the effectiveness of safety mgt system in caterpiller

CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION TO THE STUDY

Safety is inevitable to any organization when employees are

involved. An organization’s responsibility to its employees extends beyond

the payment of wages for their services. The employee’s safety both on and

off the job within the organization is a vital concern of the employer.

Providing a safe and healthy environment is a pre-requisite for any

productive effort. This research deals with the study on the safety provided to

the employees at Caterpillar.

Introduction to Safety- Begin this course with an overview of effective

safety and health programs and an understanding of their importance to both

employers and employees. Discover methods for implementing safety

programs in the industrial workplace.

Walking and working Surfaces- Identify common hazards that may

increase the probability of workplace accidents. Study proper “House

Keeping” and the correct use of ladders and stairways. Identify when to use

covers and guardrails and the steps that can be taken to minimizing slipping,

tripping, and falling in the workplace.

Prevention and Protection Plans- Study the importance of an effective

emergency management plan in reducing workplace injuries and deaths.

Learn that an effective safety plan includes proper and clearly marked exits,

functioning and regularly maintained fire-fighting equipment and employee

training programs.

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Employee Safety:

A top priority for any employer should be to take the time and

initiative to help protect their employees. If an employee becomes injured at

work, your business may suffer.

Machines in the workplace can pose operating hazards. From minor

cuts and abrasion to serious lacerations, exposure to machine operations can

be detrimental to life, health and productivity. It is highly recommended that

you purchase machinery equipped with guarding or that the guards on

existing equipment left intake and employees be trained to use them.

Hazards Materials

Chemicals and solvents in the workplace can create hazardous

conditions. Some combinations of common cleaning chemicals can cause

serious life threatening conditions.

Use a designated storage place for chemicals

Read the labels on your products and become familiar with

material safety data sheets.

Personal Protective Equipment (PPE)

When the workplace hazards cannot be eliminated or reduced,

personal protective equipment may be necessary. PPE does not eliminate a

hazardous situation; it simply creates a protective barrier between the

employee and the hazard. Equipment can be in the form of;

Non respirators

Safety glasses or goggles

Gloves

Boots

Hearing protection

Hardhats

Helmet

Earplug

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Apron

Leg guard

Arm shield

Wind shield

Respirators

Dust respirators

Chemical respirators

Welding fume

Visual air system

Definitions of safety

System Safety Engineering and Management states that safety

may be defined “as a quality of a system that allows the system to function

under pre-determined conditions with an acceptable minimum of accidental

loss”.

Air services Australia (2001, AA-Safe-001, p.1) define safety as

“Being in a situation where the risks of an aircraft accident or air safety

incident are reduced to a level as a low as reasonable practicable” reinforcing

the proposition that the working definition of Safety includes risk

management.

Safety can be framed for the purposes of this paper as a characteristic

of a system that does not permit unacceptable risks to be undertaken with

the goal of injury free operations.

The condition of being safe; freedom from danger, risk, or injury.

the state of being certain that adverse effects will not be caused

by some agent under defined conditions

Occupational safety is concerned with risks in areas where

people work: offices, manufacturing plants, farms, construction

sites, and commercial and retail facilities. Public safety is

concerned with hazards in the home, in travel and recreation,

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and in other situations that do not fall within the scope of

occupational safety.

1.2 NEED AND IMPORTANCE OFTHE STUDY

1. This study would give an overview of the safety measures existing at

Caterpillar.

2. Since safety and welfare are two important elements essential for

improving the productivity of an organization, a study on the existing

safety measures would help the organization perform better.

3. This study would throw light on the perception of the employees

regarding safety.

4. Caterpillar can identify the areas where it can improve so as to

improve the performance of the employees.

5. This study would also help to analyze if there is dependence between

departments and categories and the level of satisfaction of safety

measures

6. Suggest provisions of more safety measures.

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1.3 SCOPE OF THE STUDY

The study undertaken for CATERPILLAR aims to find the reason for

safety measures. This study is done with the help of a questionnaire which

contains questions which probe into the details so as to find the reason of

their choice.

Safety and welfare are two important elements essential for

improving the productivity of an organization, a study on the existing safety

measures would help the organization perform better.

Safety measures may be viewed as a total concept and as a relative

concept. The total concept is a desirable state of existence involving the

physical, mental, moral and economical well-being. These four elements

together constitute the structure of the welfare implies the welfare of man,

his family and community.

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1.4 OBJECTIVES OF THE STUDY

Primary Objectives:

A study on “The Effectiveness of Safety Management System” in

Caterpillar India Private Ltd.

Secondary Objectives:

To find out whether adequate safety measures are provided to

the employees

To find out the fulfillment of safety measures to employees

To analyze the safety measures followed by the contract

laborers

To observe the employees satisfaction towards the safely

training program

To find out the employees expectation towards safety measures

in this company.

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1.5 LIMITATIONS OF THE STUDY

The study is applicable to “CATERPILLAR PVT LIMITED”

The respondents have replied to the queries recalling from their

memory. Therefore recall bias and personal bias are possible.

The sample size was limited to 100.

Since the data was collected using a schedule, the interviewer’s

inability to understand and record the responses correctly is

possible.

The respondents were unable or unwilling to give a complete and

accurate response to certain questions.

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1.6 COMPANY PROFILE

For more than 80 years, Caterpillar has been building the world’s

infrastructure and, in partnership with network of Cat® dealers worldwide, has

helped drive positive and sustainable change on every continent. They are a

global company, with hundreds of locations worldwide to serve and support

customer base, and respond quickly to their needs

.

Corporate Profile

For more than 80 years, Caterpillar Inc. has been making progress

possible and driving positive and sustainable change on every continent. With

2008 sales and revenues of $51.324 billion, Caterpillar is the world’s leading

manufacturer of construction and mining equipment, diesel and natural gas

engines and industrial gas turbines. The company also is a leading services

provider through Cat Financial Services, Cat Remanufacturing Services, Cat

Logistics Services and Progress Rail Services. They are proud to be a leader

in building the world’s infrastructure, and in enabling progress for millions of

people around the globe. They manufacture more than 300 products in 23

countries and serve customers in nearly 200 countries. They are

headquartered in Peoria, Illinois.

The History of Caterpillar

1890. Benjamin Holt and Daniel Best experimented with various forms of

steam tractors for use in farming. They did so separately, with separate

companies.

1904. Holt's first steam track-type tractor.

1906. Holt's first gas track-type tractor.

1915. Holt "Caterpillar®" track-type tractors are used by the Allies in World

War I.

1925. The Holt Manufacturing Company and the C. L. Best Tractor Co. merge

to form Caterpillar Tractor Co.

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1931. The first Diesel Sixty Tractor rolled off the assembly line in East Peoria,

Illinois, with a new efficient source of power for track-type tractors.

1940. The Caterpillar product line now included motor graders, blade

graders, elevating graders, terracers and electrical generating sets.

1942. Caterpillar track-type tractors, motor graders, generators sets and a

special engine for the M4 tank are used by the United States in its war effort.

1950. Caterpillar Tractor Co. Ltd. in Great Britain is established, the first of

many overseas operations created to help manage foreign exchange

shortages, tariffs, import controls and better serve customers around the

world.

1953. In 1931, the company created a separate engine sales group to

market diesel engines to other equipment manufacturers. This group was

replaced in 1953 with a separate sales and marketing division to better serve

the needs of a broad range of engine customers. Engine sales now account

for approximately one-third of the company's total sales and revenues.

