SAFETY IS A WAY OF LIFE IN

TATA SPONGE

TATA Sponge -Operation in harmony with nature Presented By :

Mr. M. R. Dutta

TATA SPONGE IRON

LTD. Corporate Office

TATA SPONGE IRON LTD.

▪ In the Orissa province (Eastern part of India)

▪ 275 KMs from the State Capital

▪ Remote mining cum agriculture area

02

COMPANY LOCATION

• Year1982: started as a joint

venture

company between TATA Steel

and

IPICOL, Govt. of Orissa

• 1985: Kiln # 1 commissioned

• Production capacity: 90,000 MTA

• 1990: Capacity enhanced to 120,000

MTA

• 1998: Kiln # 2 commissioned

• Production capacity: 240,000

MTA

• 2001: WHRB Power Plant

• Capacity: 7.5 MW

• 2006: Kiln 3

commissioned

• Capacity: 390,000 MTA

• 2006: 18.5 MW Power

Plant added

• 2007:

220 KV Power GRID

Employee strength : 421 Contractor Workforce: 650

03

Products Facilities available

Annual Production Capacity

Sponge Iron Rotary kiln 3,90,000 MT

Power WHRB Power Plant

26 MW (7.5 +18.5) MW

TPM Award JIPM-2012

OHSAS 18001 Feb, 2009

ISO-14001 March, 2003

ISO 9001 Oct,1994

CDM Benefit from UNFCCC

Indian Coal

based Sponge

Iron Company

to receive

1 st

TATA SPONGE – SAFETY EXCELLENCE JOURNEY

SAFETY AND HEALTH POLICY

The Tata Sponge is committed to providing a safe and healthy working environment and achieving an injury and

illness free workplace. Economic considerations will not have priority over implementation of safety and health

protection measures. While safety is everyone’s prime responsibility, senior leaders are expected to demonstrate

visible commitment through their behaviour. To meet our commitment, we will;

∙ Recognise safety and health as an integral part of our operations; consider safety and health in every decision

we make and in every activity we perform

∙ Comply and endeavour to exceed applicable regulatory safety and health requirements and set the highest

standards.

∙ Impart appropriate training and develop skills by engaging employees to help them work safely

∙ Assess risks and provide controls for safety and health hazards in our operations and use audits to check

compliance

∙ Promptly report incidents, investigate for root causes and ensure lessons learnt are shared and deployed

across group companies

∙ Influence our business partners in enhancing their safety and health standards.

∙ Set safety and health metrics as indicators of excellence, monitor progress and continually improve

performance

We aspire to become industry leaders and be a benchmark in safety and health performance

22nd May, 2015 DP

Deshpande

Managing Director

Policy & Objective:

SAFETY OBJECTIVE – “INJURY & ILLNESS FREE WORK PLACE” 04

SHE OBJECTIVES

Safety & Health Policy Environment Policy

Zero Injury Zero Occupational Health

Hazard Clean Environment

Risk Assessment, safety

inspection, training, Du Pont

safety culture, participation,

R&R, Audit & Review

Health check-up, sanitation,

awareness programmes

Aspect Impact study,

environment management

program, monitoring &

measurement, compliance,

environment audit

Deploy plan & measure

results

Conduct RCA for

gaps

Corrective & preventive

action

BASIC SHE APPROCH

05

6

SAFETY DEPLOYMENT PROCESS

Monitor &

measure Identify Gaps

Analyze Root

Cause

Prepare

action plan Re-Deploy

Computerized Safety Information Management System (SIMS)

Formulate SHE Policy

Prepare Safety Objective

Formulate Safety Committees

Prepare Safety Standards

Deploy Processes, Standards

and Procedures

• Factory Act, Labour Laws, State statutory guidelines

• ISO/OHSAS/DuPont System • Tata values, group policies • Company goals, objectives and

targets • Learning from past • Best practices, Bench Marking

with other national /international industries

•LTIFR

•First Aid

Case

• Violation of

Statutory

norms

Z

E

R

O

INPUT PROCESS STEPS OUTPUT

06

7

Company Objective Dept. Objective KPIs Target Linkage with ABP

INJURY & ILLNESS FREE WORK PLACE

To help the Company to achieve Zero LTIFR

Safety observation by Sr. leader, Management team & Associate team

100% 1.3

Safety fugaies identified vs. solved 100% 1.4

Near miss reported vs. solved 100% 1.16

Implemented corrective action 100% 1.12

To help the Company to achieve Zero First aid case

Training to employee as per plan 100% 2.3

Training to Contractor employee as per plan 100% 2.3

Health check up employee 100% 1.17

Health check up contractor employee 100% 1.17

Testing of all tools, tackles & pressure vessels 100% 2.3

Compliance to Mock drills as per plan 100% 1.11

No. of gaps identified Vrs. closed In mock drill 100% 1.11

% Compliance to inspection plan of all Fire fighting equipment (Extinguishers, hydrant, etc.)

