents Reporting All incidents irrespective of its severity and nature it will be analyzed and investigated with in 24 hrs by using Why Why analysis. Necessary preventive and corrective action will be taken. The effectiveness of corrective action taken will be discussed during safety committee meeting held every month. Incident Investigation and Accident report Annexure 10.3 Incident Investigation and Root Cause Analysis team will lead the RCA Process. Annexure 10.4

18 11.0 HIRAC & SOP Nearly 200 Nos. of activities are considered for HIRAC covering plant & mines operations & critical maintenance activities. There are reviewed by; Annually or Any change in the activity or Any change in process / Technology updating or Project activities. Procedure is attached as Annexure Nos. of SOPs are made across the plant and or being followed. 252 Nos. of work instructions are prepared and also being followed. Work Instructions is attached as Annexure 11.2 Job Safety Analysis (JSA) Annexure 11.3

19 12.0 Contractors Safety Management. Any of the contractors or sub-contractors performing maintenance or repair, turnaround, major renovation, or specialty work on or adjacent to a covered process within RCL premises. Annexure 12.1 Safety review meetings between the company and Contractor management should be scheduled on a regular basis as per company frequency (minimum once in a Quarter). Based on the evaluation, The Best Safe Contractor Award will be given. Evaluation Criteria is attached as Annexure 12.5

20 13.0 Safety Audits SL. NO. AUDITS Internal No of Observation Compliance % 100% 100% Variance Nil Nil 2 External No of Observation Compliance % 100% 100% Variance Nil Nil

21 14.0 Occupational Health SL NO NAME QUALIFICATION DESIGNATION EXPERIENCE 1 Dr S Raja Kesava Prasad MBBS, Post Graduate certificate in Industrial Health. 2 KV Padmavathi General Nurse M 3 PSCH Naresh Kumar 4 G Raja Sekhar 5 MVV Ramana 6 K Satyanarayana Rao B.Sc, Diploma in Pharmacy Diploma in Medical Lab Technician B.Sc, Diploma in Pharmacy M.Sc, Diploma in Pharmacy SDGM Medical & Occupational Health Services Deputy officer paramedic (Nursing) Asst officer paramedic - Pharmacist Asst officer paramedic Lab Technician Asst officer paramedic - Pharmacist Junior Officer Paramedic Pharmacist 27 Years 27 Years 14 Years 25 Years 12 Years 9 Years

22 Visiting Doctors Gynecologist Dental Doctor : Visits our OHC twice in a Week : Visits our OHC On Every Sunday Homeopathy Doctor :Visits our OHC twice in a week

23 Pre-medical check procedure We are doing pre-employment medical examination to our employees before taking them for the job. Apart from general medical examination certain common blood tests and specific tests based on their nature of Job. Specific test is attached as Annexure 14.2 Frequency of re-medical check-up Once in a year for all employees. Vision test for drivers once in a year for less than 45 years. Once in six months for more than 45 years drivers.

24 15.0 Safety Promotional Activities SL. NO. LIST OF PROMOTIONAL ACTIVITIES-2016 & Road Safety Week Celebrations 2 National Safety Week Celebrations 3 Best Suggestion awards 4 Safety Committee awards 5 National Level Safety Competition 6 State Level Safety Competition award 7 Best Driver award 8 Fire Safety Week Celebrations 9 Selfless action for Emergency Situation 10 Safety News Letter Sharing 11 Special Safety Speech by Employees 12 Safety PPE Exhibition Room 13 Accident case studies sharing 14 Defense Driving for Drivers

25 National Safety Week Celebrations Observed National Safety Week from March 04 th to 10 th March, in this regard the following events are conducted; EVENTS Training programme on Industrial Safety PARTICIPANTS Company Employees 5 Minute Talk on EHS Company Employees EHS Skit competition Safety slogan EHS Essay competition Safety Poster competition Safety Poems / Songs Safety quiz competition Company Employees & Contract workmen Employees, School children & family members Employees, School children & family members Employees & School children Company Employees Company Employees

26 NSW Flag Hoisting and Message Safety Message given by Mrs. USHASRI, DCIF, & Mr. T Raju, IF, Vijayawada. Mr. N Ravishankar, President Mfg.

27 Safety Procession Organized Safety Procession with Safety Slogans speaking out with loudspeaker. IF, Div. Heads, All HODs, Safety Committee Members & Mentors along with all employees and contract workmen were participated.

28 PPE Exhibition Inauguration On NSW, Safety PPE Exhibition was inaugurated by Mr. T Raju, IF, Vijayawada and Mr. N Ravishankar, President Mfg.