1963. Caterpillar and Mitsubishi Heavy Industries Ltd. form one of the first

joint ventures in Japan to include partial U.S. ownership. Caterpillar Mitsubishi

Ltd. started production in 1965, has been renamed Shin Caterpillar Mitsubishi

Ltd., and is now the No. 2 maker of construction and mining equipment in

Japan.

1981-83. the worldwide recession took its toll on Caterpillar, costing the

company the equivalent of $1 million a day and forcing it to dramatically

reduce employment.

1983. Caterpillar Leasing Company is expanded to offer equipment financing

options to its customers worldwide and is renamed Caterpillar Financial

Services Corporation.

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1985-present. The product line continued to diversify to meet a variety of

customer needs. More than 300 products are now offered, more than double

the figure in 1981.

1986. The Caterpillar Tractor Co. changes its name to Caterpillar Inc. - a

more accurate reflection of the enterprise's growing diversity.

1987. A $1.8 billion plant modernization program was launched to streamline

the manufacturing process.

1990. The company decentralized its structure, reorganizing into business

units responsible for return on assets and customer satisfaction.

1997. The company continued to expand, acquiring the U.K.-based Perkins

Engines. With the addition of Germany's MaK Motoren the previous year,

Caterpillar becomes the world leader in diesel engine manufacturing.

1998. The world's largest off-highway truck - the 797 - makes its debut at the

Cat Proving Ground in Arizona.

1999. Caterpillar unveils new line of compact construction equipment at

CONEXPO, world's largest construction show, in response to changing

customer needs for smaller, more versatile construction equipment.

2000. Caterpillar celebrates its 75th anniversary.

2001. Caterpillar is the first company to globally launch 6 Sigma and deliver

first-year benefits in excess of implementation costs.

2003. Caterpillar becomes the first engine manufacturer to offer a complete

line of 2004 model year clean diesel engines fully compliant and certified by

the U.S. Environmental Protection Agency (EPA). Caterpillar's breakthrough

emissions control technology, known as ACERT®, is designed to comply with

EPA standards without sacrificing performance, reliability or fuel efficiency.

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2005. Demonstrating a pledge to sustainable development, Caterpillar

responded to a number of tragedies around the world, including the Asian

Tsunami disaster, hurricanes along the U.S. Gulf Coast and earthquakes in

South Asia. In the face of each of these challenges, employees, dealers and

corporate leaders alike joined together to build a promise of hope and growth

for all those affected by donating machinery, money and resources for relief

and recovery efforts.

2006. Benjamin Holt, one of Caterpillar Inc.'s founding fathers and designer

of the first track-type tractor was recognized for his ingenuity and

entrepreneurial spirit with an induction into the National Inventors Hall of

Fame.

2006. Caterpillar Inc. subsidiary Caterpillar Logistics Services, Inc. (Cat

Logistics) opens a new parts distribution center in the Lingang Industrial Area

in Shanghai.

2006. Caterpillar launched a revised and updated Worldwide Code of

Conduct and Enterprise Strategy. Serving new markets and new customers in

new ways, Caterpillar welcomed the opportunity to experience unchartered

growth across all business ventures.

Mission

Their mission is to enable economic growth through infrastructure

And energy development, and provide solutions that protect people and

preserve the planet.

Vision

Their vision is a world in which all people’s basic requirements—such

as

Shelter, clean water, sanitation and reliable power—are fulfilled in a way that

sustains our environment.

Strategy

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Their strategy is to provide work environments, products, services and

solutions that make efficient use of the world’s natural resources and reduce

unnecessary impacts on people, the environment and the economy. This

means that they leverage resources, including technology and innovation to:

Optimize the use of renewable resources

Minimize emissions

Maximize recycling

Promote and protect individual Safety and well-being

Minimize the use of energy, materials, water and land

Provide employment, education and training

Sustainable Development Critical Success Factors (CSFs) Progress

Culture

Create a culture of sustainable development in all their business units

and in all their daily work.

Operations

Be consistent with their sustainability principles and contribute to

enterprise sustainable development goals.

Business Opportunities

Identify and pursue business growth opportunities created by

sustainable development.

Caterpillar Enterprise Goals to 2020 (Baseline 2006)

Established in 2007, these aspirational, enterprise-wide goals focus on

sustainability in every aspect of their business.

2020 Goals for

Products, Services and Solutions

Reduce customer greenhouse gas emissions by 20%

Increase customer energy efficiency by 20%

Provide leadership in the safety of people in, on and around our

products

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Increase customer material efficiency by 20%

2020 Goals for

Operations

Use alternative/renewable sources to meet 20% of their energy needs

Reduce recordable workplace injury rates to 0.6 and lost-time case

rate due to injury to 0.15

Increase energy efficiency by 25%

Design all new construction to meet Leadership in Energy and

Environmental Design(LEED) or comparable green building criteria

Eliminate waste by reducing Hold water consumption flat waste

generation and reusing or recycling all that remains

Reduce absolute greenhouse gas emissions from existing facilities by

25%

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1.7 Industry Profile

Indian Infrastructure sector is currently going through a vast

transformation with the third largest road network of 3 million Km crisscross

the country, the automobile revolution has more than doubled from 21.3

million at the beginning of 1990’s to 48.4 million by end of the decade.

The Government has already embarked upon massive road

construction projects, with national highway development from building the

North-South and East-West corridors and golden quadrangle projects

connecting major cities. Besides government’s decision to throw open the

construction of roads, bridges and airports to private sector and allowing

100% foreign investment in real estate projects, has provided a boost to the

construction industry as well as generate demand for construction

machinery.

The total investment of road and highway construction project is

estimated as $40 billion turnover the next 15 years of which 20% is expected

to be in construction machinery. Hence a total demand of $10 billion

construction machinery is expected in next 20 years.

The present market for construction machinery is estimated to

$1312.17 million, out of which about 1% is imported. Indian construction

machinery Industry is undergoing a rapid transformation from low volume,

intensive use of equipment structure to high volume, and specific use one.

The new housing and infrastructure ventures have generated substantial

demand for construction machinery, manufacturing and servicing. While the

previous trend was to forge joint venture associations with Indian companies,

more and more multinational companies are now entering the Indian market

on their own strength.14

The major manufacturers and importers of the estimated $1312.17 industry

are:

Ashok Leyland

Atlas Copco (India)

B G Shirke Construction Equipment

Caterpillar India

Ingersoll Rand India

JCB India

Larsen & Toubro

Metso Minerals

Salgaocar Engineers

Schwing-Stetter India

Telco Construction Equipment

Terex Vectra Equipment

Voltas

In India, Caterpillar languishes in fourth position in sales of diggers, loaders

and other construction machines.

The key Success Factors are:

Focus on quality and operational efficiency

From the outset, CIPL has had a strong focus on quality. To this end, it

focused on implementing Six Sigma and the pursuit of operational excellence

using Class A disciplines.

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Superior product development capabilities

Caterpillar’s unique New Product Introduction (NPI) process gives

guidance, direction and accountability to all stakeholders while ensuring its

overall success. The cornerstone of this product development process is the

customer validation exercise where machines are placed in a non-clinical

environment and evaluated for more than 3,500 hours. The company uses

tools like the Prediction of Estimated Reliability Growth Plan (PERG) and

Statistical tools such as the Weibull Analysis for checking machine

performance prior to launch. Such processes and tools enabled the company

to successfully launch the backhoe loader, and assure success in a

competitive market.