100% 1.9

No. of gaps identified and solved during inspection 1.10

Zero Statutory Violation on account of Factories Act

Statutory compliance through E-enforce 100% 3.1

Compliance of Govt. agencies observation points 100% 3.2

SAFETY KPIs TO ACHIVE OBJECTIVES

07

Key Initiatives: • Adoption of Du Pont safety Management System.

• Safety Tree

• Safety Green Cross

• Tool Box Meeting

• Awareness & Training(Aadhar for Contract Employees, Training on Safety Standard, Awareness to community )

• IT Based Safety Information system.

• Mock Drills at regular intervals

• Improvement & Kaizens

• Reward & Recognition 08

Du Pont Safety Management System:

• Basic Beliefs: i) All injuries can be prevented

ii) All injuries must be reported immediately

Visible Felt Leadership

Safety Organization

• Safety Observations (Interact with people to eliminate unsafe act and enhance safe behavior )

• Contractor Management

1,2,3

, 4 &

5

09

Incident Investigation Process

1

2

3

4

5

Preliminary Incident Report (Prepare by Area In-charge & Submitted to Dept. Head & Head Safety within 24 hr)

Occurrence of Incident (LTI, FAC, NM)

Team Formation (Dept. Head consultation with Safety Head)

Incident investigation & Report generation (IISC approved the report)

Lesson learnt from the incident & Horizontal deployment

Chronology of Event • Event Description • Date, Time

Determining Facts • Samples/ relevant materials • Field photograph, video,

graphics, etc. • Eye-witness interviews • Documents verif ication • Condition of Equipment/

machine • Background data • Any change/ deviation

Why Tree Analysis • Root Cause Failure

Analysis

Determining Key Factors • Physical Factors • Human Factors • System Factors

System to be Strengthened

Process Technology/ Risk Analysis/ SOCP/

Management of Change/ Communication, Training

& Performance/ Contractor Safety/

Emergency Planning & Response/ Observation

& Auditing/ Safety Inspection/ Safety

Leadership

Recommending Actions • Corrective and

Preventive Actions for avoid reoccurrence

Communicating Findings (Lesson

Learnt)

Safety Observation / Tool box talk/ E-mails/ SIMS portal/ Notice Boards/

Departmental Meetings/ Safety Pause/ Corporate Communication/ Circular,

etc.

Follow up • Recommendation

Closure and Deployment Audit

10

Innovation- First aid tree

First aid tree shows first aid free man hrs.

First aid tree grow without first aid First aid tree fall due to first aid case

11

• Safety Green Cross for visual display of safety incidents

• Trousers and shirts for all women employees instead of sarees or loose dress

Best Practices – Safety

12

• Tool Box Meeting prior to start of any job

Awareness and Training: (Contract Employees)

AADHAR : A Training Programme for Contract Workforce Learning & Development

Objectives :

To educate unskilled/contract laborers with the current developments in

industrial operation.

To improve current and potential unskilled laborers’ performance by

increasing their skill and knowledge by changing their attitude towards

their job.

To address their skill needs, by keeping them current with the changing

needs.

To make them aware to be safe in job as well as in their day to day life.

To involve the contract laborers in all basic operational activities of the

company

To motivate and reward and recognize contract workforce in all

achievement by involving them in organizational improvement activities.

To apprise them of their ethical rights and how to exercise the same

To encouraging their involvement in abating carbon footprint

Results:

Tar vs. Act

13

……..continues

Training on Behaviour Safety Safety awareness program at petrol pump

Safety Booklets for Drivers Training to Truck Drivers at

NH Training to Contractor workforce

14

IT based Safety Information Management system:

Mock Drill at regular intervals

15

Theme Problem statement Proposed actions Result / Out comes

Elimination of

Repeated safety

Fugais

During safety observation visit the following natures of fugaies are identified. Drain cover-104 Guard-142 Cable-171 Earthing-63 PPE-28 Isolator-28 JB-18

Theme based safety observation

Assign the responsibility to shift in-charge to solve the problem by analysis & implementation

Implemented award system for reduction of fugaies (department wise)

Implemented measurement slip for contractor job in every day basis

Chain are fixed in all the conveyor guards

Vital few

Useful many

ELECTRICAL

MECHANICAL

CIVIL E & I

Repetitive nature of safety Fuguais.

