A PROJECT REPORT

ON

SAFETY MANAGEMENT
IN ULTRATECH CEMENT COMPANY, DURGAPUR
WEST BENGAL
By Kumar Pratik
Reg. No. EIILMU/SK/RG/0708/025

EXTERNAL GUIDENCE INTERNAL GUIDENCE

Mr. P.K.Maity (Head P&A) Mr. Kaushal Lohagan

Mr. Sital Ray (Officer Safety) (Lecturer, EIILM University)

1
 CONTENTS

 Acknowledgement 3
 A brief introduction to Aditya Birla Group
4-9
 Introduction to Ultratech cement company 10-
15
 Ultratech cement company(WBCW) Durgapur 16-
46
 Safety management in Ultratech cement
Company (WBCW) 47-91
 Questionnaire 92-97
 Data analysis 98-104
 Findings 105-106
 Recommendations
107
 Conclusion 108
 Bibliography 109

2
 ACKNOWLEDGMENT

I feel it’s my pleasure to extend my profound sense of

gratitude to the EIILM University, Sikkim which had made my study a
success.

I sincerely thanks to the inspirational guidance and

Council of my guide Mr. Kaushal Lohagan (Lecturer H.R).

I sincerely express our gratitude towards Ultratech

cement company (West Bengal Cement Works) which gives me this great
opportunity to do my project work in this prestigious company. I also
thank Mr. P.K.Maity (Head P&A), Mr. S. Kanungo, Mr.A.K.Chaturvedi,
Mr.S.Bhattacharya and all other staffs for their valuable support and their
co-operation.

I also specially thanks to Mr.Sital Ray (Officer

Safety) without whom this project will never be completed he provides all
the necessary information and relevant data which I required in my study.

Last but not the least our gratitude to all the Officer
and Staff of Personnel Department, Safety Department of Ultratech
Cement Company (WBCW) who were instrumental in making this project
a grand success.

3
 A BRIEF
INTRODUCTION
OF ADITYA BIRLA GROUP

4
 Shri. KUMAR MANGALAM BIRLA
CHAIRMAN OF ADITYA BIRLA GROUP

5
Board of Directors
:: Mr. Kumar Mangalam Birla, Chairman
:: Mrs. Rajashree Birla
:: Mr. R. C. Bhargava
:: Mr. G. M. Dave
:: Mr. N. J. Jhaveri
:: Mr. S. B. Mathur
:: Mr. V. T. Moorthy
:: Mr. S. Rajgopal
:: Mr. D. D. Rathi
:: Mr. S. Misra, Managing Director

Executive President & Chief Financial

Officer
:: Mr. K. C. Birla

Chief Manufacturing Officer

:: R.K. Shah

Chief Marketing Officer

:: Mr. O. P. Puranmalka

Company Secretary
:: Mr. S. K. Chatterjee

ADITYA BIRLA GROUP

6
 FACT SHEET(1)
A US $30 billion corporation, the Aditya Birla Group is in the
league of Fortune 500. With operations in 25 countries, the Group is anchored
by an extraordinary force of 130000 employees, belonging to 30 different
nationalities. In India, the Group has been adjudged “The Best Employees in
India and among the top 20 in Asia” by the Hewitt-Economic Time and well
Street Journal Study 2007. Over 60 percent of its revenues flow from it’s over
seas operation.

The Group operates in 25 countries:- India, UK, Germany,

Hungary, Brazil, Italy, France, Luxembourg, Switzerland, USA, Australia,
Canada, Egypt, China, Thailand, Laos, Indonesia, Philippines, Dubai, Korea,
Singapore, Myanmar, Bangladesh, Vietnam, Malaysia.

FACT SHEET (2)

GLOBALLY ADITYA BIRLA GROUP IS:-
A metals powerhouse, among the world’s most cost-efficient
aluminum and copper producers. Hindalco-Novelis is the largest aluminum
rolling company. It is one of the 3 biggest producers of primary aluminum in
Asia with the largest single location copper smelter.

 No.1 in viscose staple fiber.

 The 4th largest producer of insulators.
 The 4th largest producer of carbon black.
 The 11th largest cement producer.
 Among the world’s top 15 BPO companies and among India’s
top 4.
 Among the best energy efficient fertilizer plant.

FACT SHEET (3)

7
IN INDIA ADITYA BIRLA GROUP IS:-
 A premier branded garments player.
 The 2nd largest player in viscose filament year.
 The 2nd largest in the Cllor-alkali sector.
 Among the top 5 mobile telephony companies.
 A leading player in Life Insurance and Asset Management.
 Among the top3 super-market chains in the Retail business

Rock solid in fundamentals, the Aditya Birla Group nurtures

a culture where success does not come in the way of the need to keep
learning afresh, to keep experimenting.

FACT SHEET (4)

Beyond Business Adtiya Birla Group is:-
 Working in 3700 villages.
 Reaching out to 7 million people annually through the Adtiya
Birla Centre for Community Initiatives and Rural Development
spearheaded by Mrs. Rajashree Birla.
 Focusing on: - health care, education, sustainable livelihood,
infrastructure and espousing social causes.
 Running 41 schools and 18 hospitals.
Transcending the conventional barriers of business to send
out a message that “We Care”.

DIFFERENT SECTORS OF ADITYA

BIRLA GROUP

8
A Leader For The Youth Of India

INTRODUTION TO
ULTRATECH
CEMENT COMPANY

9
 VISION

To be a premium global conglomerate

with a clear focus on each business.

MISSION

To deliver superior value to our customers,

shareholders, employees and
society at large.

VALUES
Integrity
Commitment
Passion
Seamlessness
Speed

PLANT LOCATION OF ULTRATECH

CEMENT COMPANY IN INDIA

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 Details of Plant Location of Ultratech
cement Company
Sl.No. Name of the Plant Address of the Plant
1 Ultratech Cement, GCW(Thermal Gujarat Cement Works, Village
Power Plant)& (CCP) Kovaya, Taluka Rajula City, Dist.
Amreli, Gujrat-365541

11
2 Ultratech Cement, GCW-NMCU Ultratech Cement, GCW,NMCU Plant,
Navi Mumbai

3 Ultratech Cement, GCW-MCU Ultratech Cement, GCW,MCU Plant,

Mangalore

4 Ultratech Cement, GCW, Jetty Gujarat Cement Works, Village

Kovaya, Taluka, Rajula City, Dist.
Amreli, Gujarat-365541

5 Ultratech Cement, ACW Ultratech Cement, ACW, Location:

PO Awarpur Cement Project, Taluka,
Korpana, Dist. Chandrapur,
Maharashtra- 442917

6 Ultartech Cement, APCW Ultratech Cement, APCW, Village

Bhogasamudram, Chukkalur,
Tadipatri, Dist:-Ananatpur ,
Andhra Pradesh-515415

7 Ultratech Cement, GGU Ultratech Cement, GGU, Ginigera

Unit, Ginigera Grinding Unit, Ginigera
Village, Koppal Taluk,Karnataka
State-832280

8 Ultratech Cement, HCW Ultartech Cement, HCW, PO: Hirmi,

Taluka Singa, Via:Neora, Dist. Raipur,
Chatisgarh-493114

9 Ultartech Cement Limited, JCW Ultatech Cement Limited, JCW, PO:

Awarpur Cement Project, Taluka,
Korpana, Dist:- Chandrapur,
Maharashtra-442917

10 Ultratech Cement, JFD Jafarabad Works(NCCL), Village

Babarkot, Taluka, Jafrabad, Dist:-
Amreli, Gujarat-365540
12
 11 Ultratech Cement, MGU Magdalla Works(NCCL), Magdalla
port, Dumas Road, Surat,
Gujarat- 395007

12 Ultratech Cement, Ratnagiri Ultratech Cement, Ratnagiri, MIDC

Industrial Estate, Zadgaon Block,
Ratnagiri,
Maharashtra-415639

13 Ultratech Cement, WBCW Ultatech Cement Limited, Near EPIP

Plot, Muchipara, Post:- Rajbandh,
Durgapur, West Bengal-713212
14 Ultratech Cement, ARCW Ultratech Cement Limited, Chitteri,
PO:- Arakkonam, Dist:- Vellore,
Tamilnadu- 631003

LOCATION OF ULTRATECH CEMENT

COMPANY (WBCW) IN WEST BENGAL

13
 WBCW, DURGAPUR

Ultratech cement company (west

Bengal cement works, Durgapur)

14
 WHY DURGAPUR???
West Bengal Cement Works (WBCW) is the 10 th cement
manufacturing unit of Ultratech Cement Limited, which located at Durgapur.

