APPENDIX 4

GC3 – THE HEALTH AND Candidate’s observation

SAFETY PRACTICAL APPLICATION sheet

Sheet number 01 of 03

Student name: Velmurugan Dhandapani Student number: 00262515

Place inspected: Tube Investment of India ltd Date of inspection: 10 / 12 / 2014

Observations Control measures Timescale

Hazards and consequences Immediate and longer term actions
1. When I entered the company the
atmosphere were clean and green.

2. Fall hazard.
In the company they extend their plant, • Give proper instruction regarding, how One day
in the new plant someone working to work with ladder.
in height on ladder without proper • Instruct all about how to work with One week
instruction. It may leads to fall down. ladder.

3. Electrical hazard.
In the same plant the wires were in • Instruct them to do necessary 2 hours
improper insulated condition. These insulation and personal protective
wires can cause severe shock. equipment. One week
• Use residual circuit breaker.
4. Fall in excavation.
Beside the new plant there were One day
excavation work in progress, there • Do proper barricading. 10 days
is no trench box and no barricading • Use trench box and battering
signage. equipment.
There is more chance for fall in
excavation.
One day
5. Trip hazard. • Hang over the wires and ropes in
Near to the excavation there are wires certain height if possible. 3 days
and ropes over the surface. The trip • Buried the wires and ropes with
will leads to injuries. suitable pipes.

6. Striking with vehicle. • Make designated route for pedestrians 5 days

In the new plant there is no designated and vehicle.
route for pedestrians and vehicle. • Make temporary fencing with safety 15 days
Chances for more accident. sign boards.

7. Manual handling. • Give instruction and training how to 5days

In the new plant a worker carrying carry the load and depicting posters
materials more than there capability, in and correct technical displays. 10 days
improper stacking. These could result • Use trolleys or mechanical equipment.
in cuts, burns and bone dislocation.

5 days
8. Personnel protective equipment. • Give necessary personnel protective
In the construction some workers equipment. One week
they not using personnel protective • Give proper training and instruction
equipment. how to use personnel protective
equipment.
Immediate
9. Entrapment and fly objects. One week
In the same construction, the manual • Stop the work.
portable cutting machine is running • Make suitable and stable guards.
without guards.
One week
10. Vehicle collision with building 15 days
structure. • Provide trained banks man 20 days
A crane reversing without alarm and • Fix reverse alarm
beacon lights. Building can damage • Give more importance for vehicle
and chances for collapse. maintenance.
 Immediate
11.Welfare facility
The water distribution systems are not • Replace the contaminants parts 15 days
maintained properly in the workplace. immediately.
• Do proper maintenance and regular
inspection.
Immediate
12. Eye and face injury.
In the work place an operator working • Force him to use face visor. One week
without face visor in grinding machine. • Give necessary training about,
Personnel protective equipment. One week
• Give tool box talk.

13. Electrocution. Immediate

The operator working with defective • Disconnect the service. One day
drilling machine. • The dangerous state of flex should be
removed.

14. Slipping. Immediate

The oil spillage around the machine in • The oil spillage should be cleaned as
workplace. soon as possible. 10 days
• Implement cleaning regime.

One day
15. Falling objects. • Rearrange the stacking materials. 15 days
In a store room stacking is not in • Provide additional racks.
proper way.

20 days
16. In adequate ventilation. • Install automatic mechanical
In workplace ventilation is very less. ventilators.

Immediate
17. Fire extinguishers.
The fire extinguishers are not in good • Inspect all fire extinguishers daily and 12days
condition. report management.
• Replace or refill unconditioned fire
extinguisher.
One day
18. Flammable substance.
Welding work done over the wooden • Provide fire retardant material and
table, which is not fire proof Instruct them work over the fireproof
material. -
19. The sanitation and washing area
is good and clean with necessary -
facilities.

20. The canteen is provided with all -

facilities and good housing keeping.
-
Immediate
21. Waste disposal.
The waste disposal which is rear to • Waste disposal should be stored away 20 days
plant is not in safe storage. from work place.
• The disposal should be stored with
legal requirement of the government.
7 Days
22. Vehicle obstructs.
The loading and unloading bay is with • Make surface with even surface and
uneven surface. stable.

Immediate
23. Noise.
An air compressor and other • Control the noise level by regular 5 Days
machineries releases more noise, maintenance.
which cause stress to human. • Fix any silencing device to control the 5 Days
noise level.
• Provide personnel protective
equipment.

