Safety Pillar internal audit

UNITED BREWERIES LIMITED - NELAMANGALA 1

SAFETY PILLARSl.

No.Name Role Department

1 Rupesh Verma Pillar Leader HSE

2 V S Moorthy Pillar Member Process

3 M S Manjunath Pillar Member Logistic

4 A Narasimhulu Pillar Member Bottling

5 S Satti Babu Pillar Member Process

6 Mohan Pillar Member Security

UBL- Nelamangala11th June, 2015


To ensure a safe working environment in all our activities by educating, engaging, empowering all our stake holders by adhering to best safety practises.

Safety Pillar Mission is to develop and implement effective Safety policies, procedures and methodologies to eliminate safety related losses by• Identifying and Eliminating all the Unsafe Working Conditions• Preventing all the Unsafe Acts and Behaviours by people involvement. • Enabling a safe environment by promoting near miss reporting.

VISION

MISSION


Pillar Team Roles & Responsibilities

Member Role ResponsibilityV S Moorthy Pillar Member To inform the pillar team members for meetings and MOM

circulation.; Pillar activity audit

Satti Babu Pillar Member Board updation & Tag register review/updation.

Rupesh Leader KPI and Master plan Review Pillar Planning Risk Assessment Training of Pillar members

A Narasimhulu Pillar Member To support the different teams/running projects to further progress.; Kaizen execution.

MS Manjunath Pillar Member Warehouse Safety compliance; Training to warehouse team.

Mohan Pillar Member Traffic safety of brewery, Training to drivers, Vehicle fitness, PPE compliance

4

Pillar Route

5

Pillar master plan

Step 1 Sub step1 Sub activities step 1 Status

Identify

Safety

Priorities and

Restore

Basic Conditions

1.1 Assess all current activities performed for safety List attached

1.2 Introduce and access Safety Pyramid, formalize KPI in practiceevidence @ gemba

1.3Assess Conformance to (HeiQ) rules, standards and procedures via HeiQuest and Legal requirements. Make Gap analysis for both and action plan to close actions

Pass compliancePillar Indicators

1.4 Define visitor and Contractor Induction Program in practiceevidence @ gemba

1.5 Define review work permit system, LOTO and PPE procedure. in practiceevidence @ gemba

1.6 Perform accident, Incident, (Vertical) deployment , define Priorities, Targets & prepare improvement action plan done

1.7 Ensure Safety activities are included in 5S activities and audits. On going

1.8 Introduce safety tagging system to identify unsafe conditions OngoingKPI

1.9 Perform basic safety awareness training for all levels. on going @trg. Mandays

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Microsoft Excel Worksheet

1.1- Assess all current activities performed for Safety.

STEP 1.2 Introduce & assess safety pyramid – Iceberg Theory,formalise KPIs

FatalLTI

MTC

First Aid

Unsafe Act

Near Miss

Unsafe condition

YTD MTD

0

0

8

8

28

19

72

0

0

4

4

11

8

33

BE SAFE BE CLEAN

In Numbers

Till May 2015

8

Safety Pillar IndicatorsCalculation Remark

MONTHLY PILLAR KPI

TREND

S.N. KPI Description Measure UnitInitial Target

14-15 15-16 Apr-15

May-15

Jun-15

1 Accident Frequency ( LTI + Permananent Disability) Nos / 100 FTE 0.015 0 = 12X (No. of LTI + No. of

Permanent Disability) / 100 FTEFTE for Safety calculations Includes - Everybody coming in plant (Permanent Employees + Warehousing + Sighters + Nurse + QA workers + WTP RO contract members + Contract process + Contract Utility, Bottle feeding, Security, canteen, Housekeeping).

00

2 Incident Frequency (MTC + FA): Own & Contractor Nos / 100 FTE 3.29 1.71 =12X (No. of MTC + FA) / 100 FTE 1.33 1.35

3 Near misses : Own & Contractor Nos 48 180

= No. of Nearmisses cases reported in plant including Own and Contractual person 11 8

4 Improvement in Pass compliance Value 83.55 90 = Pass score based on pass

checklist 90.10 90.78

5Risk assessment completion wrt. Plan and (No risk above 35 RPN)