(A) Raw materials:-

i. Clinker: - Hirmi Cement Works.
ii. Fly ash: - Bakreshwar Thermal Power Station, DPL.
iii. Gypsum: - Hind Liver Chemicals, Haldia.
iv. Slag: - Durgapur Steel Plant and Bokaro Steel Plant.
(B) Power: -
DLP, DVC.
15
 (C) Transport: -
North Eastern Railways.
(D) Water :-
Damodar valley
(E) Land: -
62.92 areas of good land for construction.
(F)Capital: -
Huge no of bank for getting easy cash.
(G) Manpower: -
Available number of skilled and unskilled labours from
local area.
(H) Market: -
Local growth of city development.
(I) Demography: -
Good demographic structure is found here.

ULTRATECH CEMENT LIMITED

WEST BENGAL CEMENT WORKS
Ultra Tech Cement Limited is certified for quality as per the
standard ISO 9001:2000 by DNV.

 Ultra Tech Cement Limited is certified for environment protection

as per the standard ISO 14001:2000 by DNV.
 Ultratech is certified for Occupational Health as per the standard
OHSAS 18001:2007 by DNV.
 TPM (Total production Maintenance)

16
  Status.
 Foundation Stone Laying Ceremony: 15th September 20000 by the
then honorable Chief Minister, Sri Buddaded Bhattacharya.
 WCM(Work Class Manufacturing)
 Work started: - November 2000.
 Plant trial was: - 20th December 2001.
 Plant trial inauguration:- 12th January 2002.

UTCL started its business in Durgapur in the year 2002.It is

professionally managed conglomerate and enhancing stakeholder’s
value is critical to all their business. Our stakeholder’s universe goes
customers, shareholders and employees to include communities as well.

“Our belief that business is not an end in itself but the means
to an end.” Our people and our processes are at the core of our
professionalism. It is their passion, their emotional and intellectual equity
that has helped to build and grow our highly successful business. Aditya
Birla Group is one building stared teams rather then individual, stars. We
believe in people’s power.

Aditya Birla Group is in fact first multinational company. It has

its major investment in 9 countries across 4 continents. Its mission is to
build a major position for the group in India, while developing beachheads
over seas through profitable export business.

17
 EMPLOYEE POTENTIAL IN
ULTRATECH CEMENT COMPANY
DURGAPUR

Ultratech Cement Limited, cement division of Durgapur

has its permanent company staff including Officers, Supervisors,
Labourer, etc. counts to 41 in number. They are all salary paid and are
responsible for each and every performance of the industry. They will
have to look after every safety measures of the workmen not only during
the production of quantity and quality of goods, but also after
production. The permanent staff also called the Direct Employee. In the
18
above 41 staffs 20 staffs are form Management Cadre i.e., Officers and
above category and rest 21 are Support Staff to Assistant Officer
Category.

The company has its contract workmen, who work

under the contracted supervisors as a daily/weekly basis. They are not
the company’s permanent labourers but are hired from outside by those
contractors and they counts to 300 in numbers. They are not responsible
so much to any type of wrong performances within the industry during
production. So special type of training and safety measures are being
taken against them. These are also called Indirect Employees. These
employees are hired by different contractors. Below these contractors
and there hired employee are shown:-

Nature Of Work Name Of Overall Actual

Contractor Strength Engagement
Packing M/s Sen. 68 58
Plant Operation Brothers

Mechanical M/s Raj 57 53

Maintenance Engineering

Electrical and Megha 18 18

Instrumental Marketing
Maintenance

Hoticulture,Material Prgati 73 73
Handeling,Pentry,Wago Cooperative
n Tippler, Bag Branding and Labour
and Civil & Office Boy Contract
Supply Construction
Society Ltd

Railway Track Ganguly 12 12

Maintenance Associate

19
Project Work Of Silo M/s Singh 22 22
Construction
Company

Security Deployment M/s Orange 46 46

Securitas

INDUSTRIAL LAW FOLLOWED IN

ULTRATECH CEMENT LIMITED
WEST BENGAL CEMENT WORKS

1. Factories Act 1948 & West Bengal Rules 1957

2. Industrial Dispute Act 1947 & West Bengal Rules 1957
3. Payment of Wages Act 1936
4. Minimum Wages Act 1948
20
 5. Payment of Bonus Act 1965
6. ESI Act 1948 and Regulation 1950
7. Employees P.F & Miscellaneous Provision Act 1952
8. Payment of Gratuity Act 1972
9. Contract Labour Act 1970
10. Industrial Employment(standing order) Act 1946
11. Workmen Compensation Act 1923
12. West Bengal Labour Welfare Fund Act 1974

WEST BENGAL CEMENT

WORK MILESTONE
EVENT

WBCW Milestone Event Date

 First Land Registry October,2001
 First Excaration in Plant October,2000
 6.6 KV EHT Line Commissioned September,2001

21
  Railway Track Laid Down March,2002
 Wagon Tippler Commissioned March,2002
 First Clinker Rake Received March,2001
 Cement Mill Commissioned December,2001
 Cement Production Started January,2002
 Packers Commissioned January,2002
 Cement Dispatch by Road January,2002
 Cement Dispatch by Rail January,2002
 Wagon Loading System
Commissioned July, 2004

COMPANY
PROFILE
Company Name Ultratech Cement Company

(An ADITYA BIRLA GROUP of companies)

Industry Cement Manufacturing

Type of Company Public Limited

Company

22
Unit Name and Address West Bengal Cement Works

Near EPIP, Muchipara, G.T Road

Post:-Rajbandh, Durgapur 713212

Dist:- Burdwan, West Bengal

Registered Office Ultratech Cement Limited

B-Wing, Ahura Center, 2 nd

Floor, Mahakali Caves Road,

Andheri(east), Mumbai-400093

Study of Production System

23
 Including Transportation, Handling,
Loading, Unloading, Storage etc. of
Raw Materials,
Intermediate Goods and Finished
Goods.

In this plant they do not have any intermediate

products. The details of production system and handling of raw materials
and finished products are as under:-

Ultratech Cement Company, unit of WBCW is a dry

process plant fully equipped with modern equipments including ESP and
JPF for pollution control.

Basic raw materials for cement grinding units are

CLINKER, SLAG, GYPSUM and FLY ASH. Clinker is being procured from Hirmi
Cement Works (HCW) which is Ultratech Cement Company’s own
integrated cement plant situated at Raipur in the province of Chhattisgarh.
The clinker is being transported from HCW through rail and unloaded at
WBCW through wagon tippler and transported to clinker storage Silo if
15000MT through conveyor belt.

The other raw materials gypsum, slag and fly ash are being
procured from near by area through trucks/browsers/wagons and stored
in a covered shed of about 3000Mts. for slag and gypsum and fly ash bin
of 500Mts. for fly ash
24
 Fly ash is stored in fly-ash closed bin inside the plant to
prevent environment pollution. Fly ash is transported from Bakreshwar
Thermal Power Plant in a closed container called Bowser in a fly ash bin
with the help of pneumatic transport system.

Dedicated Separate jet pulse filter has been installed for

dedusting of 500MT capacities fly ash bins to keep environment dust free.

Raw materials are being filled in their respective hoppers

through conveyor belt and fed to the cement mill of closed circuit with
high efficiency separator, through electronic weigh feeder in the pre set
ratio. The output of the cement mill is transported through screw
conveyor and bucket elevator to a Sepax Separator where finer particles
are separated from coarser particles. The finer particles are separated
from coarser particles. The finer particles are transported to the cement
silos through bucket elevator and air slides. Coarser particles are returned
to the cement mill for further grinding.

This way very consistent fineness of product is maintained.

An ESP ensures collection of fine cement dust and

discharge into the stream of final product, and thus ensures a dust free
environment. Beside ESP, JPF have been provided at every material
transfer points and for slag drier to ensure dust free atmosphere. The
cement is dispatched through the two Rotary Packer of 90MX capacities
each in 50Kg bags.

PERSONAL
Routine Safety check is being carried out by the respective
department employee’s as well daily safety round by safety officer.

MEDICAL
A full-fledge Occupational Health Centre established and
functioning with a qualified doctor.
25
 All the eligible employees (both regular and contract
employee) are covered under ESI.

The company have tie-up with a local Nursing Home, which is

situated just 3kms away from the plant for emergency purpose.

ORGANISATIONAL ENVIRONMENT
West Bengal Cement Works has rail and road connectivity to meet
inward and outward logistics requirement. The private railway siding is
connected to main line of Eastern railway at Durgapur, which is 8.72 kms
from plant. The cement is packed in bags with the help of three packers
operating round the clock. The packed cement is dispatched to various
destinations by road and rail.