World Wide Competitors of Caterpillar are:

Komatsu(Japan)

Hitachi(Japan)

CNH-Case new Holland(France)

John Deer(USA)

Volvo (Sweden).

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1.8 REVIEW OF LITERATURE

Definitions of safety

The condition of being safe; freedom from danger, risk, or injury.

the state of being certain that adverse effects will not be caused

by some agent under defined conditions

Occupational safety is concerned with risks in areas where

people work: offices, manufacturing plants, farms, construction

sites, and commercial and retail facilities. Public safety is

concerned with hazards in the home, in travel and recreation,

and in other situations that do not fall within the scope of

occupational safety.

Introduction

Introduction to safety- Being this course with an overview of effective

safety and health programs and an understanding of their importance to both

17

employers and employees .Discover methods for implementing safety

programs in the industrial workplace.

Employee safety:

A top priority for any employer should be to take the time and

initiative to help protect their employees becomes at work, your business

may suffer.

Machines in the work place can pose operating hazards. From minor

cuts and abrasion to serious lacerations, exposure to machine operations can

be detrimental to life, health and productivity. It is highly recommended that

you purchased machinery equipped with guarding or that the guards on

existing equipment left intake and employees be trained to use them.

FACTORIES ACT, 1948

The Factories Act is a social legislation which has been enacted

for occupational safety, health and welfare of workers at work places. This

legislation is being enforced by technical officers i.e. Inspectors of Factories,

Dy. Chief Inspectors of Factories who work under the control of the Chief

Inspector of Factories and overall control of the Labour Commissioner,

Government of National Capital Territory of Delhi

SALIENT FEATURES OF THE ACT ARE:-

1.Approval of Factory Building Plans before construction/extension, under

the Delhi Factories Rules, 1950.

2.Grant of Licenses under the Delhi Factories Rules, 1950, and to take

action against factories running without obtaining License.

3.Renewal of Licenses granted under the Delhi Factories Rules, 1950, by

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the Dy. Chief Inspectors of Factories.

4. Inspections of factories by District Inspectors of Factories, for investigation of

complaints, serious/fatal accidents as well as suo moto inspections to check

compliance of provisions of this Act relating to :-

I. Health

II. Safety

III

.Welfare facilities

IV

.Working hours

V. Employment of young persons

VI

.

Annual Leave with wages etc.

1.CLEANLINESS:Every factory shall be kept clean and free from effluvia

arising from any drain, privy or other, nuisance, and in particular - (a)

accumulations of dirt and refuse shall be removed daily by sweeping or by

any other effective method from the floors and benches of workrooms and

from staircases and passages, and disposed of in a suitable manner;

(b) The floor of every workroom shall be cleaned at least once in every week

by washing, using disinfectant, where necessary, or by some other effective

method;

(c) where a floor is liable to become wet in the course of any manufacturing

process to such extent as is capable of being drained, effective means of

drainage shall be provided and maintained;

(d) all inside walls and partitions, all ceilings or tops of rooms and all walls,

sides and tops of passages and staircases shall - (ii) where they are painted

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otherwise than with washable water-paint or varnished, be repainted or re-

varnished least once in every period of five years;

(ii) Where they are painted or varnished or where they have smooth

impervious surfaces, be cleaned at least once in every period of fourteen

months by such method as may be prescribed;

(iii) In any other case, be kept whitewashed or color-washed, and the

whitewashing or color-washing shall be carried out at least once in every

period of fourteen months;

(d) All doors and window frames and other wooden or metallic frame work

and shutters shall be kept painted or varnished and the painting or varnishing

shall be carried out at least once in every period of five years;

(e) The dates on which the processes required by clause (d) are carried out

shall be entered in the prescribed register.

(2) If, in view of the nature of the operations carried on in a factory or class or

description of factories or any part of a factory or class or description of

factories, it is not possible for the occupier to comply with all or any of the

provisions of sub-section (1), the State Government may by order exempt

such factory or class or description of factories or part from any of the

provisions of that sub-section and specify alternative methods for keeping

the factory in a clean state.

12. DISPOSAL OF WASTES AND EFFLUENTS. - (1) Effective arrangements

shall be made in every factory for the treatment of wastes and effluents due

to the manufacturing process carried on therein, so as to render them

innocuous, and for their disposal.

(2) The State Government may make rules prescribing the arrangements to

be made under sub-section (1) or requiring that the arrangements made in

accordance with sub-section (1) shall be approved by such authority as may

be prescribed.

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13. VENTILATION AND TEMPERATURE. - (1) Effective and suitable

provision shall be made in every factory for securing and maintaining in

every workroom - (a) adequate ventilation by the circulation of fresh air, and

(b) Such a temperature as will secure to workers therein reasonable

conditions of comfort and prevent injury to health; and in particular, - (i) walls

and roofs shall be of such material and so designed that such temperature

shall not be exceeded but kept as low as practicable;

(ii) Where the nature of the work carried on in the factory involves, or is likely

to involve, the production of excessively high temperatures such adequate

measures as are practicable shall be taken to protect the workers there from,

by separating the process which produces such temperatures from the

workroom, by insulating the hot parts or by other effective means.

(2) The State Government may prescribe a standard of adequate ventilation

and reasonable temperature for any factory or class or description of

factories or parts thereof and direct that [ lra-48 proper measuring

instruments, at such places and in such position as may be specified, shall be

provided and such records, as may be prescribed, shall be maintained;

(3) If it appears to the Chief Inspector that excessively high temperatures in

any factory can be reduced by the adoption of suitable measures, he may,

without prejudice to the rules made under sub-section (2), serve on the

occupier, an order in writing specifying the measures which, in his opinion,

should be adopted, and requiring them to be carried out before a specified

date.

14. DUST AND FUME. - (1) In every factory in which, by reason of the

manufacturing process carried on, there is given off any dust or fume or other

impurity of such a nature and to such an extent as is likely to be injurious or

offensive to the workers employed therein, or any dust in substantial

quantities, effective measures shall be taken to prevent its inhalation and

21

accumulation in any workroom, and if any exhaust appliance is necessary for

this purpose, it shall be applied as near as possible to the point of origin of

the dust, fume or other impurity, and such point shall be enclosed so far as

possible.

(2) In any factory no stationary internal combustion engine shall be operated

unless the exhaust is conducted into the open air, and no other internal

combustion engine shall be operated in any room unless effective measures

have been taken to prevent such accumulation of fumes therefore as are

likely to be injurious to workers employed in the room.

15. ARTIFICIAL HUMIDIFICATION. - (1) In respect of all factories in which

the humidity of the air is artificially increased, the State Government may

make rules, - (a) prescribing standards of humidification;

(b) Regulating the methods used for artificially increasing the humidity of the

air,

(c) Directing prescribed tests for determining the humidity of the air to be

correctly carried out and recorded;

(d) Prescribing methods to be adopted for securing adequate ventilation and

cooling of the air in the workrooms.

(2) In any factory in which the humidity of the air is artificially increased, the

water used for the purpose shall be taken from a public supply, or other

source of drinking water, or shall be effectively purified before it is so used.

(3) If it appears to an Inspector that the water used in a factory for increasing

humidity which is required to be effectively purified under sub-section (2) is

not effectively purified he may serve on the manager of the factory an order

in writing, specifying the measures which in his opinion should be adopted,

and requiring them to be carried out before specified date.