24. Dust. 3 Days

In black smithy foundry, the flying ash
is very high in atmosphere, it leads to
• Instruct the workers to follow the
proper PPE 7 Days
• Monitor the dust level by means of 20 Days
engineering controls.
• Install local exhaust ventilators

25. Smoke. Daily

The diesel power generator exhibit • Do routine maintenance. 10 days
more smoke. • Filter the smoke by engineering control
method.

26. All circumstance in the company,

the emergency escape routes and -
signage’s and assembly point are in -
betterment way.

27. The gate securities never fail to -

check in and out of the employees and -
goods vehicles.
APPENDIX 5

UNIT GC3 – THE HEALTH AND Candidate report template

SAFETY PRACTICAL APPLICATION

Student number: 00262515

Location: Company work place Date of review: 13/12/2014

Structure report under the following headings:

Introduction including overview of area inspected and activities taking place

The health and safety inspection was carried out by me on 10th of November 2014 between 10am
– 12 noon at Tubes investment India ltd which located in Chennai. Tube products of India was
established in 1955, in collaboration with tube products limited- UK, as a measure of backward
integration with the bicycle plant in 1959, tube investment of India(TII) was formed by merging TI
Cycle of India and tube product of India. TPI is the most preferred supplier of precious tubes, Electric
resistance welded and cold drawn welded, to major automotive companies in India and abroad. The
stainless steel tube is the recent addition to TPI’s portfolio. TPI has received ISO-TS16949 for all
plants, ISO 9001:2000 for all plants, ISO 14001:2004 for Avadi, Chennai. IBD and stainless steel tube
plants, and self-certification for boiler tubes by the central boiler board. The group has 28 business
including 11 listed companies traded in NSE and BSE, headquartered in Chennai.

The organization fosters an environment of professionalism and has a work force of over 32,000
employees. In the organization they give first priority to health and safety for employees and
environment. On inspection time the following activities were progress inside the new plant, the
construction work, excavation work, electric work, painting work and other construction allied work. In
machinery shop the production work, assembly work, maintenance work and manual handling were in
progress.

Executive Summary

I am really thankful for Tube investment India limited for giving such a nice opportunity for my career
growth through the health and safety inspection analysis. The inspection was carried out on 10th of
November 2014 at Tube investment India limited in Chennai. They are the manufacturers of stainless
steel tube for automotive industries in India and abroad for past 50 years. On inspection time the
following activities were progress inside the new plant like: construction work, excavation work,
electric work, painting work and other construction allied work. In machinery shop the production
work, assembly work, maintenance work and manual handling were in progress.

The main objective of the inspection was to identify prevalent health and safety hazards which may
cause harm to health or injuries to human. The inspection reveals clearly, that there are very serious
hazards were found in company. The major area of the concern is manufacturing unit, where in
chances for electrocution, dust, noise, entrapment, entanglement, ventilation and more, especially
welfare facility and waste disposal are the main factors to consider. The other point of view, which
has minimum potential to human injuries, in the same way more potential loss in business, if company
fails to provide welfare facility, the management commitment about health and safety should be
strongly recommended that immediate action is undertaken to safe the company’s financial, social
and moral interrupts. The overall cost for implement our requirement in the company is Rupees- 9.75
lakhs approximately.
Main findings of the inspection

2 Fall hazards in pedestrian walk ways: The pedestrian walk ways always free from any destruction,
because there are more chances for injuries, striking with vehicle can leads to human loss (Death)
and damage to building structure. All the employees of company are using walk ways for their
all access. So the walk ways should be provided with roofing’s, barricading, good housekeeping,
free from vehicle movement, falling object, trip and slip and poor lightings. The Workmen's
Compensation Act 1923 requires that compensation is paid if workers are injured in the course of
employment for injuries, or benefits to dependants.

7. Manual handling: The manual handling is an activity that takes place in most work places. Often
manual handling is a routine part of day-to-day work activity. The manual handling could result in cuts,
burns, injuries, back injuries, muscle injuries, and accident. The building and other construction
workers act 1996, and the labour act 1975 will leads more action against the management. To
overcome these all, the suitable and sufficient mechanically operated equipment like: pallet truck, keg
truck, self-trolley, hydraulic lifters, etc., should need to provide and modify the task, load, environment
conditions and individual capability. And also give proper training and safe lifting technic. To buy
mechanically operated vehicles the cost around Rupees – 50,000/- for basic vehicle and Rupees –
2.5 lakh for modern technology vehicles.

9. Entrapment and fly objects: The cutting machines always should be provided with safe guards, if
fails to provide it may cause entrapment of worker and fly object can cause more injuries and chances
for human attribute loss, to avoid these all the machineries should be provided with suitable guards
and instruction about use of machines and maintenance.