ORGANISATIONAL CULTURE
PURPOSE:-
To produce the cement as per marketing requirement with minimum
lost.
OBJECTIVE:-
Zero Breakdown, Good Housekeeping, Building Trust and Support

West Bengal Cement Works is having following facilities:-

 Clinker unloading by wagon tippler(capacities 15

trips/hrs)
26
  Fly ash browsers unloading system
 Cement will 1.0 million ton per annum capacity
 Cement dispatch facility by road and rail
 Clinker, Gypsum and Fly ash receipt by rail and road
respectively

LAND DETAILS
Factory 61.67acres

16 Flat Residential Complex 10,202.4 sq. feet

Assisted Sidings 2830M

Private Assisted Siding 2210M

PROCESS FLOW IN ULTRATECH

CEMENT COMPANY (WEST BENGAL
CEMENT WORKS), DURGAPUR

27
 Ultratech Cement Company
West Bengal cement works
M/s Larsen and Toubro Ltd with effect from 14th May,
2004 demerged its business and a new company named “Ultratech Cemco
Ltd” paving the way for the cement business to be acquired by Aditya Birla
Group’s Grasim Industries. It is a wholly owned subsidiary of L&T.

According to deal, the L&T will hold 20% of the equity

shares of the new cement company and the balance 80% will be allotted
to the existing L&T shareholders in proportion to their shareholding in the
company.

Grasim Industry Ltd. agreed to acquire 8.50% of equity

shares of the new cement company from L&T at Rs.99.30/share and
therefore to make an open offer for acquiring 30% of equity shares at the

28
same price to the shareholders of the new company with a view to take
management control.

The pioneer of L&T Ltd. presently known as Ultratech

Cemco Ltd. which was setup on 1968 are:-

 Henning Holck Larsen

 SOREN Toubro
Ultratech Cemco Ltd. is being lots of specified sectors and
few of them can be said as business tycoon:-

 Engineering and Construction Project

 Construction
 Heavy Engineering
 Electrical Business Group
 Information Technology
 Cement- formally known as L&T Ltd.

WEST BENGAL CEMENT WORKS

PROFILE

WBCW is HCW’s second cement grinding unit after

Jharsuguda Cement Works with a production capacity of 1.0 MPTA. It is
located in the industrial town of west Bengal at Durgapur with 61.67
acres of land. Durgapur is known as Ruhr of Bengal. WBCW is 173 km
from Kolkata-New Delhi National Highway (NH-2) i.e., G.T Road. The
factory is situated 4 km away from Durgapur railway station on Howrah-
New Delhi Rail route. It is well connected by both road and rail.

The construction started in October 2000 and

completed on November 2001.

29
 The factory is producing two types of blended
cement namely Portland Pozzolona Cement (PPC) and Portland Slag
Cement (PSC). But presently they are only producing Portland Pozzolona
Cement (PPC). They are getting Clinker from their mother plant at Hirmi
(HCW). Fly-ash is sourced from Bakreshwar Thermal Power Plant and
Durgapur Project Limited. Slag is procured from Durgapur Steel Plant and
Gypsum (Mineral) from Jodhpur, Rajasthan.

The WBCW is playing a vital role in respect of Corporate Social

Responsibility toward the society.

KEY TO DEVELOPMENT
The development of a company depends upon its
performance in the market. In Ultratech the management follows various
methods for initializing the development process. Some of the main
processes that Ultratech follows are:-

1) World Class Manufacturing: - WCM is primarily

organized for bringing the employees closer. In this process various
seminars are arranged to discuss the different problems occurs during
work and try to find out there possible solution through positive
interaction, brainstorming, and discussions on the topics concerned. In
many instances, the solutions are achieved thus developing the
decision making power of the employees. Sometimes WCM’s seminars
are held with the aid of video conferencing, which further enable the
employees to with a wider cross section of people. The WCM process
gives results through

30
Q
P
IT
A
D
R
C
U
N
V
L
E
Y
S
O
2)
stands for Total Quality Management. The philosophy of TQM says
that quality is a holistic word and can only be achieved through the
participation of each and every employee of an organization
whether she/he is a worker or a top officer. It also says that quality
is the responsibility of all the employees in an organization.
3)
so as to check the quality standards of a process or the degree of
variation of the planned standards or universally accepted
standards. Numerically Six Sigma standards for any process are 3.4
defects per million opportunities.
4)
for Total Process Management. It means that the processes should
be such managed that they produces the optimum output within
the operating constraints in a cost effective manner.

31
Tota

Six

Tota
 5) Lea
produces only that much which is demanded or which maximizes
the value of the firm.

IN ULTRATECH CEMENT COMPANY

32
 (WEST BENGAL CEMENT WORKS)

SAFETY MANAGEMENT
What is Safety Management?
Documented process for managing risk that integrates
operations and technical system with the management of financial and
human resource to ensure safety of employee.

Employee Safety
The main purpose of effective safety programme in an
organization is to prevent work-related injuries and accidents. A well
managed factory will see to it that there are no physical hazards such as
(i) Slipping and Falling Hazards, (ii) Collision and Obstruction Hazards,
(iii) Equipment Hazards, (iv) Fire Hazards, (v) Hazards from Falling objects,
etc.

1. Slipping, tripping, or falling on the floor hazards: People fall when

they slip. Highly polished surface, accumulation of water, soap, or oil,
etc., on the floor, torn or loose coverings cause the floor to be slippery.
2. Obstruction and Falling hazards: When the factory layout and space
management are poor, it results in improper placement of furniture
and equipment causing collision of employees with equipment and
machinery, tables, chairs, etc. Further, overcrowding and a narrow
space for movement also result in accidental collision between
employees.

33
3. Equipment hazards: Quit often, unguarded moving parts, wiring,
switches and cards, edges of metal equipment, etc., can cause injuries
to employees working in these surroundings. Further, waste paper
baskets, lobbies, plumbing fixtures and small snail carts also cause
problems for employees. All these should be guarded against
4. Hazards from Falling objects: When file cabinets, lockers and shelves
are not properly placed, they could fall on employees and injure them.
Also, the stocked materials, paper stands, when placed on the working
tables might fall on employees.
5. Fire hzards: The places where paperwork is heavy and precautionary
measures taken are nil; the possibilities of accidents are high. Improper
disposal facilities for smokers, lack of provision of safety cans for
inflammable materials, non-existence of fire escapes and exits are the
factors that contribute to fire accidents. It is necessary for the manager
to see that fire protection equipment and extinguishers are available at
all times in the factory.

34
 LEGAL PROVISIONS REGARDING
SAFETY
THE FACTORIES ACT 1948
The Factories Act, 1948, puts emphasis on
the following safety provision from section (21-41H).
Section 41A to 41H comes after the Bhopal Gas tragedy.
21. Fencing of Machinery.

22. Work on near machinery in motion.

23. Employement of young person on dangerous machines.

24. Striking gear and device for cutting off power.

25. Self-acting machines.

26. Casing of new machinery.

27. Prohibition of employment of women and children near cotton-

openers.

28. Hoists and Lifts.

35
29. Lifting machines, chains, ropes and lifting tackles.

30. Revolving machinery

31. Pressure plant.

32. Floors, stairs and means of excess.

33. Pits, sumps, openings in flors etc.

34. Excessive weights.

35. Protection of eyes.

36. Precautions against dangerous fumes, gases etc.

36 (A). Precautions regarding the use of portable electric light.

37. Explosive or inflammable dust, gas etc.

38. Precaution in case of fire.

39. Power to require specifications of defective parts or test of stability.

40. Safety of building and machinery.

40 (A). Maintenance of building.

40 (B). Safety Officers.

41. Power to make rules.

41 (A).Constitution of Site Appraisal Committees.

41 (B).Compulsory disclosuser of information by the occupier.

41 (C). Specific responsibility of the occupier in relation to hazardous

process.

36
 41 (D). Power of Central Government to appoint Inquiry Committee.

41 (E). Emergency standards

41 (F). Permissible limits of exposure of chemical and toxic substance.

41 (H). Right of workers to about imminent danger.

The extracts of this provision are given below:-

21. Fencing of machinery:- In every factory the
following namely-i) every moving part of a prime mover and every
flywheel connected to a prime mover, whether the prime mover or
flywheel is in the engine house or not. II) The headrace and tailrace of
every water-wheel and water turbine. III) Any stock-bar which projects
beyond the head stock of a lathe and IV) unless they are in such position
or of such construction as to be safe to every person employed in the
factory as they could be if they were securely fenced.

This provision is strictly

followed by UTCL & the details are as follows: All rotating parts of
machines are guided by proper mechanical fencing in such a way to
achieve zero access machine guard.

22. Work on or near machinery in motion:-

1) Where in any factory it becomes necessary to examine any part of
machinery referred in Section 21, while the machinery is in motion , or,
as a result of such examination, to carry out- a) in a case referred to in
clause i) of the provisions to sub-section(1) of Section 21, lubrication or
other adjusting operation; or b) in case referred to in clause (ii) of the
provisions aforesaid, any mounting or shipping of belts or other adjusting

37
operations, while the machinery is in motion such examination shall be
made.