16. OVERCROWDING. - (1) No room in any factory shall be overcrowded to

an extent injurious to the health of the workers employed therein.

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(2) Without prejudice to the generality of sub-section (1), there shall

be in every workroom of a factory in existence on the date of the

commencement of this Act at least 9.9 cubic meters and of a factory

built after the commencement of this Act at least 14.2 cubic meters or

space for every worker employed therein, and for the purposes of this

sub-section no account shall be taken of any space which is more than

4.2 meters above the level of the floor of the room.

(3) If the Chief Inspector by order in writing so requires, there shall be posted

in each workroom of a factory a notice specifying the maximum number of

workers who may, in compliance with the provisions of this section, be

employed in the room.

(4) The Chief Inspector may by order in writing exempt, subject to such

conditions, if any, as he may think fit to impose, any workroom from the

provisions of this section, if he is satisfied that compliance therewith in respect

of the room is unnecessary in the interest of the health of the workers

employed therein.

17. LIGHTING. (1) In every part of a factory where workers are working or

passing there shall be provided and maintained sufficient and suitable

lighting, natural or artificial, or both.

(2) In every factory all glazed windows and skylights used for the lighting of

the workroom shall be kept clean on both the inner and outer surfaces and,

so far as compliance with the provisions of any rules made, under sub-section

(3) of section 13 will allow, free from obstruction.

(3) In every factory effective provision shall, so far as is practicable, be made

for the prevention of - (a) glare, either directly from a source of light or by

reflection from a smooth or polished surface;

(b) The formation of shadows to such an extent as to cause eye-strain or the

risk of accident to any worker.

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(4) The State Government may prescribe standards of sufficient and suitable

lighting for factories or for any class or description of factories or for any

manufacturing process.

18. DRINKING WATER. - (1) In every factory effective arrangements shall

be made to provide and maintain at suitable points conveniently situated for

all workers employed therein a sufficient supply of wholesome drinking water.

(2) All such points shall be legibly marked "drinking water" in a language

understood by a majority of the workers employed in the factory, and no such

point shall be situated within six meters of any washing place, urinal, latrine,

spittoon, open drain carrying salvage or effluent or any other source of

contamination unless a shorter distance is approved in writing by the Chief

Inspector.

(3) In every factory wherein more than two hundred and fifty workers are

ordinarily employed, provisions shall be made for cooling drinking water

during hot weather by effective means and for distribution thereof.

(4) In respect of all factories or any class or description of factories the State

Government may make rules for securing compliance with the provisions of

sub-sections (1), (2) and (3) and for the examination by prescribed

authorities of the supply and distribution of drinking water in factories.

19. LATRINES AND URINALS. - (1) In every factory - (a) sufficient latrine

and urinal accommodation of prescribed types shall be provided conveniently

situated and accessible to workers at all times while they are at the factory;

(b) Separate enclosed accommodation shall be provided for male and female

workers;

(c) Such accommodation shall be adequately lighted and ventilated, and no

latrine or urinal shall, unless specially exempted in writing by the Chief

Inspector, communicate with any workroom except through an intervening

open space or ventilated passage;

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(d) All such accommodation shall be maintained in a clean and sanitary

condition at all times;

(e) Sweepers shall be employed whose primary duty it would be to keep

clean latrines, urinals and washing places.

(2) In every factory wherein more than two hundred and fifty workers are

ordinarily employed - (a) all latrine and urinal accommodation shall be of

prescribed sanitary types;

(b) the floors and internal walls, up to a height of ninety centimeters, of the

latrines and urinals and the sanitary blocks shall be laid in glazed titles or

otherwise finished to provide a smooth polished impervious surface;

(c) without prejudice to the provisions of clauses (d) and (e) of sub-section

(1), the floors, portions of the walls and blocks so laid or finished and the

sanitary pans of latrines and urinals shall be thoroughly washed and cleaned

at least once in every seven days with suitable detergents or disinfectants or

with both.

(3) The State Government may prescribe the number of latrines and urinals

to be provided in any factory in proportion to the numbers of male and

female workers ordinarily employed therein, and provide for such further

matters in respect of sanitation in factories, including the obligation of

workers in this regard, as it considers necessary in the interest of the health

of the workers employed therein.

20. SPITTOONS. –

(1) In every factory there shall be provided a sufficient number of spittoons

in convenient places and they shall be maintained in a clean and hygienic

condition.

(2) The State Government may make rules prescribing the type and the

number of spittoons to be provided and their location in any factory and

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provide for such further matters relating to their maintenance in a clean and

hygienic condition.

(3) No person shall spit within the premises of a factory except in the

spittoons provided for the purpose and a notice containing this provision and

the penalty for its violation shall be prominently displayed at suitable places

in the premises.

(4) Whoever spits in contravention of sub-section (3) shall be punishable with

fine not exceeding five rupees.

Safety Culture

An organization with a "safety culture" is one that gives appropriate priority

to safety and realizes that safety has to be managed like other areas of the

business. For the shipping industry, it is in the professionalism of seafarers

that the safety culture must take root.

That culture is more than merely avoiding accidents or even reducing the

number of accidents, although these are likely to be the most apparent

measures of success. In terms of shipboard operations, it is to do the right

thing at the right time in response to normal and emergency situations. The

quality and effectiveness of that training will play a significant part in

determining the attitude and performance - the professionalism - the seafarer

will subsequently demonstrate in his, or her, work. And the attitude adopted

will, in turn, be shaped to a large degree by the 'culture' of the shipping

company.

The key to achieving that safety culture is in:

recognizing that accidents are preventable through following correct

procedures and established best practice;

constantly thinking safety; and

Seeking continuous improvement.

26

It is relatively unusual for new types of accidents to occur on board and many

of those that continue to occur are due to unsafe acts by seafarers. These

errors, or more often violations of good practice or established rules, can be

readily avoided. Those who make them are often well aware of the errors of

their ways. They may have taken short-cuts they should not have taken.

Most will have received training aimed at preventing them but, through a

culture that is tolerant to the 'calculated risk', they still occur.

The challenge for trainers and training, and managers ashore and afloat, is

how to minimize these unsafe acts, how to instill not only the skills but also

the attitudes necessary to ensure safety objectives are met. The aim should

be to inspire seafarers towards firm and effective self-regulation and to

encourage personal ownership of established best practice. Internationally

recognized safety principles and the safeguards of best industry practice

have to become an integral part of an individual' own standards.

Hazards, risks, outcomes

The terminology used in OSH varies between states, but generally speaking:

A hazard is something that can cause harm if not controlled.

The outcome is the harm that results from an uncontrolled hazard.

A risk is a combination of the probability that a particular outcome will

occur and the severity of the harm involved.

“Hazard”, “risk”, and “outcome” are used in other fields to describe e.g.

environmental damage, or damage to equipment. However, in the context of

OSH, “harm” generally describes the direct or indirect degradation,

temporary or permanent, of the physical, mental, or social well-being of

workers. For example, repetitively carrying out manual handling of heavy

objects is a hazard. The outcome could be a musculoskeletal disorder (MSD)

or an acute back or joint injury. The risk can be expressed numerically (e.g. a

0.5 or 50/50 chance of the outcome occurring during a year), in relative

27

terms (e.g. "high/medium/low"), or with a multi-dimensional classification

scheme (e.g. situation-specific risks).