10. Collision with vehicle: In the work place collision with vehicle are major issues in now-a-days,
because there are many injuries, accident, and damage to machineries, building structure and with
other vehicles too. To control this, make contemporary pedestrian walk way design, avoid over
speeding, the load could not affect the driver and the vehicle should be maintained regularly as per
manufactures instruction. The new designed vehicles can minimise the rate of accident in the work
place.

18. Flammable substance: The flammable substance must be used and stored with appropriate care
to minimise the associated fire risk, the flammable substance should be displayed with warning sign
and MANUFACTURERS SAFETY DATA SHEET. The flammable substance like: petrol, oil, solvent
and the gaseous flammable like: acetylene, methane, propane are should separate and store with
minimum quantity. Otherwise The Indian explosive substances act, 1908 will forced against any
explosion in company. The minimum cost for temporary arrangement Rs-25,000/- and Rs-2, 00,000/-
for permanent recovery.

21. Waste disposal: The waste disposal can be managed by adopting simple procedure like reusing,
recycling, and other recovery methods. If it is not possible for recovery process, the waste disposal
should be stored in separate area. The unsafe handling and storage of waste may leads to breaches
of law and it could end with termination of company licence as per The Environment Protection Act
1986. So is this necessary to build a new segregation for waste disposal, the cost about Rupees -
3lakh.

24. Dust control: The substance is breathed in through the nose and mouth and down into the lungs.
The dust can cause skin defect through absorption, injection, ingestion. In many ways dust can
cause ill-health to human, these can result in Asthma, carcinogens, mutagens and death at the end,
The labour act 1975 and The Environment Protection Act 1986 may leads legal action against
company. To overcome this all, the proper Personnel Protective Equipment must be provided and in
the same way some mechanically operated local exhaust ventilator, Dilution ventilation, air respiratory
system should be installed where ever is possible.
Conclusions

The health and safety inspection was carried out with the intent to identifying the extent of
implementation of health and safety policies and procedures in our company and the activities which
have the more possibilities to cause serious dangers to our company.

I hereby recommend to the management keeping view of our strong and continual commitment
towards safe system of health and safety. I noted that the employees in our company, owing to tough
work pattern and job nature. We have lapses in implementing health and safety.

The company has to provide suitable and sufficient equipment, which make free from hazards to
employees, the worker feel happy in work place, more profit for company and zero accidents.

Recommendations – include as a table in the following format:

Recommendation Likely resource implications Priority Target date

2. Fall hazards in Required resources:
pedestrian walk ways: 1. Barricading tape, net and
walk ways should be make alternative walk ways.
provided with roofing’s,
barricading, good 2.Provide security guard High 5 to 10 Days
housekeeping, free from
vehicle movement, falling Cost: Rupees - 25,000/
object, trip and slip and
poor lightings
7. Manual handling: Required resources:
The suitable and 1. Pallet truck, keg truck, self-
sufficient mechanically trolley, hydraulic lifters.
operated equipment High 1 month
and vehicle should be
providing. Cost: Rupees – 2lakhs

9. Entrapment and fly Required resources:

objects: 1. Fix automatic or adjustable
All the machineries guards, which can withstand for
should be provided with long period.
suitable guards.
2. Provide Personnel protective High 3 to 7 Days
equipment

Cost: Rupees – 40,000/-

10. Collision with Required resources:

vehicle: 1. Appoint competent person to
Make contemporary operate the vehicle. High 15 Days
pedestrian walk ways and 2. Appoint banks man.
path way design, avoid
over speeding. Cost: Rupees – 60,000/-

18. Flammable Required resources:

substance: 1. Allocate separate store area
The flammable substance for different types of flammable
should be displayed with substance. High One month
warning sign and should
be stored in separate 2. Build fire retardant store area.
place.
Cost: Rupees – 1.5 lakh
21. Waste disposal: Required resources:
The waste disposal 1. Record and maintain all
should be stored in hazardous substance.
separate area. The
unsafe handling and 2. Build separate store area, High One month
storage of waste may which not make potential to
leads to breaches of laws. human and environment.

Cost: Rupees – 3 lakh.

24. Dust control: Required resources:
Mechanically operated 1.Eliminate the dust hazards
local exhaust ventilator, by installing LOCAL EXAUST
Dilution ventilation, air VENTILATORS,
respiratory system should 2. Provide personnel protective High 20 Days
be installed where ever is equipment.
possible. 3. Do periodical health survey.