23. Employment of young persons on

dangerous machines: - 1) No young person at any machine to
which this section applies, unless he has been fully instructed as to the
dangers arising in connection with the machine and the precautions to
be observed and
(a) has received sufficient training in work at the machine, or
(b) is under adequate supervision by a person who has a thorough
knowledge and experience of the machine. 21 sub-section(1) shall apply
to such machines as may be prescribed by the State Government, being
machines which in its opinion are of such dangerous character that
young person ought not to work at them unless the foregoing
requirements are complied with.

24. Striking gear and device for cutting off

power:- (1) In every factory (a) suitable striking gear or other
efficient mechanical appliance shall be provided and maintained and
used to move driving belts to and from fast and loose pulleys which from
part of the transmission machinery, and such gear or appliances shall be
so constructed, placed and maintained as to prevent the belt from
creeping back to the fast pulleys; (b) driving belts when not in use shall
not be allowed to rest or ride upon shafting in motion.
(2) In every factory suitable devices for cutting off power in emergencies
from running machinery shall be provided and maintained in every
workroom:
Provided that in respect of factories in operation before the
commencement of this Act, the provisions of this sub-section shall apply
only to workrooms in which electricity is used as power. (3) When a
device, which can advertently shift off to on position, is provided in a
38
factory to cut off power, arrangements shall be provided for looking the
device in safe position to prevent accidental starting of the transmission
machinery or other machines to which the device is fitted.

25. Self – acting machines: - No traversing part of a self-

acting machine in any factory & material carried thereon shall, if the
space over which it runs is a space over which any person is liable to
pass, whether in the course of his employment or otherwise, be allowed
to run on its outward or inward traverse within a distance of forty five
centimeters form any fixed structure which is not part of the machine.
Provided that the Chief Inspector may permit the continued use
of a machine installed before the commencement of this Act which does
not comply with the requirements of this section on such conditions for
ensuring safety as he may think fit to impose.

26. Casing of new machinery: - (1) In all machinery

driven by power and installed in any factory after the commencement of
this Act
(a) Every set screw, bolt or key revolving shaft, spindle, wheel
or pinion shall be so sunk, uncased or otherwise effectively guarded as to
prevent danger.
(b) All spur, worm and other toothed or friction gearing which
does not require frequent adjustment while in motion, shall be
completely encased unless it is so situated as to be as safe it would be if
it were completely encased.
(2) Whoever sells or lets on hire or, as agent of a seller or hirer, causes
or procures to be sold let on hire, for use in factory any machinery driven
by power which does not comply with the provisions of sub-section [1]
or any rules made under sub-section [3], shall be punishable with
imprisonment for a term which may extend to three months or with fine
which may extend to five hundred rupees or with both.

39
(3) The State Government may make rules specifying further safeguards
to be provided in respect of any other dangerous part of particular
machine or class or description of machines.

27. Prohibition of employment of women &

children near cotton: - No women or child shall be employed in
any part of factory for pressing cotton in which in a cotton-opener at
work:
Provided that if the feed-end of a cotton-opener is in a room
separated from the delivery end by a partition extending to the roof or
to such height as the Inspector may particular case specify in writing,
women and children may be employed on the side of the partition where
the feed-end is situated.

28. Hoists and Lifts: - (1) In every factory - a) every hoist

and lift shall be
 Of good mechanical construction, sound material and adequate
strength;
 Properly maintained, and shall be thoroughly examined by a
competent person at least once in every period of six months, and
a register shall be containing the prescribed particulars of every
such examination.
b) every hoist way and lift way shall be sufficiently protected by an
enclosure fitted with gates, and the hoist or lift and every such enclosure
shall be constructed as to prevent any person or thing from being
trapped between any part of the hoist or lift any fixed structure or
moving part.
c) The maximum safe working load shall be plainly marked on every hoist
or lift, and no load shall be carried thereon.
d) The cage of every hoist or lift used for carrying persons shall be fitted
with a gate on each side from which access is afforded to a landing.

40
e) Every gate referred to in clause [b] or clause [d] shall be fitted with
interlocking or other efficient device to secure that the gate cannot be
opened except when the cage is at landing and that the cage cannot be
moved unless the gate is closed.
(2) The following additional requirements shall apply to hoists and lifts
used for carrying persons & installed or reconstructed in a factory after
the commencement of this Act, namely-
a) Where the cage is supported by rope or chain, there shall be at
least two ropes or chains separately connected with the cage & balance
weight & each rope or chain with its attachments shall be capable of
carrying the whole weight of the cage together with its maximum load,
b) efficient devices shall be provided & maintained capable of supporting
the cage together with its maximum load in the event of breakage of
ropes, chains or attachments. c) An efficient automatic device shall be
provided & maintained to prevent the cage from over running.
This provision is strictly followed by ULTRATECH
CEMENT LIMITED and the details are as follows: - They have 2
electrical operators overhead hoists/crane which are using for lifting of
machinery during maintenance work. Details of these cranes are as
follows A) One is located at cement mill area. The capacity of this crane
SWL is 20 tones. B) Another EOT is located at wagon tippler at wagon
tippler area. The safe working load of this crane is 5 tones.
They are having a hoist which is used in production
department & located at packing plant (back go down for lifting empty
bags from ground level to back godown). The safe working load of this
hoist is 20 tones. All these cranes of the hoists are maintained by
mechanical department & recorded. These lifting cranes/hoists along
with the sling. Deshakles are tested by the competent persons
authorized by the Chief Inspector of Factories as per Factories Acts.

41
 29. Lifting machines, chains, ropes, lifting
tackles:- (1) In any factory the following provision shall be complied
with respect of every lifting machine & every chain, rope & lifting tackle
for the purpose of raising or lowering persons, good or materials-
a) All parts including the working gear, whether fixed or movable of
every lifting machine.

30. Revolving machinery:- In every factory in which the

process of grinding is carried on there shall be permanently affixed to or
placed near each machine in use a notice indicating the maximum safe
working peripherals speed of every grindstone, the speed of the shaft or
spindle upon which the wheel is mounted & the diameter of the pulley
upon such shaft or spindle necessary to secure such safe working
peripheral speed.

31. Pressure Plant: - (1) If in any factory, any plant or

machinery or any part thereof is operated at a pressure above
atmospheric pressure, effective measures shall be taken to ensure that
the safe working pressure of such plant or machinery or part is
exceeded. (2) The State Government may make rules providing for the
examination and testing of any plant or machinery.
This provision is strictly followed by
UTCL & the details are as follows: For operating of their manufacturing
processes, they use air which is more than atmospheric pressure & used
for correct operation of pneumatically controlled device/machinery. The
pneumatic pressure which is more than atmospheric pressure is
generated by Air Compressor machine, driven by electric energy. The
pressurize air is stored in a closed vessel & carried through enclosed
pipelines to the device. This complete setup of pressure valve is used in
operation is 7kg/cm². These pressure plants are tested by the competent

42
person authorized by Chief Inspector of Factories. The test certificates
are available at safety department.

32. Floors, Stairs & means of access: - In every

factory- A) All floors, steps, stairs, passages & gangways shall be of sound
construction & properly maintained & where it is necessary to ensure
safety, stairs, passages and gangways shall be provided with substantial
handrails. B) There shall, so far reasonably practicable, be provided and
maintained safe means of access to every place at which any person is
any time required to work.

33.Pits, Sumps, Openings in floor etc., :- (1) In every

factory every fixed vessel, sumps, tank, pit or opening in the ground or in
the floor, which by reason if its depth, situation, construction or contents
is or may be a source of danger, shall be either securely covered or
fenced.
These two provisions (Section 32 & 33) are strictly followed
by UTCL and the details are as follows: A) Proper housekeeping is
followed & strictly controlled by the management in this unit.
(2) To achieve good housekeeping 5S technique is followed and
maintained.
5S technique is basically a Japanese technique to achieve
good housekeeping. These 5S are:-
 Seiri – Identification and separation of necessary and unnecessary
items at the work place.
 Seiton – Arrangement of necessary items in a good order.
 Sieso – Cleaning of work place to remove dust.
 Sriketsu – Maintain and record of high standard of housekeeping.
 Shitsuke – Training of people to follow the housekeeping.

43
 34.Excessive Weights:- (1) No person shall be employed in
any factory to lift, carry or move any load so heavy as to be likely to
cause him injury. (2) The State Government may make rules prescribing
the maximum weights which may be carried or moved by adult men,
adult women, adolescents & chidren.
This provision is strictly followed in
UTCL and the details are as follows: - The excessive weight carried by
men is 55kg. No women or children are employed in this unit.