% 83 doneNo >200= 0 175

= (No. of Risk assessment completed with action/ No. of Risk assessment schedule by that time )X100

act-8sub

act- 17>200=

0

act-15sub

act- 63>200=

0

6 Average time to solve Safety Tags Days

tags put wef oct-14 to mar-15 =

237tags closed- 113

%age closed-47.6%

65% closure

PM= Average No. of days required to solve safety related tags. Near miss Unsafe

Conditions and other audit Observations

TP-57TC-30%age

-52.6%

TP-44TC-17%age -38.6%

STEP 1.2 Introduce & assess safety pyramid – Iceberg Theory,formalise KPIs

Step 1.3 Assess conformance to (HeiQ) Rules, Standards & Procedures via HeiQuest & legalrequirements. Make gap analysis on both & prepare action plan to close actions (1)

POSITIVE SAFETY ASSURANCE SYSTEM ACTION PLAN

Sl No. (as per

checklist) Initiative FPR Status

10Training calendar for each workmen and executive HRP

In process; target- 30 june.

12Refresher training of cont. and engg. And certificate RKV 14 June.

21 Restaring APEX safety committee HRP DONE22 Safety committee points review RKV DONE

28 PPE compliance by contractor supervisor CRDONE (Training, audit, TBT in

place).34 List of authorized permit issuer RKV 15th June33 Permit being issued as per module CR DONE

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Different color code badges are provided to contract workers depending on the area in which they are working

HRP Budget, next contract renewal.

93 Color coding of plants & pipes are in place CR Will start on 20th June

103

Check adequacy of the number of lighting arrestors & their location CR DONE

Step 1.4 Define visitor and contractor safety/introductionprogram

Identity Type FPR

Visitor/ contractor Induction PPT in English/ Kannada Security

Contractor Equipment Checking and registerElectrical/Mechanical Engineer

New J oineeInduction PPT in English

Induction by HSE Manager HR

Contract employees Safety Talk Shift engineer

Safety Induction Procedure

Step 1.5 Define, review Work permit system, LOTO & PPEprocedures

Work permit system

LOTO Procedure

PPE Procedure

Adobe Acrobat Document

PPE Procedure

LOTO Procedure

SWP Procedure

1.6 Safety Incident Deployment 2014-15

Pacakaging Warehouse & logistics/stores

Process /lab Admn./others Utility

157

2515 9 7

First Aid 2014-15

Pacakaging Admn./others Utility

9

2 2

MTC 2014-15

Pacakaging

1

LTI 2014-15

FA MTC LTI

213

13 1

2014-15 Incident deployment

Deployment First aid 2014-15

13

Empty

bottl

e fee

ding

Crate f

eedin

g

Bypas

s/ L-b

ent-

Line 2

Paste

urize

r

glass

culle

t disp

osal

Packe

r

Labe

ller

Test

lamp-1

(pos

t pas

teuri

zer)

Washe

r

Crating

Shift

ing of

bag

Unload

ing of

bags

Filler EB

I

Test

lamp-2

(pos

t pas

teuri

zer)

Test

lamp-2

(pas

teuri

zer in

feed)

hous

ekee

ping o

f bro

ken g

lass

Carton

form

ing

Pressu

re les

s com

biner

(line

-2)

Test

lamp-1

(pas

teuriz

er inf

eed)

BBH work

shop

Pressu

re les

s com

biner

(line

-1) -

5

10

15

20

25

30

0

20

40

60

80

100

120

27 26

18

13 11 11

8 7 7 7 5

3 3 2 2 2 1 1 1 1 1 -

17

3445

5461

6873 77 82 86 89 91 93 94 96 97 97 98 99 99 100100

Area of concern packaging-157

incidents

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1.7-Ensure Safety activities are included in 5S activities and audits.

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1.8- Introduce safety tagging system to identify unsafe conditions.

Safety tag by tagger posted and

handed over to safety pillar

Tag register maintained by

Pillar team

Follow-up with concern HOD and

tag hand over.

Follow-up with concern HOD and

tag hand over.

Closed tag returned back to

safety pillar

Keep informed the status

to AM pillar

Safety tag collected from TCO, nearmiss,

whats app.

OPLs and trainings

Safety Tags

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1.9- Perform basic safety awareness training for all levels.

Fall arrestor- ORR project

Fall arrestor- ORR project

Safety in pallet handling- ORR project

Fire trainingSCBA trainingDaily Tool box talk meeting at time office

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Shift wise Tool box talk at shop floor.


