Safety Week Special | How to Make Manufacturing Facilities Safe | Schmersal | Hailstone | Messer Cutting | RSB Global
mojo4industry presents a power-packed exclusive Digital Dialogue on How to Make Manufacturing Facilities Safe.
Speakers: • Muthu Sekkar, COO, Hailstone Innovations; Additional Director on Board, Revathi Equipment Ltd • Prashant Chaturvedi, Joint Director – Sales & Marketing, Messer Cutting Systems India • Anand Chandra Das, Plant Head, RSB Transmissions (I) Ltd, Lucknow • Girish Alawe, DGM – tec.nicum, Schmersal India.
Technology Partner: Schmersal
Muthu Sekkar: Discover the essence of safety with “I” for individual and “U” for universal. In a manufacturing environment, prioritizing workplace safety is paramount. Understanding potential hazards and learning from past accidents is key to creating a secure environment. Identifying risks, hazardous areas, and unsafe behaviors enables us to implement corrective measures such as training programs, protective guards, and ensuring clear pathways.
Maintaining proper housekeeping is crucial as it facilitates early detection of issues like wiring faults or leaks, preventing potential hazards. Upholding a culture where housekeeping serves as a means to report incidents fosters a safer workplace. Safety equipment, including safety shoes, attire, and goggles for specific tasks like welding or plasma cutting, is non-negotiable.
Prioritizing visitor safety involves familiarizing them with emergency exits and assembly points, a standard practice in many organizations globally. Implementing adequate installation and guarding measures around machinery operating under extreme conditions ensures employee safety. Proper illumination, like the natural lighting in our Hailstone factory, enhances visibility and reduces risks.
Continuous training and education are vital components of safety culture, ensuring ongoing awareness and preparedness. Utilizing modern tools such as fatigue management software and real-time monitoring systems further enhances safety protocols. Safety isn’t a one-time event; it’s an ongoing commitment that requires diligence, education, and utilizing available resources for real-time risk mitigation.
Girish Alawe: When discussing machine safety at our plant or manufacturing facilities, it’s essential to understand that it begins even before the machines arrive onsite. Machine safety starts at the supplier center during the manufacturing process. This is because certain adjustments or modifications may be challenging to make once the machine is in your facility, whereas the manufacturer can easily incorporate these changes during the design phase if requested beforehand.
During project development, it’s crucial to identify the most effective risk-reduction techniques and implement them. Often, advanced systems are utilized, but inadequate operator training and documentation can lead to operational challenges. Therefore, thorough documentation and training on safety procedures are imperative.
Validation is the final step in the process. Despite implementing safety measures and mitigating risks, it’s essential to verify that these control measures do not introduce further hazards or risks. Understanding the required level of safety involves considering factors such as the severity of potential injuries, the frequency and duration of exposure to risks, and the feasibility of avoiding hazards altogether.
One common mistake is connecting safety circuits to standard automation circuits. Safety components like light curtains or emergency stops should be linked to a dedicated safety controller. This controller should directly monitor machineries such as motors or robots. Rectifying this issue, known as machinery safety arc, can be achieved through simple wiring adjustments, enhancing overall safety protocols.
Prashant Chaturvedi: It’s widely said that safety begins at home, and I wholeheartedly agree. Safety is not just a practice but a mindset that should permeate every aspect of our lives. Having visited numerous plants across India, I’ve noticed a concerning trend. While the offices boast impressive facilities, the workspace often lacks basic safety equipment for contract laborers. This discrepancy is stark and concerning.
During my interactions, I’ve encountered resistance to investing in essential safety devices like flashback thrusters. Some argue that these devices are costly, but in reality, they’re relatively inexpensive and crucial for safeguarding lives and assets. I firmly believe that prioritizing safety is not just a moral obligation but a strategic investment that directly impacts an organization’s profitability and culture.
Consider simple processes like gas cutting, where cylinders pose significant safety risks. These cylinders require proper handling, storage, and color-coded identification to prevent accidents. Yet, many organizations overlook these protocols, putting lives at risk.
Similarly, hoses used in industrial settings have expiration dates and color-coded standards for different gases. Neglecting to replace worn-out hoses can lead to catastrophic failures. Investing in quality equipment is essential; compromising on safety for cheaper alternatives is never advisable.
In industries like welding, safety gear such as aprons and goggles are indispensable for protecting operators from harm. Integrating safety training and awareness into key performance indicators (KPIs) for all employees ensures a culture of safety throughout the organization.
Ultimately, safety should never be compromised for cost savings. It’s a fundamental responsibility that requires continuous investment and commitment from every individual within an organization.
Anand Chandra Das: At RSB Transmission India Limited, we uphold the highest safety standards across our group of companies, focusing primarily on the automotive and CMI verticals. We implement various safety practices to ensure the well-being of our employees and visitors.
Regular audits, including GEMBA and safety audits, are conducted on the shop floor every month to assess and improve safety measures. Visual aids displaying best practices are strategically placed throughout the shop floors to encourage operators and associates to adhere to safety protocols.
Our commitment to safety is evident in the comprehensive display of safety policies and the availability of Personal Protective Equipment (PPE) at all workstations. Critical PPE requirements, such as gloves and helmets, are clearly outlined for each station, ensuring their compulsory use where necessary.
We maintain a transparent approach to safety by recording and displaying all reportable incidents and accidents within 24 hours on the shop floors. It’s noteworthy that we haven’t had any accidents in the past four years, a testament to our dedicated safety efforts.
Employee recognition and rewards are part of our safety culture, where commendable practices are acknowledged promptly. Additionally, our rigorous housekeeping practices on the shop floor ensure a clean and hazard-free environment, mitigating the risk of accidents caused by oil spills or leaks.
Our commitment to human safety extends beyond our employees to visitors and guests. Safety protocols are visibly displayed at the entrance, including safety measures for CO2 cylinders and the replacement of wooden baskets with steel bins for improved safety.
Innovative safety measures, such as sensors and reflectors installed in blind turns and forklift areas, further enhance safety awareness and prevent accidents. By prioritizing safety initiatives across all aspects of our operations, we strive to create a secure working environment for everyone at RSB Transmission India Limited.
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