35.Protection of Eyes:- In respect of any such manufacturing

process carried on in any factory as may be prescribed, being a process
which evolves - A) Risk of injury to the eyes from particles or fragments
thrown off in the course of the process, or B) Risk to the eyes by reason
of exposure to excessive light, the government may by rules require that
effective screens or suitable goggles shall be provided for the protection
of persons employed on, or in the immediate vicinity of the process.

36. Precautions against dangerous Fumes, Gases

etc., - (1) No person shall be required or allowed to enter any
chamber, tank, vat, pit, pipe flue or other confined place in any factory in
which gas, fume vapor or dust is likely to be present to such an extent as
to involve risk to persons being overcome thereby, unless it is provided
with a manhole of adequate size or other effective means of aggress. (2)
No person shall be required or allowed to enter any confined space as is
referred to in sub-section[1] until all applicable measures have been to
remove any gas, fume, vapour or dust, which may be present so as to
bring its level within the permissible limits and to prevent any ingress of
such gas, fumes, vapour or dust and unless – (a) a certificate in writing
has been given by a competent person, based on a test carried out by
himself that the space is reasonably free from dangerous gas, fumes,
vapour or dust; or (b) such person is wearing suitable breathing
44
apparatus and a belt securely attached to a rope the free end of which is
held by a person outside the confined space.

36(A).Precautions regarding the use of potable

electric light :- In any factory – (a) no portable electric light or any
other electric appliances of voltage exceeding twenty-four volt shall be
permitted for use inside any chamber, tank, vat, pipe, flue or other
confined space; (b) if any inflammable gas, fume or dust is likely to be
present in such chamber, tank, vat, pipe or other confined space, no
lamp other than that of flame proof construction shall be permitted to
be used therein.

37.Explosive or Inflammable dust, gas etc.,:- (1)

Where in any factory any manufacturing process produces dust, gas,
fumes or vapour of such character and to such extent as to be likely to
explode to ignition, all practicable measures shall be taken to prevent
any such explosion by – a) effective enclosure of the plant or machinery
used in the process; b) removal of the accumulation of such gases, dust,
fumes or vapour; c) exclusive enclosure of all possible sources of ignition.
(2) Where in any factory any manufacturing used in a process such as is
referred to be in sub-section [1] is not so constructed as to withstand the
probable pressure which such an explosion as to aforesaid would
produce, all practicable measures shall be taken to restrict the spreads
and effects of the explosion by the provision in the plant or machinery of
chokes, baffles, vents or other effective appliances. (3) Where any part of
a machinery in a factory contains any explosive or inflammable gas or
vapour under pressure greater then atmospheric pressure; a) before the
fastening of any joint of any pipe connected with the part, any flow of
the gas or vapour into the part shall be effectively stopped by a stop-
valve or other means; b) before any such fastening as aforesaid is
removed, all practicable measures shall be taken to reduce the pressure

45
of the gas in the part to atmospheric pressure. (4) No plant, tank or
vessel which contains or has contained any explosive or inflammable
substance shall be subjected in any factory to any welding, brazing,
soldering or cutting operation which involves the application of heat
unless adequate measures have first been taken to remove such
substance and any fumes arising therefrom.

38.Precaution in case of Fire:- (1) In every factory, all

practicable measures shall be taken to prevent outbreak of fire and its
spread, both internally and externally and to provide and maintain –
a) safe means of escape for all persons in the event of fire; b) the
necessary equipment and facilities for extinguishing fire. (2) Effective
measures shall be taken to ensure that in every factory all the workers
are familiar with the means of escape. (3) The State Government may
make rules in respect of any factory or class.

39.Power to require specification of defective

parts or test of stability:- If it appears to the Inspector that
any building or part of building or any parts of the ways, machinery or
plant in a factory is in such a condition that it may be dangerous to
human life or safety, he may serve on the factory of an order in writing
requiring him before a specific date – a) to furnish such drawings,
specifications and other particulars as may be necessary to determine
whether such building, ways, machinery or plant can be used with safety,
or b)n to carry out such tests in such manner as may be specified in the
order, and to inform the Inspector of the result thereof.

40. Safety of Building & Machinery: - (1) If it appears

to the Inspector that any building or any part of the ways, machinery or
plant in a factory is in such a condition that it is dangerous to human life
or safety, he may serve on the an order in writing specifying the
46
measures which in his opinion should be adopted, and requiring them to
be carried out before a specified date.
(2) If it appears to the Inspector that the use of any building or part of a
building or any part of the ways, machinery or plant in a factory involves
imminent danger to human life or safety, he may serve on the factory an
order in writing prohibiting its use until it has been properly repaired or
altered.

40(A).Maintenance of Building: - If it appears as to the

Inspector that any building or any part of the building in a factory is in
such a state of disrepair as is likely to lead to conditions detrimental to
the health and welfare of the workers, he may serve on the occupier or
manager or both of the factory an order in writing specifying the
measures which in his opinion should be taken and requiring the same to
be carried as is specified in the order.

40(B).Safety Officers: - (1) In every factory wherein one

thousand or more workers are ordinarily employed. (2) The duties,
qualifications and conditions of service of Safety Officer shall be such as
may prescribed by the State Government.

41. Power to make Rules to supplement this

chapter: - The State Government may make rules requiring to the
provisions in any factory or in any class or description of factories of such
further for securing the safety of persons employed therein as it may
deem necessary.

41(A).Constitution of Site Appraisal

Committees:- (1) The State Government may, for purpose of
advising it to consider application for grant of permission for the
expansion of any such factory, appoint a Site Appraisal Committee
47
consisting of A) The Chief Inspector of the State, B) A representative of
Central Board for the Prevention and Control of Water Pollution, C) A
representative of Central Board for the Prevention and Control of Air
Pollution, D) Representative of State Board, E) A representative of State
Board for the Prevention and Control of Air Pollution, F) Representative
of Department of Environment in the State, G) Representative of
Meteorological Department, H) An expert in the field of Occupation
Health & I) Representative of Town Planning Department. (2) The Site
Appraisal Committee shall examine an application for the establishment
of a factory involving hazardous process.

41(B).Compulsory disclosure of Information by

the Occupier: - (1) The occupier of every factory involving a
hazardous process shall disclose in the manner prescribed in all
information regarding dangers, including health hazards. (2) The
occupier shall act the time of registering the factory involving a
hazardous policy with respect to health and safety. (3) Every occupier of
a factory shall A) If such factory engages in a hazardous process on the
commencement of Act 1987, within a period of 30 days of such
commencement & B) If such factory purposes to engage in a hazardous
process inn any time after such commencement within a period of 30
days before the commencement of that process.

41(C).Specific Responsibility of the Occupier in

relation to Hazardous process: - Every occupier of the
factory involving any hazardous process shall A) Maintain accurate and
up to date health record. B) Appoint person who posses qualification and
experience in handling hazardous substance. C) Provide medical
examination of every worker.

48
 41(D).Power of Central Government to appoint
Inquiry Committee:- (1) Central Government may, in the event
of the occurrence of an extraordinary situation involving a factory
engaged in a hazardous process, appoint an enquiry committee into the
standards of health and safety observed in the factory. (2) The
committee appointed consists of Chairman and two other members and
the tenure of office of its member shall be determined by Central
Government.

41(E).Emergency Standards: - Where the Central

Government is satisfied that no standards of safety have been prescribed
in respect of a hazardous process. The emergency standard shall be
incorporated in the rules made under this Act.

41(F).Permissible limits of Exposure of Chemical

& Toxic substance: - (1) The maximum permissible threshold
limits of exposure of chemical & toxic substance in manufacturing
process in any factory shall be of the value. (2) The Central Government
may, at any time, for the purpose of giving effect to any specific proof
obtained from specialized institutions or expert in the field.

41(G).Worker’s Participation in Safety

Management:- (1) The occupier in every factory where an
hazardous process takes place or where hazardous substance are used or
handled, set up a Safety Committee of equal member of representative
of workers and management and promote cooperation between them.
(2) The composition of Safety Committee, the tenure of office of its
members and their rights and duties shall be such as may be prescribed.

49
 41(H).Right of workers to warn about Imminent
Danger: - (1) Where the workers employed in any factory engaged
in a hazardous process have reasonable apprehension that there is
likelihood of imminent danger to their lives or health due to any
accident. (2) It shall be the duty of such agent or manager or person in
charge of the factory or process to take remedial action if he is satisfied
about the existence of such imminent danger. (3) If the occupier is not
satisfied about the existence of any imminent danger as apprehended by
the workers, he shall refer the mate forth with to the nearest Inspector.

ULTRATECH CEMENT LIMITED

Health and Safety Policy (Rule 63 B of W.B
Factories Rules, 1958)

(A) OBJECTIVE :-

Management of Ultra Tech Cement Ltd. West Bengal Cement Works is

engaged in manufacturing of Portland Slog Cement (PSC) & Pozzollon
Portland cement (PPC).

