Ultratech Final Report Submission Final 2010

A PROJECT REPORT ON

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

EXTERNAL GUIDENCEMr. P.K.Maity (Head P&A)1

INTERNAL GUIDENCEMr. Kaushal Lohagan

Mr. Sit l Ray (Offic r Safety)

(Lecturer, EIILM University)

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ACKNOWLEDGMENTI feel its 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.

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A BRIEF

IN RODUC IONOF ADITYA BIRLA GROUP

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Shri. KUMAR MANGALAM BIRLA CHAIRMAN OF ADI YA BIRLA GROUP

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%RDUGRI'LUHFWRUV:: :: :: :: :: :: :: :: :: :: 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

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Mr. K. C. Birla

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R.K. Shah

&KLHI0DUNHWLQJ2IILFHU:: Mr. O. P. Puranmalka

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:: Mr. S. K. Chatterjee

AD TYA B LA GROFACT S EET(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 S EET (2)GLOBALLY AD TYA B RLA GRO S: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 4.8

Among the best energy efficient fertilizer plant.

FACT S EET (3)N ND A AD TYA B RLA GRO

S:-

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 S EET (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 .

D FFERENT SECTORS OF AD TYA B RLA GRO9

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INTRODUTION TO ULTRATECH CEMENT CO PANY

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9,6,21

To be a premium global conglomerate with a clear focus on each business.

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To deliver superior value to our customers, shareholders, employees and society at large.

9$/8(6Integrity Commitment Passion Seamlessness Speed

LANT LOCAT ON OF LTRATEC CEMENT COM ANY N ND A

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De lS1

f Pl

L c Comp

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ech cemeAddress of the Plant

Name of the PlantUltratech Cement, GCW(Thermal Power Plant)& (CCP)

Gujarat Cement Works, V llage Kovaya, Taluka Rajula City, Dist. Amreli, Gujrat-365541

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2

Ultratech Cement, GCW-NMCU

Ultratech Cement, GCW,NMCU Plant, Navi Mumbai Ultratech Cement, GCW,MCU Plant, Mangalore Gujarat Cement Works, Village Kovaya, Taluka, Rajula City, Dist. Amreli, Gujarat-365541 Ultratech Cement, ACW, Location: PO Awarpur Cement Project, Taluka, Korpana, Dist. Chandrapur, Maharashtra- 442917 Ultratech Cement, APCW, Village Bhogasamudram, Chukkalur, Tadipatri, Dist:-Ananatpur , Andhra Pradesh-515415 Ultratech Cement, GGU, Ginigera Unit, Ginigera Grinding Unit, Ginigera Village, Koppal Taluk,Karnataka State-832280 Ultartech Cement, HCW, PO: Hirmi, Taluka Singa, Via:Neora, Dist. Raipur, Chatisgarh-493114 Ultatech Cement Limited, JCW, PO: Awarpur Cement Project, Taluka, Korpana, Dist:- Chandrapur, Maharashtra-44291714

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Ultratech Cement, GCW-MCU

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Ultratech Cement, GCW, Jetty

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Ultratech Cement, ACW

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Ultartech Cement, APCW

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Ultratech Cement, GGU

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Ultratech Cement, HCW

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Ultartech Cement Limited, JCW

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Ultratech Cement, JFD

Jafarabad Works(NCCL), Village Babarkot, Taluka, Jafrabad, Dist:Amreli, Gujarat-365540 Magdalla Works(NCCL), Magdalla port, Dumas Road, Surat, Gujarat- 395007 Ultratech Cement, Ratnagiri, MIDC Industrial Estate, Zadgaon Block, Ratnagiri, Maharashtra-415639 Ultatech Cement Limited, Near EPIP Plot, Muchipara, Post:- Rajbandh, Durgapur, West Bengal-713212 Ultratech Cement Limited, Chitteri, PO:- Arakkonam, Dist:- Vellore, Tamilnadu- 631003

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Ultratech Cement, MGU

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Ultratech Cement, Ratnagiri

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Ultratech Cement, WBCW

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Ultratech Cement, ARCW

LOCAT ON OF LTRATEC CEMENT (WBCW) N WEST BENGAL

COM ANY

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WBCW, DURGAPUR

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ech ceme comp (we Be g l ceme works, Durg pur

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

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DZPDWH LDO Clinker: - Hirmi Cement Works. Fly ash: - Bakreshwar Thermal Power Station, DPL. Gypsum: - Hind Liver Chemicals, Haldia. Slag: - Durgapur Steel Plant and Bokaro Steel Plant.

