Safety Week Special | How to Make Manufacturing Facilities Safe | Schmersal | Hailstone | Messer Cutting | RSB Global
National Safety Week is observed in India every year from the 4th to the 10th of March to raise awareness about industrial safety and to promote the importance of a safe and healthy work environment. This year’s theme, “Focus on Safety Leadership for ESG Excellence,” highlights the crucial role of safety in achieving sustainable development. Read on to gain insights from experts on “How to Make Manufacturing Facilities Safe?” where they discuss understanding the importance of workplace safety, actions for enhancing machine safety, and more.
Understanding the Importance of Workplace Safety
Muthu Sekkar, COO, Hailstone Innovations and Additional Director on Board at Revathi Equipment Ltd, emphasized the significance of safety in manufacturing facilities. He said, “Safety starts with I and U. What is this I and U? I is individual and U is universal. Workplace safety in a manufacturing facility is achievable only when we know the potential hazards and the history of the accidents. So that will help us to identify the hazards, hazardous places, behaviors, and activities. Those activities can be rectified by training programs or some guarding mechanisms or clearing the pathways.”
He further highlighted the importance of safety gear and proper installation and guarding mechanisms. “No compromises on safety gears. Safety gears include shoes, dresses, or goggles for welding or plasma cutting. Proper installation and guarding mechanisms are essential, especially if machines are working under red-hot conditions or potential splashes are present. Continuous training is crucial as safety is not just a week-long celebration but a continuous exercise,” he added.
Actions for Enhancing Machine Safety
Girish Alawe, DGM – tec.nicum, Schmersal India, elaborated on the actions required to make any manufacturing plant safe. He said, “When we start about machine safety in our plant, it begins when your machine is manufactured at your supplier center. Risk reduction techniques should be applied during the design phase to mitigate risks. Documentation and training of these safety projects are important. Validation is the last step to ensure that the implemented control measures are effective.”
He also discussed the importance of identifying the level of safety required based on severity, frequency, and possibility of avoiding hazards. “One of the common mistakes we make is implementing machine safety but connecting all safety circuits to normal automation circuits. Safety controllers should directly monitor your motor or robot to ensure effective safety measures,” he noted.
Comprehensive Safety Training for Employees
Prashant Chaturvedi, Joint Director – Sales & Marketing at Messer Cutting Systems India, emphasized the necessity of comprehensive safety training for all employees. He stated, “Safety begins at home, and it is a complete mindset. Investment in safety should be the priority in an organization.” Chaturvedi observed that many plants overlook essential safety measures, such as using proper gas cylinders and hoses, adhering to color coding for gases, and following protocols for welding. He stressed that these measures are crucial for maintaining a safe work environment and should not be compromised.
Chaturvedi further highlighted the importance of incorporating safety training and awareness into the key performance indicators (KPIs) of each individual. He explained that proper safety training not only ensures the well-being of employees but also positively impacts the overall productivity and culture of the organization. By prioritizing safety investments and integrating safety protocols into daily operations, companies can significantly reduce the risk of accidents and create a more secure workplace.
Implementation of Safety Equipment and Technology
Anand Chandra Das, Plant Head, RSB Transmissions (I) Ltd, Lucknow, shared the safety practices at his plant. “We conduct GEMBA audits and safety audits every month. Safety policies and good practices are displayed all over the shop floors. Personal Protective Equipment (PPE) management is very good in our company. Critical PPE like gloves and helmets are compulsory in certain machines. Reportable incidents and accidents are recorded and displayed on the shop floors. Employee rewards and recognition are provided for good safety practices.”
He also highlighted human safety initiatives, including providing safety protocols for visitors, using steel bins instead of wooden baskets, and installing sensors and reflectors for blind turns and forklift movement. “We have replaced packaging materials with paper instead of plastic. Housekeeping is also a priority to prevent accidents due to oil or water leakage,” he added.
Conclusion
Creating a safe manufacturing facility requires a comprehensive approach that includes understanding potential hazards, implementing proper safety gears and guarding mechanisms, ensuring continuous training, and incorporating advanced safety technologies. By fostering a culture of safety and prioritizing investment in safety measures, manufacturing facilities can achieve a safer and healthier work environment, contributing to overall sustainable development.
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