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Safety talk- speakers at main gate & time office

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Pillar master plan

Step2 Sub Step 2 sub activities step 2 status

Systematic Analy

se accident and

incidents

2.1 Select and train Safety Experts/ champions in all Departments

Fire-SOFA- Nurse

Dept- Champions identified

2.2 Perform accident and Incident analysis to establish root causes via 5Why

Done for all incidents

Evidence 0f CAPA2.3 Prepare and execute countermeasure plan Done

evidence example

2.4 Start horizontal expansion of actions to similar areas Ongoing evidence @ gemba

STEP 2.1 Select & train safety experts/ champions in all departments

Safety Training Committee 1 Rupesh Verma HSE

2 V S Moorthy PROCESS

3 M S Manjunath P &L

4 Madhu BBH

5 Dinesh Nayak Electrical

6 Mahesh, Saju & Lalitha OHC

8 Mohan & Vikas Security

10 Kumar, Sidhappa & Srinivas BBH

12 Umesh Warehouse

13 Saravanan PROCESS

Safety Hand book has been created by steering committee and training being delivered to all. Basic safety training is provided to all levels

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2.2- Perform accident & incident analysis to establish root cause via % why

Case- 1. Swami was doing his usual duty of wet spent grain unloading.2. Swami is engaged in the brewery since last 20 years through Vendor.3. Swami climbed up the lorry to level the spent grain heap. While

levelling ,his gum boot got stuck in the spent grain, he lost his balance and has fallen on the hot (70 degree) heap of spent grain. His right leg and right hand got stuck into the spent grain.

4. His colleague Mr. Umesh ( who was standing nearby at ground floor), after hearing the noise of injured, rescued Swami.

5. Immediately the injured was sent to nearby JP hospital at Nelamangala by company owned Ambulance for treatment.

6. After the treatment doctor declared him out of danger with 30% burn. Later as per the advice of the Doctor, he was shifted to Victoria Hospital in Bangalore City for further treatment as JP hospital does not have burnt care specialist.

7. The injured was in the influence of liquor and was suffering with convulsions.

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why why

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25


26


27


28


SOP Spent

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2.3- Perpare and execute counter measures.

With access platform- person need not to get exposed with hot spent.

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2.2-Incident Analysis – LTIDate Incident Description Reason CA PA

29th Oct’14 Mrs. Sakamma was engaged for crate removal at sighter point, line-1 past-1. The loose arm sleeve came in contact with moving guide & entangled which resulted cut injury in right wrist. Immediately sent to Hospital for treatment.

1. Uncovered rotating part.2. Loose Arm sleeve

1. Replaced all the arm sleeves with skin fit sleeves.

Guarding of all the rotating parts done.

2.3- CAPA

Loose arm sleeve near moving part. Fit sleeve with guards on moving part.

WRONG RIGHT

SITUATION BEFORE

Wrong method of using Arm guard which causes exposed arms

SITUATION AFTER

Right method which improves the guarding of arms.

LOCATION AREA DATEBBH FEEDING/ SIGHTER

AREA12.11.14

Team: Kavach TeamSAFETY IMPROVEMENT

2.4 start horizontal expansions of actions to similar areas

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Pillar master plan

Step 3 sub step 3 sub activities step 3 status

Hazard Identification and Risk Manage

ment

3.1 Prepare, plan and perform hazard Identification and risk assessment across the site

RA done as per planPillar KPI's

3.2 As priority define and implement risk management for " risk of death and serious Injury" Done

3.3 Prepare " Operational risk reduction " team roll out plan for site and execute. ORR @ gemba

3.4 Prepare safety approval eg: CILT, OPL, SOPS and maintenance standards to maintain safe work practices

safety sop's , OPL @ gemba

3.5 Introduce safety Visual Management, signages and physical eg: Walkways, PPES, Machine Poka Yoke..

Visual management on safety@ gemba

3.6 Rewiew work permit & LOTO procedures.LOTO review doen during pass auidt-

monthly

3.7 Improve Ergonomics and environmental conditions light, noise, temperature

LUX level monitoring and DB monitoring

and appropriate countermeasures

takenEvidence @ gemba

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3.1- Prepare, plan and perform hazard Identification and risk assessment across the site

Function Area Done Q1 Q2 Q3 Q4

Packaging 8 5

Process 9 2

Utility 12 2

Admn. 7 3

Warehouse 3

Stores 5 2

Lab 1

CTC 1

Shared services 1

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3.2- As priority define and implement risk management for " risk of death and serious Injury"

Activity Action Taken Score Current Dept.