Hazard Assessment

Hazard analysis or hazard assessment is a process in which individual

hazards of the workplace are identified, assessed and controlled/eliminated

as close to source (location of the hazard) as reasonable and possible. As

technology, resources, social expectation or regulatory requirements change,

hazard analysis focuses controls more closely toward the source of the

hazard. Thus hazard control is a dynamic program of prevention. Hazard-

based programs also have the advantage of not assigning or implying there

are "acceptable risks" in the workplace. A hazard-based program may not be

able to eliminate all risks, but neither does it accept "satisfactory" -- but still

risky—outcomes. And as those who calculate and manage the risk are usually

managers while those exposed to the risks are a different group, workers, a

hazard-based approach can by-pass conflict inherent in a risk-based

approach.

Risk assessment

Modern occupational safety and health legislation usually demands

that a risk assessment be carried out prior to making an intervention. It

should be kept in mind that risk management requires risk to be managed to

a level which is as low as is reasonably practical.

This assessment should:

Identify the hazards

Identify all affected by the hazard and how

Evaluate the risk

Identify and prioritize appropriate control measures

28

The calculation of risk is based on the likelihood or probability of the harm

being realized and the severity of the consequences. This can be expressed

mathematically as a quantitative assessment (by assigning low, medium and

high likelihood and severity with integers and multiplying them to obtain a

risk factor, or qualitatively as a description of the circumstances by which the

harm could arise.

The assessment should be recorded and reviewed periodically and whenever

there is a significant change to work practices. The assessment should

include practical recommendations to control the risk. Once recommended

controls are implemented, the risk should be re-calculated to determine of it

has been lowered to an acceptable level. Generally speaking, newly

introduced controls should lower risk by one level, i.e, from high to medium

or from medium to low.

1.9 RESEARCH METHODOLOGY

Methodology is a systematic way to solve the research problem. It may

be understand as a science of studying how research is done logically. The

various steps that are generally adopted by a researcher problem are also

the main function of the research methodology.

RESEARCH DESIGN

Descriptive research studies are concerned with describing the

characteristics of a particular individual or of a group, or a situation. This type

of research design can be used in conditions where decision problem are

linked to answer specific question concerning who, what when, and how a

topic. In the study the researcher wants to elevate “how” effective the

performance appraisal system are using a structured Questionnaire for

collection of data, hence the research design used is descriptive in nature.

DATA COLLECTION

29

The two types of data used for the purpose and study are Primary data

& Secondary data,

1. Primary data

It relates to the study was collected from the operators level in the

company. It was collected through interview and questionnaire method. The

other methods such as observation, indirect oral interview and detailed

discussion with the employees had been conducted for the purpose of data

collection.

2. Secondary data

Secondary data are those which have already been collected by some

other agency and which have already been processed. Secondary data for

the study has been complied from the reports and official publication of the

organization, which have helped in getting and insight of the present scenario

existing in the operation of the company.

Sampling plan

Sampling is the selection of some part of an aggregate or totality on

the basic of which a judgment or inference about the aggregate or totality is

made.

Sampling technique

A population is the collection of elements about which one has

to make some inference. The population was 100 the researcher followed

censes sampling method, which is the count of all elements, in a population.

RESEARCH METHODOLOGY

Key issue Options selected

Data source Primary and secondary data

30

Research approach instrument Interview survey questionnaire

Contact method Personal contact.

QUESTIONNAIRE DESIGN

The questionnaire used for collecting the data is a structured one. It

was a mixture of open ended, closed ended and multiple industry choices.

The words used were simple and help in avoiding confusion and

misunderstanding among the respondents.

During questions were avoided in order to make sure that the

questions were arranged in a logical order and So that the respondent would

not find the questions confusing.

Sampling Procedure

KEY ISSUES OPTION SELECTED

Sample Unit Operators

Sample Size100

SAMPLING PROCEDURE

The first step of research design is used to formulate the

objective of research plan, which while specify the way of achieving research

objectives questionnaires were used to collect the needed information. The

sampling method was conveniences sampling and it is made in such a view

freely with hesitation.

31

SAMPLING UNIT

The operators were surveyed

SAMPLE SIZE

100 samples of operators considered for the study.

SURVEY METHOD

The survey method used by the researcher was self- administered

survey. Self –administered survey is data collection technique in which the

respondent read the survey question and records his /her answer without the

presence of a trained interviewer.

STATISTICAL TOOLS

1. Simple Percentage

Percentage refers to a special kind of ration .Percentage are used in

making comparisons between two or more series of data. Percentage is used

to describe relationships.

Percentage can also be used to compare the relative terms the

distribution of two or more or more series of data.

2. Chi-Square Analysis

Chi square test is a non-parametric test. Marking researches to test

hypotheses uses it most frequently. The test is employed for testing

hypotheses when distribution if population is not know and when nominal

data in to be analyzed.

The quantity x2 describes the magnitude of discrepancy between

theory and observation. Verity the distribution of observed data with

answered theoretical distribution non parametric test. The symbol “X2” is the

Greek letter Chi. the Test was first used by Kara person in the year 1990.

The Quantity 2 is defined as 2 = (Oi-Ei/Ei) 2

Where,

Oi = Refers to the observed frequency

Ei = Refers to expected frequency

32

CHAPTER II

2.1 DATA ANALYSIS AND INTERPRETATION

1.1.1 PERCENTAGE ANALYSIS

TABLE: 2.1.1 DISTRIBUTION OF THE RESPONDENTS- AGE WISE

S. No ParticularsNo. of

respondents Percentage1 Up to 20 0 0

33

2 21-30 10 103 31-40 20 204 41-50 50 505 Above50 20 20

Total 100 100

CHART: 2.1.1 DISTRIBUTION OF THE RESPONDENTS- AGE WISE

INFERENCE:

It is found from the above table that 10% of the respondents between

21-30 years of age level, 20% of the respondents between 31-40 years of age

level, 50% of the respondents between 41-40 years of age level, 20% of the

respondents belongs to above 50 years of age level and none of the

respondents are below 20 years of age,

TABLE: 2.1.2 DISTRIBUTION OF THE RESPONDENTS- DESIGNATION WISE


RespondentsPercent

age

1 Operator 65 65

2 Fitter 15 15

3 Welder 10 10

4 Burner 4 4

5 Painter 6 6

Total 100 100

34

CHART: 2.1.2 DISTRIBUTION OF THE RESPONDENTS- DESIGNATION WISE

INFERENCE:65% of the respondents are operator, 15% of the respondents are fitter, 10% of the

respondents are welder, 4% of the respondents are burner and 6% of the respondents are

painter.

TABLE: 2.1.3 DISTRIBUTION OF THE RESPONDENTS- DEPARTMENT WISE


respondentsPercent

age

1 Loader Assembly 40 40

2 Axle Plant 15 15

3 Dumber FABN 30 30

4 Tool Room 5 5

5 FOP Paint 10 10

Total 100 100

35

CHART: 2.1.3 DISTRIBUTION OF THE RESPONDENTS- DEPARTMENT WISE

INFERENCE:

It is found from the above table 40% of the respondents are

loader assemble, 15% of the respondents are axle plant, 30% of the

respondents are dumber FABN, 5% of the respondents are tool room and 10%

of the respondents are FOP paint.