50
 Management is committed to provide safe and healthy environment to
all its employees and associates engaged in the activity of production
directly or indirectly.

To achieve this object “HEALTH AND SAFETY POLICY” is being formulated

as follow:-

(B) THE POLICY :-

 Health and safety procedure of all employees is a major part of the
establishment.
 The health and safety procedure of the organization is to serve as
safety consciousness amongst the employees at all levels.
 Promote and maintain safe & healthy working atmosphere with an
objective to achieve a zero accident.
 The management shall conduct and implement awareness
programmers for all levels of employees based on safe working
methods and relevant statutory requirements.
 Every employee of the factory is responsible in the light of his
knowledge & experience with regard to his own personal safety &
that of his coworkers as well as of any material/property entrusted
to his care.
 It should be his duty to………………….
(a) Observe the safety
(b) Make use of safety appliances supplied to him.
(c) Ensure usage of safety appliances supplied to employers
under him by such employers.
(d) Follow instruction of the appropriate authority.
(e) It shall be the responsibility of every employees and every
person undertaking work or every person working in the
premises of the factory to act in such a way so that :-
51
 (i) They do not endanger themselves, other people plant or
machineries or materials.
(ii) They follow safe working practice, and
(iii) They do not damage any equipment or facility provided by
the company for ensuring safety measures.
 The management will have the final authority to take action for
violation of the statutory provision for safety and health as well as
the rules and procedures.
 All employees at the time of their joining the company would be
given mduction training in safety.
 Regular safety training for all employees would be arranged on a
continuous basis.
 The health and safety policy of the factory would be adopted
without prejudice to the statutory provision.

(C)MEDICAL EXAMINATION :-
 Periodical medical examination will be carried out of all employees
in accordance with the rules framed as per West Bengal Factory
Rule, 1958.
 Occupational health center will be set up with part time medical
officer, if required. However, ambulance and first-aid facility with
be available in the health center.
 During emergencies patients are referred to specialists, nursing
home or hospital directly through ESI medical benefit scheme. Such
nursing homes are at a stone throw distance from the factory.
 We take personal care, by visiting patients who are admitted in
nursing home or hospital.

52
(D) JOINT CONSULTATION :-
 To effectively implement the safety policy of the factory and to
elicit full co-operation of the employees though their
representative in the safety committee.

(E) FUNDS AND FACILITIES :-

 The company will make separate annual budget for the safety and
health of the employees and provision of the funds & facilities in
order to effective implementation of the policy of the company.

(F) RULES AND PROCEDURE :-

 The rule & procedure would be same as laid in the statutory
provision in the sphere of safety & health & also may be
supplemented as agreed by management.

(G) STATISTCS AUDITS AND REVIEW :-

 The management shall undertake periodical audit of safety &
health by a constituted audit committee with a view to finding out
the status of implementation of and compliance of the safety &
health recommendation.

53
(H) STANDIND ORDERS :-
 Every employee would be personally responsible to abide by the
provision of low & rules on safety & health.
Safety committee would oversee & monitor
implementation of the provision of the safety & health.

(I) SAFETY AUDIT :-

 An audit team will be formed under the leadership of a senior
officer. This team would be conducting safety audit in the whole
factory on regular basis to bring out deficiencies in safety
application/procedures with an objective to have continuous
improvement in the safety standards.
 Another safety audit is conducted by well known safety auditor
M/s DNV in every six months.

(J) EVERY EMPLOYEE SHALL UNDERTAKE

SAFETY :-
 Education of the co-workers voluntarily, thus contributing
effectively to the implementation of the safety & health policy of
the factory. He should :-
(a) Observe the safety rules.
(b) Make use of safety appliances supplied to employees under
him.
(c) Ensure usages of safety appliances supplied to employees
under him.
(d) Follow instruction of the appropriate authority high order of
safety discipline has to be maintained by all employees.
High order of safety discipline has
to maintain by all employees.
54
(K) SAFETY ORGANISATION :-
 Safety committee shall have the following broad functions :-
(a) Accidents prevent & control including maintenance & upkeep
of safety appliance.
(b) Publicity, propaganda, education, training & liaison.

T
I
O
C
S
P
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A
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T
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I
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A
&
N
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I
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A
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A
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A
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Management View towards Safety

55
 This organization is having separate Quality, safety;
Health & Environment Policy Management implemented all possible steps
to achieve total safety towards zero accident work place in this unit. They
are having a separate safety department which is looking after exclusively
for safety and health of the employees at work place and this department is
equipped with all possible modern techniques and control.

The department is headed by the general manager

technical with one qualified safety officer and other supervisors who are
engaged with monitoring and implementing safety measures for continuous
improvement to achieve zero accident and health hazard.

Quality, Safety, Health & Environment Policy:-

They are committed to produce and deliver cement of consistent
quality to our customers. It shall be our commitment to maintain production
improvement and cost effectiveness. We shall continually upgrade
employee’s knowledge, skills & attitude through systematic training &
development by utilizing informational technology.

They are committed to develop and implement quality

management system as per ISO 9001, environment management system as
per ISO 14001 & OHSAS as per OHSAS 18001 and to bring continual
improvement in quality, safety and health & environmental performances.

They are committed to conserve the environment and treat natural

resources with cave and respect. Not only they shall abide by all statutory
rules and regulation of environment and safety but to reduce it to an
absolute minimum by setting and reviewing environmental and safety
objectives and targets.
56
 They apply all realistic efforts to prevent injuries, fire explosions,
pollution & conditions that may harm the health to the employees or
damage the equipments or environment.

SAFETY COMMITTEE IN ULTRATECH

CEMENT LIMITED:-
Members:-
1. Chairman/technical head.
2. Secretary- safety officer of the plant.
3. Body members- senior persons from each department
(technical/mechanical/P&A).
4. 50% of the workers participation is compulsory.

Function:-
1. Monitoring of unsafe condition and activities.
2. Providing suggestion to management to improve health and safety.
3. Providing guidelines to improve safety measures.
4. We follow 50% of participation of workers.
5. We follow the meeting of members monthly.

57
Types of accident in Ultratech cement
limited:-

i
c
A
t
s
r
fi
a
e
n
o
p
e
R
n
o
N d
r
t
r
t
n
e
d
a
s
i
m
a b
t
o
p
e
r
e
l
b
a l
e

Reportable: - if a worker is not able to work for 48 hours, due to an

accident.

58
 No reportable: - if somebody meets an accident and getting injury but
again join his work before 48 hours then it is not reportable accident and
it will be called non reportable.

First aid: - if a worker meets an accident, and after getting first aid
continue his normal work.

Near miss: - if an incident happens which may cause for an accident

but not made an accident and nearer to that, that is called nearness.

In Ultratech cement limited (WBCW) award is given to the person

who reports near miss with possible related causes.

Causes of accidents:-
1. Fall of height.
2. Electrocution (electric shock).
3. Impact with rotating machineries.
4. Accident during railway operation.
5. Accident during material handling.
6. Accident during lifting of equipment.
7. Eye injury due to contact of cement dust.

Different causes of accidents in this unit for the

year 2007-08:-
1. Lack of concentration.
2. Because of the excavation of soil staked near the power control
circuit.
3. Violation of safety rules.
59
4. Malfunctioning of machinery.
5. Bad condition of road.
6. Unsafe act /unsafe practice.
7. Unknown about the hazard.

ACCIDENT REPORT FROM 2007- July 09

YEAR 2007
Type of Accident No. of Cases
Non-Reportable 1
Reportable 1
Fatality 0

YEAR 2008
Type of Accident No. of Cases
Non-Reportable 0
Reportable 0
Fatality 0

60
 YEAR 2009(till July)
Type of Accident No. of Cases
Non-Reportable 0
Reportable 1
Fatality 0

SAFETY STATITICS OF THE YEAR

2007 and 2008

Safety Statistics
Year
Sl. No Description
2007 2008
No. of Fatal accidents to
1 Nil Nil
Our employee

2 No. of Fatal accidents to Nil Nil

Contractor’s employee.
3 No. of reportable accidents Nil Nil
4 Man days lost Nil Nil
5 Man-hours worked 707610 662684
6 Frequency rate 0 0
61
 (Reportable)
7 Severity rate (Reportable) 0 0
8 Major fire incidences Nil Nil

PROCESS OF SAFETY
MEASURES

H-Hazard
I-Identification
R- Risk
A-Assessment
Incident is defined as the combination of accident and near miss.

STEPS TOWARDS ACCIDENT FREE WORK

PLACE:-
If there is a hazardous source, then it may hit the target and
accident happens.

Hazard
62
 Source Target

In UTCL they can make their workplace accident free by

the following steps.