Cost: Rupees – 2lakh.

 mark.
APPENDIX 6

Marks to be awarded
11 - 15 6 - 10 1- 5

1.1 4-5 different types of 2-3 different types of 1 type of hazard

hazards outlined hazards outlined outlined
Range and outline
of hazards and 14-20 uncontrolled 7-13 uncontrolled 1-6 uncontrolled
consequences hazards / hazards / hazards /
consequences consequences consequences outlined
outlined outlined
1

Completion of 11 - 15 6 - 10 1-5
observation sheets
1.2
Immediate and longer- Identification of Reference to immediate
Identification of term actions identified immediate and longer actions only
GC3 Marking Matrix

suitable control for majority of hazards term actions for some

measures and of the identified
timescales hazards

Majority of Some recommended Recommended actions

recommended actions actions generally limited in reducing risk
effective in reducing effective in reducing and unrealistic in terms
risk and realistic in risk and realistic in of timescales
terms of timescales terms of timescales

1. Typical issues are listed in Table 1 and internal assessors must complete Table 1 to assist in allocating marks.
For each element, 0 marks should be awarded if that aspect of the report fails to meet the criteria for 1
 Marks to be awarded
4-5 2-3 1

2.1
Clear and appropriate Some description of Limited description of
Introduction description of the the chosen area and the chosen area and
providing an chosen area and of of the activities in lack of details on the
overview of the the activities occurring area activities taking place in
chosen area in the area area
2

Management
Report –
4-5 2-3 1
Introduction and
Executive
Summary
2.2 Concise overview of Overview of some Limited overview
important points and important points and
Executive Summary main conclusions / some conclusions /
recommendations recommendations
 Marks to be awarded
11-15 6-10 1-5

Logical progression Logical progression Limited progression from

from the from the observation the observation sheets and
3 observation sheets sheets but some duplication of observation
3.1 does not duplicate duplication of sheets
observation sheets observation sheets
Management
Quality of Majority of key Some key issues Minority of the key issues
Report –
interpretation of issues identified in identified in the observation
findings identified in observation sheets sheets have been
Main findings of
observation sheets have been appropriately selected and
the inspection
have been appropriately discussed
appropriately selected and
selected and discussed
discussed
 5 4 3 2 1

Appropriate references Appropriate references Appropriate references to Appropriate references to A list of international
to 5 possible breaches to 4 possible breaches 3 possible breaches of 2 possible breaches of standards with no
of international of international international standards international standards explanation of how
3.2 standards with a clear standards with a clear with a clear understanding with a clear the international
understanding of the understanding of the of the reasons for the understanding of the standards were
Identification of reasons for the reasons for the breaches reasons for the breaches breached, or how
possible breaches of breaches breaches they relate to the
legislation and/or hazards, unsafe
international conditions or work
standards practices selected
 Marks to be awarded
8-10 4-7 1-3

Clear legal, moral Some legal, moral Limited legal, moral and
and financial and financial financial arguments
arguments arguments

3 3.3 Convinces Some persuasion in Limited persuasiveness in

management to management action management action
take action
Management Persuasiveness/
Report- conciseness / Report is well Report is reasonably Report is poorly structured
technical content structured and well structured
Main findings of appropriate length
the inspection
 Marks to be awarded
11 - 15 6 - 10 1- 5

4.1 Findings identified in report Logical progression from the Limited progression from the
summarised clearly and report report
Clear and concise concisely
4 conclusions which are
clearly related to report Relevant and Some key issues Limited discussion of the
findings and are appropriate information identified in report have key issues identified in the
Management effective in convincing provided to persuade been appropriately report
Report – management to take management to take discussed
actions actions
Conclusions and
Recommendations

11 - 15 6 - 10 1–5

4.2 Recommendations based Most recommendations Limited progression from

upon conclusions follow on from the conclusions
Recommendations conclusions
which present realistic
actions to improve Realistic Most recommendations are Recommendations not
health and safety in the recommendations and realistic all realistic
chosen area target dates

Appropriately Some attempt at No prioritisation

prioritised prioritisation
recommendations

Appropriate resource Appropriate resource Limited resource implications

implications for all implications for most
recommendations recommendations
 TABLE 1
1. and 2. Range of issues identified and number of hazards
Issues description Issue range Number of hazards Comments
( if covered) identified
1. Electricity
2. Ergonomics
3. Falling objects
4. Fire
5. First Aid
6. Good practice
7. Hazardous substances
8. Housekeeping
9. Information
10. Machinery
11. Manual handling
12. Noise
13. Obstructions / trailing cables
14. Personal Protective
Equipment
15. Signage
16. Vehicles / routes
17. Vibration
18. Welfare / hygiene
19. Work at height
20. Work environment
21. Any other appropriate

TOTAL