TABLE: 2.1.4 DISTRIBUTION OF THE RESPONDENTS-MARTIAL STATUS

S. No ParticularsNo. Of

respondentsPercent

age

1 Single 18 18

2 Married 82 82

Total 100 100

CHART: 2.1.4 DISTRIBUTION OF THE RESPONDENTS- MARTIAL STATUS

36

INFERENCE:

It is found from the above tables 18% of the respondents are single and 82% of

the respondents are married.

TABLE: 2.1.5 DISTRIBUTION OF THE RESPONDENTS-QUALIFICATION WISE


respondentsPercenta

ge

1 10th 30 30

2 12th 34 34

3 Diploma 16 16

4 PG 2 2

5 Others 18 18

Total 100 100

37

CHART: 2.1.5 DISTRIBUTION OF THE RESPONDENTS-QUALIFICATION WISE

INFERENCE:

It is inferred from the above table that 30% of the respondents have

qualified in 10th, 34% of the respondents have qualified in 12th, 16% of the

respondents have qualified in diploma, 2% of the respondents have in PG

level and 18% of the respondents have qualified in others.

TABLE: 2.1.6 DISTRIBUTION OF THE RESPONDENTS-EXPERIENCE WISE

S. No ParticularsNo. Of respondents

Percentage

1 Up to 5 yrs 6 6

2 6-10 Yrs 9 9

3 11-15 Yrs 11 11

4 16-20 Yrs 15 15

5 >20 Yrs 59 59

Total 100 100

38

CHART: 2.1.6 DISTRIBUTION OF THE RESPONDENTS-EXPERIENCE WISE

INFERENCE:

It is inferred from the above table 6% of the respondent belongs

up to 5 years’ experience level, 9% of the respondents between 6-10 years

experience level, 11% of the respondents between 11-15 years, 15% of the

respondents between 16-10 years level and 59% of the respondents above

20 years experience level.

TABLE: 2.1.7 AWARE OF THE SAFETY SYSTEM


respondentsPercent

age1 Yes 100 1002 No 0 0 Total 100 100

CHART: 2.1.7 AWARE OF THE SAFETY SYSTEM

39

INFERENCE:

100% of the respondents are aware of the safety system prevailing in

factory.

TABLE: 2.1.8 WORK PERMIT SYSTEM


respondentsPercent

age1 Yes 52 522 No 48 48 Total 100 100

CHART: 2.1.8 WORK PERMIT SYSTEM

40

INFERENCE:

58% of the respondents are satisfied with their work permit systems

and 42% of the respondents are unsatisfied with their work permit systems.

TABLE: 2.1.9 SAFETY IN TOOL BOX MEETING


respondentsPercent

age1 Yes 90 902 No 10 10 Total 100 100

CHART: 2.1.9 SAFETY TOOL BOX MEETING

41

INFERENCE:

90% of the respondents have agreed with their tool box meeting and

10% of the respondents have disagreed with their tool box meeting.

TABLE: 2.1.10 CONTROL MEASURE TO ENSURE

SAFETY


respondentsPercent

age1 Yes 86 862 No 14 14 Total 100 100

CHART: 2.1.10 CONTROL MEASURE TO ENSURE

SAFETY

42

INFERENCE:

It is inferred from the above table 86% of the respondents have agreed

with their proper control systems and 14% of the respondents have disagreed

with their proper control systems.

TABLE: 2.1.11 IMPORTANCE OF SAFETY IS

COMMUNICATED TO THE EMPLOYEES

S. No Particulars

No. Of respondents

Percentage

1Observance of the safety weeks 76 76

2 Safety competitions 78 783 Talks on safety 82 82

4Booklet in Boards/Slogans 69 69

5 Booklets 14 146 House Magazines 14 147 Visual Displays 33 33

43

Total 100 100

CHART: 2.1.11 IMPORTANCE OF SAFETY IS

COMMUNICATED TO THE EMPLOYEES

INFERENCE:

76% they agree with safety weeks, 78% they agree with safety

competitions, 82% they agree with talks on safety, 69% they agree with

bullet in boards, and each 14% they agree with booklets, house magazines

and 33% they agree with visual displays.

TABLE: 2.1.12 REDUCE THE RISK OF HAVING

ACCIDENTS


respondentsPercent

age1 Strongly agree 7 72 Agree 82 823 Disagree 5 54 Strongly Disagree 6 6 Total 100 100

44

CHART: 2.1.12 REDUCE THE RISK OF HAVING

ACCIDENTS

INFERENCE:


strongly agreed with their reduce the accidents, 82% of the respondents have

agree, 5% of the respondents have disagree and 6% of the respondents have

strongly disagree.

TABLE: 2.1.13 ASSES THE RISK RATING IN WORK


responsibilityPercent

age1 Strongly agree 6 62 Agree 81 813 Disagree 9 94 Strongly disagree 4 4 Total 100 100

45

CHART: 2.1.13 ASSES THE RISK RATING IN WORK

INFERENCE:


strongly agreed with their asses the risk rating in work , 81% of the

respondents have agree, 9% of the respondents have disagree and 4% of the

respondents have strongly disagree.

TABLE: 2.1.14 ADEQUATE NUMBER OF TRAINING

PROGRAMS




46

CHART: 2.1.14 ADEQUATE NUMBER OF TRAINING

PROGRAMS

INFERENCE:


strongly agreed with their adequate number of training programs on safety ,

77% of the respondents have agree, 13% of the respondents have disagree

and 4% of the respondents have strongly disagree.

TABLE: 2.1.15 PROGRAMS CONDUCTED ON SAFETY




47

CHART: 2.1.15 PROGRAMS CONDUCTED ON SAFETY

INFERENCE:


strongly agreed with their programs conducted on safety, 76% of the

respondents have agree, 14% of the respondents have disagree and 4% of

the respondents have strongly disagree.

TABLE: 2.1.16 TRAINING NEEDS IDENTIFIED FOR THE

EMLOYEES




48

CHART: 2.1.16 TRAINING NEEDS IDENTIFIED FOR THE

EMLOYEES

INFERENCE:


strongly agreed with their training needs, 83% of the respondents have

agree, 8% of the respondents have disagree and 3% of the respondents have

strongly disagree.

TABLE: 2.1.17 SAFETY RULES, INSTRUCTIONS HAVE BEEN

DISPLAYED




49

CHART: 2.1.17 SAFETY RULES, INSTRUCTIONS HAVE BEEN

DISPLAYED

INFERENCE:


strongly agreed with their safety rules, instructions have been displayed, 80%

of the respondents have agree, 9% of the respondents have disagree and 5%

of the respondents have strongly disagree.

TABLE: 2.1.18 LAY OUT OF WORK PLACE

S. No Particulars

No. of responsibil

ityPercent

age

1Strongly agree 6 6

2 Agree 83 83

3 Disagree 8 8

4Strongly disagree 3 3

Total 100 100

50

CHART: 2.1.18 LAY OUT OF WORK PLACE

INFERENCE:


strongly agreed with their layout of work place have been properly designed

to avoid the accidents, , 83% of the respondents have agree, 8% of the

respondents have disagree and 3% of the respondents have strongly

disagree.

TABLE: 2.1.19a INTEGRATED SAFETY SYSTEM

S. No Particulars

No. of respondent

sPercent

age1 Yes 35 352 No 65 65 Total 100 100

CHART: 2.1.19a INTEGRATED SAFETY SYSTEM 51

INFERENCE:

35% of the respondents have agreed with their integrated safety

system and 65% of the respondents have disagreed with their integrated

safety system.