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DLP, DVC.

& 7UDQVSRUW North Eastern Railways.

' :DWHU Damodar valley

( /DQG 62.92 areas of good land for construction.

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&DSLWDO Huge no of bank for getting easy cash.

* 0DQSRZHU Available number of skilled and unskilled labours from local area.

+ 0DUNHW Local growth of city development.

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'HPRJUDSK\ Good demographic structure is found here.

ULTRATEC CEMENT L M TEDWEST BENGAL CEMENT WORKSUltra Tech Cement Limited is certified for quality as per the standard ISO 9001:2000 by DNV.

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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) 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.

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EM LOYEE OTENT AL N ULTRATEC CEMENT COM ANY DURGAPURUltratech 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 are20

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 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 Packing Plant Operation Mechanical Maintenance Electrical and Instrumental Maintenance Hoticulture,Material Handeling,Pentry,Wagon Tippler, Bag Branding and Civil & Office Boy Supply Name Of Contractor M/s Sen. Brothers M/s Raj Engineering Megha Marketing Overall Strength 68 Actual Engagement 58

57

53

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Prgati Cooperative and Labour Contract Construction21

73

73

Society Ltd Railway Track Maintenance Project Work Of Silo Ganguly Associate M/s Singh Construction Company M/s Orange Securitas 12 12

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Security Deployment

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INDUSTRIAL LAW FOLLOWED IN ULTRATEC CEMENT LIMITED WEST BENGAL CEMENT WORKS1. Factories Act 1948 & West Bengal Rules 195722

2. Industrial Dispute Act 1947 & West Bengal Rules 1957 3. Payment of Wages Act 1936 4. Minimum Wages Act 1948 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:%&:0LOHVWRQH(YHQW'DWH First Land Registry First Excaration in Plant23

October,2001 October,2000

6.6 KV EHT Line Commissioned Railway Track Laid Down Wagon Tippler Commissioned First Clinker Rake Received Cement Mill Commissioned Cement Production Started Packers Commissioned Cement Dispatch by Road Cement Dispatch by Rail Wagon Loading System Commissioned

September,2001 March,2002 March,2002 March,2001 December,2001 January,2002 January,2002 January,2002 January,2002 July, 2004

COMPANY PROFILECompany Name Ultratech Cement Company (An ADITYA BIRLA GROUP of companies)

Industry

Cement Manufacturing

Type of Company Company

Public Limited

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Unit Name and Address

West Bengal Cement Works Near EPIP, Muchipara, G.T Road Post:-Raj andh, Durgapur 713212 Dist:- Burdwan, West Bengal

Registered Office

Ultratech Cement Limited B-Wing, Ahura Center, 2nd Floor, Mahakali Caves Road, Andheri(east), Mumbai-400093

Stud of Production System Includ ng Transportation, Handl ng,25

Loadin , Unloadin , Stora e et . o Ra 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 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.

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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.

3(5621$/Routine Safety check is being carried out by the respective department employee s as well daily safety round by safety officer.

0(',&$/A full-fledge Occupational Health Centre established and functioning with a qualified doctor. All the eligible employees (both regular and contract employee) are covered under ESI.27

The company have tie-up with a local Nursing Home, which is situated just 3kms away from the plant for emergency purpose.

25*$1,6$7,21$/(19,5210(17West 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.