 Elimination towards hazards.

 Substitution towards hazards.
 Management control towards hazards.
 Engineering means towards hazards.
 Personal protective equipments towards hazards.

Elimination, substitution and engineering means are given

the first priority.

Management control and personal protective equipment

(PPE) are given the second priority.

Elimination: -
If the source that causes accident is permanently
eliminated, then accident can be presented. This process is called
elimination.

Substitution: -
If the source is substituted by another are then accident can
be prevented.

Engineering means: -
63
 If barriers are made between target and source, thus accident
can be prevented.

(A)

(B)

64
 These are the measures taken by
Ultratech to protect the environment from suspended
particulate matter (SPM).

Management control and education

Safety training is provided to the employees both
internally and externally. Internal training is provided by safety officer and
other departmental senior engineers and external training is arranged by
P&A through the external institution like Stale Productivity Council,
Kolkata, West Bengal, Occupational Health Monitoring Task Force, City
Center, Durgapur, & Det Norkse Veritas as India, Park Street, Kolkata.

Every workman or supervisor, who are entering our

premises are provided with safety induction training before common-
center of work we issue a green card to the workman or supervisor, after
completion of training.

The duration of training of workers is 45 minutes and for

supervisors is 1 and1\2 hours.

(C) Permit to Work (PTW):- Following safety measures are

taken while permit to work are:

(1) Switches/fazes/breakers switched off/taken out.

(2) Is there any possibility of feedback of power?

65
 (3) Temporary earth connection details.

(4) Caution plates placed on switch/breaker.

(D) Confined Space/Area:- Following safety measures are

taken while entering the confined space in Ultra Tech:

 Equipment isolated from main production line.

 Minimum Oxygen level of 19.5%. Power ventilation arrangement
ensured.
 Work area is free from toxic gas/high temperature.
 Sufficient light & use of 24 V lamps ensured.
 Stairs ladders, platform provided to approach work.
 Process clearance for hold up obtained & ensures to be
maintained.
 Fire fighting arrangement made, if required.
 Rescue arrangement made, First Aid Box updated.
 To check abd ensure.
 Personal protective equipment provided.
 Associated job hazards explained to workers.
 Person engagement is experienced for the job.

(E) Work at Height: - Following safety measures are taken

while working at height in Ultratech:

 Persons engaged are experienced and suitable for the job.

 Necessary instructions for safe job execution given.
 Stairs/ladders provided approach work at height.
 Ladder tied and supported properly at ends.
 Work Platform/scaffold of sound construction provided.
 Safe walk ladder or crawling board provided for working on
fragile/false roof.

66
(F) Hot Work
(1)Gas Cutting (Precautions)
 It should be always kept in a trolley.
 Both cylinders (Diluted Acetylene and Oxygen) should be kept
separately with proper clamping on the trolley.
 There must not be any leakage in the rubber host pipe.
 Fuel host pipe (Diluted Acetylene) is red coloured and Oxygen host
pipe is sky blue colour.
 The gas cutting torch should be fitted i.e., equipped with flash back
arrester.
 Gas cutter must be provided with gas cutting goggles and apron.
 The area should be clean before starting the gas cutting mark.
There should not be any combustible material near by the job.
 A fire aid extinguisher of DCP type should be kept there for
extinguishing any fire incident.

(2)Welding Safety Measures

 Check the proper insulation of welding cables.
 Fitness certificates of welding machines.
 Welding should be done by trained welder.
 Cleaning of the area. There should not be any combustible material.
 Welder must be equipped with the following PPE- welding screen,
leather, hand gloves, welding apron and welding gloves.
 A fire extinguisher is required.

67
 PERSONAL PROTECTIVE
EQUIPMENTS

1.Safety helmets
2.Safety shoes
3.Safety belts
4.Safety goggles
68
 5.Safety gloves
6.Welding screen
7.Welding apron
8.Ear plug
9.Ear muff

FIRE AND FIRE

PREVENTION
The three components required for fire are Fuel, Oxygen and
Heat.

CLASSES OF FIRE
 Combustible Solid like COAL, WOOD, PAPER, GRASS, etc.
69
  Combustible Liquid like PETROL, DISEL, KEROSEN, GREASE, etc.
 Combustible Gases like HYDROGEN, ACETYLENE, LPG, etc.
 Combustible Metal like POTASSIUM, SODIUM, CALCIUM, etc.

EXTINGUISHERE USED
The extinguishers which are used for the prevention of
large and dangerous fire in a plant area, must have to a effective and
strong enough for quick prevention and some of these type used are as
follows:

1)Water CO₂ Type

2)Fome Type
3)Dry Chemical Type
4)Carbon Dioxide

COLOUR COADING OF PIPES

The most complex piping requirements may be found in
the chemical and allied industries, where, in addition to general industrial
applications, pipe systems are used for distribution of raw materials,
compounds in process and final products.
COLOUR USED IN THE PIPES
RED: - Red is used exclusively in connection with fire prevention and fire
fighting equipments.

ORANGE: - It indicates dangerous points of machineries that can cut,

shock or otherwise, injures.
70
YELLOW: - The universal signal for caution. It is used most often to make
areas when there are tripping, falling, storing against, or being caught-in-
between hazards.

GREEN: - The basic Safety colour. It should be used to indicate the

location of first aid equipments, gas masks, and safety bulletin boards.

BLUE: - A cautionary colour. It is a specific warning against starting

equipment that being required. It may be used as a general cautionary
aid around such equipment as elevator, boilers, scaffolding, ladders, etc.

PURPLE: - It indicates the presence of radiations hazards. Tags, Labels,

Signs, and floor markers are made with a purple and yellow colour
combination.

BLACK, WHITE or BLACK & WHITE Combination: - It indicates traffic and

housekeeping locations such as stairs ways, dead ends of aisles, etc.

71
 MOCK DRILLING PRACTICES
Mock drill fighting is a rehearsal of fire fighting
training. It is both indoor & outdoor. There is a participation of response
element teams. The mock drill fighting helps to know the drawbacks of
the emergency plan.

This helps to test the response skill & simultaneous

operations. Real life conditions are tested & decision taken.

72
OTHER SAFETY BANNERS IN
COMPANY PREMISES

73
74
 FIRST AID

For first aid the management of UTCl is very conscious

they do the following practices for workers so that they will know about
the first aid.

1) Register should be documented.

(2) The training for first aid is provided to every department.

75
(3) The first aid box is provided to every department.

(4) External guidance is given.

The main constituents in the first aid are:-

(1) Small size roller bandages (2).

(2) Medium size roller bandages (2).

(3) Large size roller bandages (1).

(4) Cotton wool (2).

By the following practices the workers of UTCL gets the

basic training of first aid and how to use the first aid box in any
emergency.

76
 On Safety Management

Personal Profile:
Name :
Designation :
Department: - Technical/Non Technical:
No. of years in the company :

Candidate’s Profile:
Sir, I am Kumar Pratik, pursuing M.B.A form EIILM University, Sikkim and at
present undergoing Summer Training Programme which is mandatory for the
partial fulfillment of the course curriculum.

Here are some questions, which I would like to ask you as a

part of my Summer Training survey, you are kindly requested to put “√”
against your view/response.

77
1) Does Ultratech provide any special training on safety?
a) Strongly agreed b) Agreed c) Disagree

2) Is worker’s participation is compulsory for safety committee

in UTCL?
a) Strongly agreed b) Agree c) Disagree

3) Is the management provides special Fire fighting training to

the worker’s in UTCL?
a) Strongly agree b) Agree c) Disagree

4) Does the management take care at the maintenance of all

machinery to prevent accident in UTCL?
a) Strongly agree b) Agree c) Disagree

5) Is the management provides any special training on First

Aid?
a) Strongly agree b) Agree c) Disagree

6) Do the workers use safety belts while working at height?

a) Strongly agree b) Agree c) Disagree

7) Is there any engineering device implemented to minimize the

dust in the work place in UTCL?
a) Strongly agree b) Agree c) Disagree

8) Does the awareness of safety help the employees efficiently

in performing their work in UTCL?
a) Strongly agree b) Agree c) Disagree

9) Is there are periodical health checkup system in UTCL?

a) Strongly agree b) Agree c) Disagree

10) Is the factory noise under control?

a) Strongly agree b) Agree c) Disagree
78
11) Is there any Safety committee formed in UTCL?
a) Strongly agree b) Agree c) Disagree