TABLE: 2.1.19b ADHERENCE TO THE SYSTEM IS GOOD




CHART: 2.1.19b ADHERENCE TO THE SYSTEM IS GOOD 52

INFERENCE:


strongly agreed with their adherence system, 57% of the respondents have

agree, 17% of the respondents have disagree and 11% of the respondents

have strongly disagree.

TABLE: 2.1.20a FIRST AID BOXES ARE AVAILABLE


respondentsPercent

age

1 Yes 31 31

2 No 69 69

Total 100 100

CHART: 2.1.20a FIRST AID BOXES ARE AVAILABLE

53

INFERENCE:

31% of the respondents have agreed with their first aid boxes are

available at the work place and 69% of the respondents have disagreed.

TABLE: 2.1.20b ADEQUATE MEDICINES AVAILABLE




CHART: 2.1.20b ADEQUATE MEDICINES AVAILABLE

54

INFERENCE:


strongly agreed with their adequate medicines are available in work place,



TABLE: 2.1.21 LIGHTING FACILITIES PROVIDED TO THE

WORKPLACE




CHART: 2.1.21 LIGHTING FACILITIES PROVIDED TO THE

WORKPLACE

55

INFERENCE:


strongly agreed with their adequate lighting facilities provided to the work

place, 85% of the respondents have agree, 5% of the respondents have

disagree and 4% of the respondents have strongly disagree.

TABLE: 2.1.22 SAFETY VALVES HAVE BEEN PROVIDED




TABLE: 2.1.22 SAFETY VALVES HAVE BEEN PROVIDED

56

INFERENCE:


strongly agreed with their safety valves provided at the pressure vessels,



TABLE: 2.1.23 NOISE LEVEL MONITORED


respondentsPercent


CHART: 2.1.23 NOISE LEVEL MONITORED

57

INFERENCE:


strongly agreed with their noise level is regularly monitored and controlled at

the work place, 24% of the respondents have agree, 64% of the respondents

have disagree and 6% of the respondents have strongly disagree.

TABLE: 2.1.24 FULL FLEDGED MEDICAL CENTRE


respondentsPercent


TABLE: 2.1.24 FULL FLEDGED MEDICAL CENTRE

58

INFERENCE:


strongly agreed with their full fledged medical centre, 25% of the

respondents have agree, 65% of the respondents have disagree and 6% of


TABLE: 2.1.25 ALL ACCIDENTS AND NEAR-MISSES ARE

FORMALLY INVESTIGATED


respondentsPercent


59

CHART: 2.1.25 ALL ACCIDENTS AND NEAR-MISSES ARE

FORMALLY INVESTIGATED

INFERENCE:


strongly agreed with their accidents and near-misses are formally

investigated, 91% of the respondents have agree, 0% of the respondents

have disagree and 6% of the respondents have strongly disagree.

TABLE: 2.1.26 OPENION ABOUT SAFETY FACILITIES ARE

PORVIDED


respondentsPercent

age1 Highly satisfied 7 72 Satisfied 86 863 Dissatisfied 5 54 Highly Dissatisfied 2 2 Total 100 100

60

CHART: 2.1.26 OPENION ABOUT SAFETY FACILITIES ARE

PORVIDED

INFERENCE:

It is inferred from the above table that 7% of the respondents are

highly satisfied with their safety measures provided by the company, , 86% of

the respondents have agree, 5% of the respondents have disagree and 2% of


2.2.1 CHI-SQUARE TEST

TABLE 2.2.1 AGE AND FIRST AID BOXES

Null Hypothesis (H0) : There is no significant relationship

between age and first aid boxes.

Alternative Hypothesis (H1) : There is a significant relationship


61

Age and

First Aid

Boxes

Up to

20

21-30 31-40 41-50 >50 Total

Strongly

Agree

0 2 0 1 3 6

Agree 0 3 5 8 9 25

Disagree 0 2 7 39 17 65

Strongly

Disagree

0 1 0 2 1 4

Total 0 8 12 50 30 100

Observed

Frequency(Oi)

Expected

Frequency(Ei)

(Oi-Ei)2/Ei

0 0 0

2 0.48 4.8

0 0.72 0.72

1 3 1.3

3 1.8 0.8

0 0 0

3 2 0.5

5 3 1.3

62

8 12.5 1.62

9 7.5 0.83

0 0 0

2 5.2 1.97

7 7.8 0.08

39 32.5 1.3

17 19.5 0.32

0 0 0

1 0.32 1.4

0 0.48 0.48

2 2 0

1 1.2 0.03

CHI - SQUARE TEST

The formula for

Ψ 2 = Σ (Oi-Ei) 2 / Ei

Calculated 2 value = 17.45

Degree of Freedom = (R-1) (C-1)

= (4-1) (5-1)

= 12

Table value 2 = 21.03

Result = Calculated 2 value 17.45 <

Table value 2 21.03 at 5% level of

significant.

63

INFERENCE

It is found from the above table that calculated value is less

than the table value at 12 degree of freedom. Hence, Null hypothesis

(H0) accepted. It concluded that there is no significant relationship


TABLE 2.2.2 EXPERIENCE AND NOISE LEVEL


between experience and noise level.


between experience and noise level.

Experien

ce and

Noise

Level

Up to

5 Yrs

6-10

Yrs

11-15

Yrs

16-20

Yrs

>20 Yrs Total

64

Strongly

Agree

1 1 0 0 2 4

Agree 3 3 4 8 10 28

Disagre

e

1 5 6 7 46 65

Strongly

Disagre

e

1 0 1 0 1 3

Total 6 9 11 15 59

100

Observed

Frequency(Oi)

Expected

Frequency(Ei)

(Oi-Ei)2/Ei

1 0.24 2.41

1 0.36 1.14

0 0.44 0.44

0 0.6 0.6

2 2.36 0.5

3 1.68 1.04

3 2.52 0.09

4 3.08 0.27

8 4.2 3.44

65

10 16.5 2.57

1 3.9 2.16

5 5.85 0.12

6 7.2 0.18

7 9.8 0.78

46 38.4 1.53

1 0.18 3.74

0 0.27 0.27

1 0.33 1.36

0 0.45 0.45

1 1.77 0.34

CHI - SQUARE TEST

The formula for

Ψ 2 = Σ (Oi-Ei) 2 / Ei



= (4-1) (5-1)

= 12


Result = Calculated 2 value 23.43 >


significant.

INFERENCE

66

It is found from the above table that calculated value is

greater than the table value at 12 degree of freedom. Hence, Null

hypothesis (H0) rejected. It concluded that there is significant

relationship between experience and noise level.

TABLE 2.2.3 TRAINING AND SATISFACTION


between training and satisfaction.


between training and satisfaction.

Experien

ce and

Noise

Level

Up to

5 Yrs

6-10

Yrs

11-15

Yrs

16-20

Yrs

>20 Yrs Total

Strongly

Agree

1 1 0 0 2 4

67

Agree 3 3 4 8 10 28

Disagre

e

1 5 6 7 46 65

Strongly

Disagre

e

1 0 1 0 1 3

Total 6 9 11 15 59

100

Observed

Frequency(Oi)

Expected

Frequency(Ei)

(Oi-Ei)2/Ei

1 0.24 2.41

1 0.36 1.14

0 0.44 0.44

0 0.6 0.6

2 2.36 0.5

3 1.68 1.04

3 2.52 0.09

4 3.08 0.27

8 4.2 3.44

10 16.5 2.57

1 3.9 2.16

68

5 5.85 0.12

6 7.2 0.18

7 9.8 0.78

46 38.4 1.53

1 0.18 3.74

0 0.27 0.27

1 0.33 1.36

0 0.45 0.45

1 1.77 0.34

CHI - SQUARE TEST

The formula for

Ψ 2 = Σ (Oi-Ei) 2 / Ei



= (4-1) (5-1)

= 12


Result = Calculated 2 value 23.43 >


significant.