25*$1,6$7,21$/&8/785(385326( To produce the cement as per marketing requirement with minimum lost. 2%-(&7,9( Zero Breakdown, Good Housekeeping, Building Trust and Support West Bengal Cement Works is having following facilities:y Clinker unloading by wagon tippler(capacities 15 trips/hrs) y Fly ash browsers unloading system28

y Cement will 1.0 million ton per annum capacity y Cement dispatch facility by road and rail y Clinker, Gypsum and Fly ash receipt by rail and road respectively

/$1''(7$,/6Factory 16 Flat Residential Complex Assisted Sidings Private Assisted Siding 61.67acres 10,202.4 sq. feet 2830M 2210M

PROCESS FLOW IN ULTRATEC CEMENT COMPANY (WEST BENGAL CEMENT WORKS), DURGAPUR

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Ultratech Cement Company West Bengal cement worksM/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 ac uired 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 e uity shares of the new cement company and the balance 80% will be allotted30

to the e isting L&T shareholders in proportion to their shareholding in the company. Grasim Industry Ltd. agreed to ac uire 8.50% of e uity shares of the new cement company from L&T at Rs.99.30/share and therefore to make an open offer for ac uiring 30% of e uity shares at the 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:y Henning Holck Larsen y SOREN Toubro Ultratech Cemco Ltd. is being lots of specified sectors and few of them can be said as business tycoon:y y y y y y Engineering and Construction Project Construction Heavy Engineering Electrical Business Group Information Technology Cement- formally known as L&T Ltd.

WEST BENGAL CEMENT WORKS PROFILEWBCW 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

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factory is situated 4 km away from Durgapur railway station on HowrahNew Delhi Rail route. It is well connected by both road and rail. The construction started in October 2000 and completed on November 2001. 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 DEVELOPMENTThe 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) :RUOG&ODVV0DQXIDFWXULQJ WCM is primarily organizedfor 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 the32

employees to with a wider cross section of people. The WCM process gives results through

QUALITY

COST

PRODUTIVITY

DELIVERY

INNOVATION

7RWDO XDOLW 0DQDJHPHQW7 0The TQM standsfor 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.

6L 6LJPDSix Sigma is a quality standard setup for operationso 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.33

7RWDO3URFH 0DQDJHPHQW730TPM stands forTotal 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.

/HDQ0DQDJHPHQWIn Lean Management the firmproduces only that much which is demanded or which maximizes the value of the firm.

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IN ULTRATEC CEMENT COMPANY (WEST BENGAL CEMENT WORKS)

SAFETY MANAGEMENT:KDWLV6DIHW\0DQDJHPHQW"Documented process for managing risk that integrates operations and technical system with the management of financial and human resource to ensure safety of employee.

(PSOR\HH6DIHW\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 as35

(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. 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.

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LEGAL PROVISIONS REGARDING SAFETY T E FACTORIES ACT 19487KH)DFWRULHV$FWSXWVHPSKDVLVRQ WKHIROORZLQJVDIHW\SURYLVLRQIURPVHFWLRQ+6HFWLRQ $WR+FRPHVDIWHUWKH%KRSDO*DVWUDJHG\21. Fencing of Machinery.37

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 cottonopeners. 28. Hoists and Lifts. 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.38

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. 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.

7KHH[WUDFWVRIWKLVSURYLVLRQDUHJLYHQEHORZ

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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.39

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. :RUNRQRUQHDUPDFKLQHU\LQPRWLRQ

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 operations, while the machinery is in motion such examination shall be made. (PSOR\PHQWRI\RXQJSHUVRQVRQ

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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.

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6WULNLQJJHDUDQGGHYLFHIRUFXWWLQJRII

SRZHU

(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 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. 6HOIDFWLQJPDFKLQHV

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.41

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(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. (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. 3URKLELWLRQRIHPSOR\PHQWRIZRPHQ

FKLOGUHQQHDUFRWWRQ No women or child shall be employed inany 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.42

+RLVWVDQG/LIWV

(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. 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, namelya) 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

43

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 UL

RA EC

CEMEN LIMITED and the details are as follows: - They have 2electrical 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. /LIWLQJPDFKLQHVFKDLQVURSHVOLIWLQJ

WDFNOHV

(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 materialsa) All parts including the working gear, whether fixed or movable of every lifting machine. 5HYROYLQJPDFKLQHU\

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 pulley44

upon such shaft or spindle necessary to secure such safe working peripheral speed. 3UHVVXUH3ODQW

(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/cm. These pressure plants are tested by the competent person authorized by Chief Inspector of Factories. The test certificates are available at safety department. )ORRUV6WDLUVPHDQVRIDFFHVV

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.