12) Does the management take care at fencing of machinery

in UTCL?
a) Strongly agree b) Agree c) Disagree

13) Is there any safety guards provided to rotating machine

parts in UTCL?
a) Strongly agree b) Agree c) Disagree

14) Do the employees in Ultratech use P.P.E during their

work?
a) Strongly agree b) Agree c) Disagree

15) Is there any rewarding system established for the

employee?
a) Strongly agree b) Agree c) Disagree

16) Are the injuries recorded and discussed in safety

committee meeting from time to time?
a) Strongly agree b) Agree c) Disagree

17) Do you agree that safety awareness can add value to the
organizational effectiveness?
a) Strongly Agree b) Agree c) Disagree

18) Do you think that safety awareness is a tool for achieving

“ZERO” level of accident?
a) Strongly agree b) Agree c) Disagree

19) Are the safety induction training is given to the new

workman in the plant?
a) Strongly agree b) Agree c) Disagree
79
20) Are the equipments being tested by the competent person
under Factory Act in UTCL?
a) Strongly agree b) Agree c) Disagree

21) Does the company have any Published Health and Safety
manual?
a) Strongly agree b) Agree c) Disagree

22) Does the management take care of the maintenance of

the extinguishers time to time in UTCL?
a) Strongly agree b) Agree c) Disagree

23) Does the management provide First Aid Box to the entire
department?
a) Strongly agree b) Agree c) Disagree

24) Does the management take care of Floors, Stairs and

means of access in UTCL?
a) Strongly agree b) Agree c) Disagree

25) Do you know about the PTW (Permit to Work) System?

a) Strongly agree b) Agree c) Disagree

26) Do you know that UTCL got OHSAS 18001:2007 Certificate

for Health and Safety?
a) Strongly agree b) Agree c) Disagree

80
Questions Related to Management
27) Do you feel the employees are well known regarding the
new techniques and way of performing their Job or
Operation?
a) Strongly agree b) Agree c) Can’t Say d) Disagree

28) Do you think that the employees are maintaining good

Interpersonal Relationship?
a) Strongly agree b) Agree c) Can’t Say d) Disagree

29) Do you feel the employees are successful in maintaining

the industrial environment healthy and hazard free?
a) Strongly agree b) Agree c) Can’t Say d) Disagree

30) Do you feel that employees are well aware of

Organization’s Rule and Regulations?
a) Strongly agree b) Agree c) Can’t Say d) Disagree

31) In UTCL does Safety awareness among employees helps to

work efficiently in performing his/her task?
a) Strongly agree b) Agree c) Can’t Say d) Disagree

32) What do you think that “On the Job Training” is always
effective for the organization?
a) Strongly agree b) Agree c) Can’t Say d) Disagree

33) Does the company have any appraisal system for the
excellent performance of staff of UTCL?
a) Strongly agree b) Agree c) Can’t Say d) Disagree

81
 DATA ANALYSIS
1) Does Ultratech provide any special training on safety?
a) Strongly agreed b) Agreed c) Disagree

WORKERS

20
Strongly Agree
Agree
Disagree

75

75% of Workers are strongly agreed that UTCL provides them special
training on Safety, 20% Workers only agreed that it provides training but
to some extent, 5% Workers says that it do not provide any special
training.

2) Is the management provides special Fire fighting training

to the worker’s in UTCL?
b) Strongly agree b) Agree c) Disagree

82
 WORKERS

10

Strongly Agree
20
Agree
Disagree

70

From the above question we get to know that 70% of the Workers syas
that UTCL provide them special training on Fire fighting where, 20% says
it provides but not good enough. 10% says that they do not provide any
special training on fire fighting.

3) Is there are periodical health checkup system in UTCL?

b) Strongly agree b) Agree c) Disagree

WORKERS

Strongly Agree
Agree
Disagree

100

83
From the above question we get to know that 100% of the Workers says
that UTCL Provide their periodical Health Checkup.

4) Do the employees in Ultratech use P.P.E (Personal

Protective Equipment) during their work?
b) Strongly agree b) Agree c) Disagree

WORKERS

5
10

Strongly Agree
Agree
Disagree

85

85% of the Workers are Strongly Agreed that they use PPE during their
work where, 10% only Agree with this question and 5% are Disagree with
this.

5) Do you know about the PTW (Permit to Work) System?

b) Strongly agree b) Agree c) Disagree

84
 WORKERS

Strongly Agree
Agree
Disagree

100

100% of the Workers of UTCL are Strongly Agree that they know about
the PTW (Permit to Work) system and they use this system when it
required.

6) Is there any Safety committee formed in UTCL?

b) Strongly agree b) Agree c) Disagree

WORKERS

Strongly Agree
Agree
Disagree

100

100% of the Workers of UTCL are Strongly Agree that there is a Safety
Committee in UTCL no worker says that there is not any Safety
Committee in UTCL.
85
 7) Do you think that safety awareness is a tool for achieving
“ZERO” level of accident?
b) Strongly agree b) Agree c) Disagree

WORKERS

10

Strongly Agree
Agree
Disagree

90

90% of the Workers Strongly Agree that Safety Awareness is a tool for
achieveing “ZERO” level of accident while 10% of workers only Agree
with that point.

8) Is there any engineering device implemented to minimize

the dust in the work place in UTCL?
b) Strongly agree b) Agree c) Disagree

86
 WORKERS

10

10
Strongly Agree
Agree
Disagree

80

80% of Workers Strongly Agree that yes the Dust of the Plant is
minimized through engineering device while 10% only Agree that it is not
good enough to minimize the dust and rest 10% are Disagree with this
question they says that the dust is not minimized.

9) Is there any rewarding system established for the

employee?
b) Strongly agree b) Agree c) Disagree

WORKERS

Strongly Agree
Agree
Disagree

100

87
100% of the Workers of UTCL Strongly Agreed that yes there is a
Rewarding system in UTCL they got reward when they report any near
miss case in the plant for every near miss report they got Rs.20

10) Does the management take care at the maintenance

of all machinery to prevent accident in UTCL?
b) Strongly agree b) Agree c) Disagree

WORKERS

10

Strongly Agree
Agree
Disagree

90

In UTCL 90% of the workers Strongly Agreed that yes the management
takes care of the maintenance of machineries to prevent accident while
10% only agree with this.

88
 FINDINGS
 After survey it is found that majority is agreed that UTCL provides
Special Safety Training to them for Safety Awareness.
 Though majority agreed that management does provide special training
on First Aid but few suggest that there should be more improvement in
this.
 Some of the workers agreed that UTCL does provide special training on
Fire Fighting but few are disagree with this view.
 Though maximum are agreed that they use PPE during their work while
are not agree with this.
 Though maximum of the employees agreed that the awareness of
safety help them to work efficiently in UTCL, but few disagree with this
view.
 Majority agreed with the view that they use safety belts while working
at height.
 Maximum agreed that the management take care of machineries.
 Majority agreed that workers participation is compulsory in safety
committee.
 Maximum employees strongly agreed that there is a engineering device
that minimize the dust.
 Maximum employees are strongly agreed that the machineries are well
fenced.
 Majority of workers are agreed that their periodical medical check up is
done under UTCL.
 Maximum workers are strongly that yes UTCL have a rewarding system
 Majority of workers are agreed that they take special permit for
working in confined space.
 Maximum employees are known about the PTW system.

89
 Most of the workers strongly agreed that safety awareness is a tool for
achieving “ZERO” level of accident in plant but few are disagree with
that point.

90
RECOMMENDATION
S

 The duration of Safety Training should be increased.

 Little importance s required in the training of First Aid.
 More emphasis should be given on the training of Fire Fighting.
 There should be availability of PPE in UTCL.
 There should be more programmed schedules to enhance
awareness of Safety among employees in UTCL.

 There should be sufficient availability of Safety Belts in UTCL.

 The machines should be maintained properly.
 The participation of both the workers and management in Safety
Committee in UTCL is necessary.

 More modernized device should be implemented to minimize dust

 All are satisfied with First Aid Box.
 Approaching road to the factory area outside the main entrance is
very hazardous.

91
 CONCLUSION

The management of Ultratech Cement Company (West

Bengal Cement Works) Durgapur, implemented all possible steps to
achieve total Safety towards “ZERO” accident workplace.

Any visitor before entering the premises of the factory has

to show the gate pass. It is the rule in UTCl to wear Safety Helmets while
entering on the premises.

UTCL provides regular health checkup for workers and for

staffs also. It also provides all needed safety training to the workers for the
safety awareness so that there is no accident.

For better and good safety environment the management do

the safety audit weekly to identify and rectify the near miss cases also
there is a monthly safety review meeting is held.

UTCL also got the ISO certificate OHSAS 18001:2007 for

occupational health and safety system.

UTCL is doing the entire possible thing to maintain the safety

in the plant also by keeping the worker happy.

92
 BIBLOGRAPHY
The following web site and books I have used for collecting more
information

 web site of Aditya Birla Group

www.adityabirlagroup.com
www.ultratech.com

 Book which I have used for the project

V.S.P.Rao of Human Resource Management

93