INFERENCE

It is found from the above table that calculated value is

greater than the table value at 12 degree of freedom. Hence, Null

69

hypothesis (H0) rejected. It concluded that there is significant

relationship between experience and noise level.

CHAPTER III

3.1 SUMMARY OF FINDINGS

This chapter deals with the main findings which are mainly drawn from the

previous chapter (Analysis and Interpretations). These main findings are very

important for this study to come out with the appropriate suggestions. The

followings are main findings drawn from the study.

MAIN FINDINGS

Majority(50%) of the respondents working in Caterpillar age between

41-50

Majority (65%) of the respondents are operator.

Majority (40%) of the respondents are under come loader assembly

department.

More than three fourth of the employees (82%) were married.

100% of the respondents working in Caterpillar were male.

Majority of the respondents (34%) educational status were +2.

70

Majority of employees (59%) had served at caterpillar for more than

twenty years.

100% of the respondents are aware of safety system prevailing n the

factory

Nearly half of the employees (52%) have been provided with work

permit systems in their factory

Majority of the respondents (90%) are provided with priority for safety

in Tool box meeting.

86% of the respondents say that they have been provided with proper

control measure to ensure safety in their work place.

Nearly half of the employees (82%) of respondents the importance of

safety is communicated through talks on safety.

Nearly three fourth (82%) of the employees agree that safety

measures will reduce the Risk of having accidents.

Nearly half of the respondents (81%) accepted that there is a system

in a place to asses the risk rating in their day to day work.

77% of the respondents feel that they have been given adequate

number of training programs in Caterpillar.

Three fourth of the respondents (76%) say’s that the programs

conducted on safety is very effective.

Majority of the respondents (83%) think that the training programs as

per identified training needs.

80% of the respondents agree that safety rules, instructions have been

displayed everywhere in the factory permanently.

Nearly three fourth (83%) of the employees accepted that the layout of

the work place have been properly designed to avoid accidents.

65% of the employees feel that there is no integrated safety systems

provided in machines and they suggested that company can adhere to

a system which is good.

More than half of the respondent (69%) says that there is adequate

number of first aid boxes available in the factory.

85% of the respondents are agreed with their lighting facilities

provided to the employees at work place.

71

More than half of the respondents agree that the safety valves have

been provided with pressure vessels.

Nearly three fourth of the employees strongly disagree that the noise

level is regularly monitored and controlled in the factory.

Nearly three fourth of the employees (65%) feels that the company do

not have the full fledged first aid provision.

Majority of the employees (91%) agree that all accidents and all near

misses are formally investigated.

86% of the respondents are satisfied with the overall safety provisions

provided in the factory.

3.2 SUGGESTIONS

Adequate number of first aid boxes should be provides in every

department and also provides an adequate number of medicines

in the work place.

The companies try to provide different way of awareness

programs on safety.

Full fledged first aid centre should be improved and maintained.

Noise level should be control and monitor regularly.

Safety valves should be providing to pressure vessels.

Electric circuit and electric wires should be checked, maintained

properly.

The integrated safety system of the machines should be

improved.

Work permit system to be implemented.

Company should asses the equipments used by every

employees.

72

3.3 CONCLUSION

A study was conducted on the safety management system at CIPL.

A majority of 86% of the respondents were found to be satisfied

with the safety measures at CIPL, 7% were highly satisfied, and only 5% were

dissatisfied , 2% of them highly dissatisfied.

Most of the employees feel company should improve their first aid centre and

adequate medicines are easily available in all work place Employees also feel

noise level should be monitored and controlled.

The company should be given improved work permit system to employees.

73

BIBLIOGRAPHY

BOOKS:

Industrial Safety - J. Nagaraj and V.Ramachandra

Rao

Industrial Relations -

ArunMonapa

Human Resource and Personnel Management

Fourth Edition, Tata Mc Graw Hill Publishing -K. Aswathappa

Organization Behaviour - L.M.

Prasad

Personnel Management - Dr. Gupta

websites

http://en.wikipedia.org/wiki/Safety_culture

http://www.theiplgroup.com/safety culture-review

http:// safety atworkblog.wordpress.com

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http://safetyatworkblog.wordpress.com/

http://en.wikipedia.org/wiki/Safety_culture

APPENDIX

“A STUDY ON SAFETY MANAGEMENT SYSTEMS WITH

REFERENCE TO CATERPILLAR INDIA PRIVATE LIMITED”

QUESTIONNAIRE

Personal Details

Age : [ ] up to 20 [ ] 21-30 [ ] 31-40 [ ]

41-50 [ ]>50

Designation :

Department :

Martial Status : [ ] Single [ ] Married

Gender : [ ] male [ ] female

Educational Level : [ ] 10th [ ] 12th [ ] Diploma

[ ] UG [ ] PG [ ] Others

Length of Service : [ ] up to 5 Yrs [ ] 6-10 Yrs [ ] 11-15 Yrs

[ ] 11-15 Yrs [ ] >20 Yrs

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1. Are you aware of the safety system prevailing in your factory?

[ ] Yes [ ] No

2. Do you have any work permit systems in your factory?

[ ] Yes [ ] No

3. Is there any priority for safety in Tool Box Meeting?

[ ] Yes [ ] No

4. Is there any proper control measure to ensure safety at your work

place?

[ ] Yes [ ] No

5. How the importance of safety is communicated to the employees?

Please tick the appropriate answer.

Observance of the safety weeks

Safety competitions

Talks on Safety

Bullet in Boards/Slogans

Pamphlets

Booklets

House Magazines

Visual Displays

6. A safety measures reduce the risk of having accidents in your work

place.

[ ] Agree [ ] Strongly Agree [ ] Disagree[ ] Strongly

Disagree

7. There is a system/method in place to asses the risk rating in your day

to day work.


Disagree

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8. Adequate number of training programs on safety is conducted for the

employees of caterpillar.


Disagree

9. The programs conducted on safety are very effective.


Disagree

10.Training programs are conducted as per training needs identified for

the employees


Disagree

11.A safety rules, instructions have been displayed everywhere in the

factory permanently


Disagree

12.The layouts of the workplace have been properly designed to avoid

accidents.


Disagree

13.Has any integrated safety system been provided in the machines?

[ ] Yes [ ] No

If yes, adherence to the systems is good


Disagree

14.Adequate numbers of first Aid boxes are available at the work place.

[ ] Yes [ ] No

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If yes, adequate numbers of medicines are available


Disagree

15.Adequate lighting facilities have been provided at the workplace.


Disagree

16. Safety valves have been provided at the pressure vessels?


Disagree

17. Company have a full-fledged medical centre


Disagree

18.Noise level is regularly monitored and controlled at the work place


Disagree

19. All accidents and all near-misses are formally investigated


Disagree

20.Are you satisfied with the safety measures provided by your company?

[ ] Highly Satisfied [ ] Satisfied [ ] Dissatisfied

[ ] Highly Dissatisfied

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