45

3LWV6XPSV2SHQLQJVLQIORRUHWF

(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. ([FHVVLYH:HLJKWV

(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 bymen is 55kg. No women or children are employed in this unit. 3URWHFWLRQRI(\HV

In respect of any such manufacturing46

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. 3UHFDXWLRQVDJDLQVWGDQJHURXV)XPHV*DVHV

HWF (1) No person shall be required or allowed to enter anychamber, 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 apparatus and a belt securely attached to a rope the free end of which is held by a person outside the confined space. $3UHFDXWLRQVUHJDUGLQJWKHXVHRISRWDEOH

HOHFWULFOLJKW 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, no47

lamp other than that of flame proof construction shall be permitted to be used therein. ([SORVLYHRU,QIODPPDEOHGXVWJDVHWF

(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 stopvalve or other means; b) before any such fastening as aforesaid is removed, all practicable measures shall be taken to reduce the pressure 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. 3UHFDXWLRQLQFDVHRI)LUH48

(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. 3RZHUWRUHTXLUHVSHFLILFDWLRQRIGHIHFWLYH

SDUWVRUWHVWRIVWDELOLW\ If it appears to the Inspector that anybuilding 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. 6DIHW\RI%XLOGLQJ0DFKLQHU\

(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 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.49

$0DLQWHQDQFHRI%XLOGLQJ

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. %6DIHW\2IILFHUV

(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. 3RZHUWRPDNH5XOHVWRVXSSOHPHQWWKLVFKDSWHU

The State Government may make rules requiring to the provisions in anyfactory or in any class or description of factories of such further for securing the safety of persons employed therein as it may deem necessary. $&RQVWLWXWLRQRI6LWH$SSUDLVDO&RPPLWWHHV

(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 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 the50

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. %&RPSXOVRU\GLVFORVXUHRI,QIRUPDWLRQE\WKH

2FFXSLHU (1) The occupier of every factory involving a hazardousprocess 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. &6SHFLILF5HVSRQVLELOLW\RIWKH2FFXSLHULQ

UHODWLRQWR+D]DUGRXVSURFHVV Every occupier of the factoryinvolving 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. '3RZHURI&HQWUDO*RYHUQPHQWWRDSSRLQW

,QTXLU\&RPPLWWHH (1) Central Government may, in the event ofthe occurrence of an extraordinary situation involving a factory engaged51

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. ((PHUJHQF\6WDQGDUGV

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. )3HUPLVVLEOHOLPLWVRI([SRVXUHRI&KHPLFDO

7R[LFVXEVWDQFH (1) The maximum permissible threshold limitsof 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. *:RUNHUV3DUWLFLSDWLRQLQ6DIHW\

0DQDJHPHQW (1) The occupier in every factory where anhazardous 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. +5LJKWRIZRUNHUVWRZDUQDERXW,PPLQHQW

'DQJHU (1) Where the workers employed in any factory engaged in52

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.

ULTRATEC CEMENT LIMITEDealth and Sa ety Poli y (Rule 63 B o W.B Fa tories Rules, 1958) $ 2%-(&7,9( Management of Ultra Tech Cement Ltd. West Bengal Cement Works is engaged in manufacturing of Portland Slog Cement (PSC) & Pozzollon Portland cement (PPC). Management is committed to provide safe and healthy environment to all its employees and associates engaged in the activity of production directly or indirectly.53

To achieve this object HEALTH AND SAFETY POLICY is being formulated as follow:-

% 7+(32/,&