Truck parking by driver at parking outside the gate.

1. Parking at 10m distance from access road of factory. 2. Admin. Control through security & Safety KPI monitor.

200 140 Admin.

To align the bottle if get stuck/ fall in between test lamp to PLC.(sub activity- Removal of stuck bottle.)

1. PPEs, PVC strip, PVC net on conveyor. (existing).2. Acrylic guard to contain the hazard.3. SOP/OPL for handling bottles. (done)4. Only trained and experienced person to be deployed. (done)5. Emergency s/w at operator point(3-phase). 6. Guide alignment, conveyor alignment, wear strip replacement.7. SS hood cover on post labeler conveyor. (done line-2)8. Preventive maintenance for conveyors and guide.

300 84 BBH

Broken bottle removal, Fallen bottle removal.(Remove the bottle and dispose in cullet drum.)

1. PPEs, PVC strip, PVC net on conveyor. (existing control)2. Acrylic guard to contain the hazard.3. SOP/OPL for handling bottles. (done)4. Only trained and experienced person to be deployed.

(done)5. Emergency s/w at operator point(3-phase).6. Guide alignment, conveyor alignment, wear strip

replacement.7. SS hood cover on post labeller conveyor. (done for line-2)8. Preventive maintenance for conveyors and guide.9. Synchronization of conveyor as per labeller speed.

300 84 BBH

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3.3- As priority define and implement risk management for " risk of death and serious Injury"

W45 W46 W47 W48 W49 W13 W14 W15 W16 W17 W18 W19 W20 W21 W22 W23 W24 W25 W26 W27 W28PlanActPlanAct c c c cPlanActPlan P P P PActPlan P P P P P P P P P P P PAct c c c cPlanAct c c c cPlanActPlan P P P P P P P P P P P PAct c c c cPlan P P P P P P P PActPlan p p p p p p p p p p p pActPlan P P P P P P P PAct

2015April May June July

Casepacker Line 2 Parmeshwarpa MSM

Pasteruizer-Line 2 Ramanna AN

Tank Farm Sanjeev G A MANJUNATH,

fabrication and welding operations RN RKV,AN

Fall arrest system AN Veranjanelu

Lab BKS RKV, UNDRU, VIRENDRA,

Conveyor Pasteruizer to labellor MSM

Truck Loading MSP

Bottle unloading and empty bottle feeding AN Chalpathy, Mahesh

Conveyors Labellor to Taping RKV

December

Manual palletizing in warehouse (completed-Jan'14)

RKV AN, MSM,BNG,RN, VIJAY

OPERATIONAL RISK REDUCTION ROLL OUT PLAN - SAFETY PILLAR

Area Team Leader Team Members2014

Project Done Area Type StatusPVC hood BBH, post labeler-2 Kaizen Done

Slop removal feeding and old stores Kaizen Done

Caustic unloading Stores Kaizen Ongoing

Rotating parts guard BBH, Refrigeration, ETP Kaizen Done

Automation of Sugar addition to wort kettle-2 Brew House Kaizen On going

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3.4- Prepare safety approval eg: CILT, OPL, SOPS and maintenance standards to maintain safe work practices

SOP and OPL

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3.5- Introduce safety VM, signage & physical e.g walkways, PPE, machine poke-yoke…

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3.6- Review work permit & LOTO procedure.

1. Work permit is being issued at Gemba after evaluating the hazards and mutual understanding with all signers (contractors & area incharge).2. Daily alert in morning meeting on total work permit issued.3. Audit of Work permit system & LOTO is being done by Unit head & HODs on weekly basis.

SWP monitor SWP review form

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3.7- Improve ergonomics & environmental conditions, light noise, temp….

1. Conveyor modification at palletizer for manual handling2. Lighting improved at loading bay, filtration and labelling area.3. Ear plugs provided at all high noise areas4. Provided fan at slighter, palletizer area.

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Learnings

1. Revised Safety Pillar Route2. Team Building3. Communication skills4. Visual Management5. Why-why Analysis 6. Audit Planning.

Safety Pillar internal audit

Documents

Transcript of Safety Pillar internal audit