29 Road Safety Week Celebrations Observed Road Safety Week from January 1 st to 7 th, in this regard the following events are conducted; EVENTS Road safety slogan Road Safety quiz Road safety training programme with film show Road safety Poster PARTICIPANTS Employees, School children & Family members Employees & Family members Local auto drivers, company drivers & contract drivers Employees & School children

30 Road Safety Campaign Being Created on Road Safety Awareness among the Jaggaiahpet people and also conducted Road Safety Campaign near JPT bus stand and Toll Gate on National Highway.

31 Safety Suggestion Box The objectives of the Suggestion Scheme are: To encourage innovations, creativity and value addition by individual employees for overall improvement. To improve safety culture, quality, productivity, profitability and service through employee participation. 31

32 Safety Flag Hoisting, Safety Pledge & Slogan Every Monday, Safety Flag hoisting and 5 minutes Safety Talk by Company or Contract employees. Everyday, Safety Pledge and Slogan by Company employees.

33 Pep Talk 5 Minutes Safety Talk is being conducting on each and every day at all sections of plant premises. Creating awareness on the particular risky job before going to do that work.

34 Work Permit System Work Permit System to carryout the hazardous work activities in a safe manner. The following Work Permit System is implemented. Hot work Work at height Confined space entry Electrical works Jam clearance Excavation Barrel cutting. General Work

35 LOTO System All electrically connected equipments to ensure that they are properly isolated for hazardous or potentially hazardous electrical energy sources during servicing and or maintenance and properly protect against re-energisation.

36 Safety Committee Activities To identify and suggest control measures for the hazards in their area / department. To suggest changes / modifications, if any, to ensure safe working conditions. Review of corrective and preventive actions regarding the accidents / incidents in the concerned departments. To carry out Internal Safety Audits by Safety Committee Members (7 Teams) once in a month. To submit a report on periodical basis on the above matters to the Top Management.

37 Cont., Safety Committee Members for the Year : S C Chairman S C Secretary Staff & Officers -Plant - Head -Safety - Head - 15 Members Company Workmen - 14 Members Contract Workmen - 6 Members Safety Committee awards are presented to Safety Committee members for following categories; Highest attendance percentage. Highest no. of points referred by a member.

38 Safety Committee Mentors To educate the co-worker, regarding the safety practice associated with the work. To inform the unsafe activities & unsafe condition to the section in charges & safety dept. To co-ordinate the safety related function. Safety Committee Mentors for the Year : Staff Company workmen Contract workmen - 04 Nos Nos Nos.

39 Safety PPE Exhibition Room To inculcate safety awareness / PPE to the new comers and visitors, Safety PPE Exhibition Room is inaugurated on

40 Safety Training Videos

41 DSPA (Dry Sprinkler Powder Aerosol) is installed in Fine Coal Bin to control the Fire and Explosion, once the temp. reaches O C it will activate and extinguish the fire.

42 Helmet Colour Coding System Company Workmen Electrician Visitor Staff and Officers Contract Workmen Safety Members & Mentors.

43 Welding Curtain Welding curtain was implemented on at Mechanical workshop. The purpose of welding curtain is to control splash of arc and fumes on others while crossing the welding area during welding process.

44 Safety Management System

45 Hazard Entry Details

46 Injury-Free Man-Hours Display Board Injury -Free Man-Hours board displayed at in front of prayer assembly point. For the purpose of each and every day Injury- Free Man-Hours to be updated. Even small First aid injury also we consider as accident and mention zero hours in that board.

47 16.0 Awards & Rewards Mr. Rambabu Company workmen got 3 rd Prize in Safety Slogan, Awarded by NSC AP Chapter, State Level Safety Competitions.

48 Best Management Award to Sri P R Ramasubrahmaneya Rajha, Chairman & Managing Director, Ramco Cements Limited and the award is being received by Sri P B Gopala Krishna, President-Mfg., and Executives of Ramco Cements on the occasion of MAY DAY on

49 Better Environmental Practices being followed by Cement Sector for the year of in the State of Andhra Pradesh

50 Performance in 5 S Surveillance audit for the year Par excellence

51 Best Supporting Organization for QC Movement Award receiving from Sri T. Harish Rao, Irrigation Minister, TS Government, Sri C. Vidyasagar Rao, Governor, Maharashtra and TN State, Sri Ch. Balakrishna Rao, Chairman, QCFI by Sri T. Sridhar Reddy, AVP-Works, and Executives from M/s The Ramco Cements Limited, KSR Nagar on the occasion of 30 th chapter convention on Quality Concepts, Hyderabad on Dt:

52 On the occasion of Viswakarma Day celebrations Best Workmen Award receiving from Hon ble Labour Minister Sri.Bandaru Dattatreya by Sri.P.Yedukondala Rao, HEO and Sri.K.Satyanarayana, Sr.Fitter on

53 Thank you for Attention & Pleasant Listening..