CABLE

DRAIN COVER

PPE

EARTHING

ISOLATOR

JB

CABLE

ISOLATOR

JB

GUARDING

PPE

PPE

PPE

Cause-Effect

Analysis

Pareto

Analysis

Problem solving

16

Analysis:

KAIZEN Theme :To Ensure safe fabrication in the plant Idea : Provision of fire extinguisher stand with gas cylinder trolley

Activity JH PM KK QM SHE E&T IFC /DM OTPM

Result Area P Q C D S M

Equipment/Area/Location : WORKSHOP

Team :(Name,Emp.No)

•Mr. N.K LOHAR(1147) •Mr. S.B MOHANTY

•Mr. S. K. DASH

Kzn.Start Date :20/12/15

Kzn.Finish Date 26/12/15

Analysis : (Why-Why) :

Problem / Before Improvement:

Countermeasure/After Improvement:

Results :

Benefits : •Safe approach •Operation friendly •Moral boosting. Horizontal deployment At all gas cylinder trolley in workshop

KAIZEN IDEA SHEET

Fire hazard during gas cutting

WHY

Non availability of Fire fighting facility at various locations

WHY

Difficulties to carry fire fighting equipment always

WHY

No provision to fix fire fighting equipment with gas cutting set

WHY

Fixing of fire extinguisher at trolley was not envisaged.

GOOD

No safe approach for taking Fire Extinguisher with Gas

cylinder trolley. Portable f ire extinguisher stand attach with trolley

100%

0

KAIZENS

17

• Photo Identity and PPE are mandatory for the Gate Entry

• Face Detection based employee attendance system to restrict unauthorized entry

• Positive Isolation – before undertaking jobs at site - Lock Out and Tag Out

• Safety Induction Training to visitors and Contractors

OtherBest Practices - Safety

18

• Safety Quiz competition for Contractors

Safety month celebration with Reward & Recognition:

Safety Oath in the celebration Safety Nukad by Employees

Poster competition among children Reward & Recognition

Training to Township ladies

Instant Quiz competition 19

Health Check-up of Contractor workmen

Malaria prevention Activities

Dengu prevention job in progress

Yoga Practice in Progress Dengu awareness Camp. Blood Donation Camp

Regular fogging in township & Plant

Best Practices - Health

20

Health Report Normal Moderate Risk High Risk

BMI 54.49% BMI < 25

39.10% BMI 25 – 30

6.41% BMI > 30

Blood Pressure 41.33%

120/80 or less 49.11%

121-139/81-89 9.56%

> 140/90

Cholesterol 80.30%

< 200mg/dl 13.74%

200-300 mg/dl 5.96%

> 300mg/dl

Sugar Level 73.82%

< 140mg/dl 13.73%

140 – 199mg/dl 12.45%

> 200mg/dl

Health Status as on December 2015

Total Strength of employees at Joda 421

Total (4 criteria) health checkup done 421

Sample Size : 100 %

Avg Co Health Index : 3.35/4

ZERO Malaria cases in TSIL

township since 2011

21

5 6

8

10 9

3

7

1

2

4

Location Dust

Level

(in

µg/m3)

Norm: 2000 µg/m3

1 I.Ore hopper area

619

2 Coal hopper area

883 3. I.Ore crusher area

920

4. Coal Crushere area

1058

5. K-I ISB area 1321

6 K-1 Disch area

791

7 K-2 ISB area

1265

11

KEY INITIATIVES (Dust Mapping at Plant area)

Focused Hazards : Dust

Identified Areas Measures in place

RM Yard Dust suppression through water Tanker, Water monitors, Boundary wall etc.

Coal Circuit Fogging system, Chemical dust suppression system, Enclosed circuit, Cleaning chutes.

Iron Ore circuit Water suppression system, enclosed circuit, cleaning chutes

FP circuit DE system, Enclosed circuit

ISB Areas DE system, Water monitor

Bagging Machine Dust extraction system,

Unloading areas Unloading spouts, Water jacketing with pressurised water

Weighbridge area Road dust suppression

NB: Required PPEs (Nose mask, Safety Goggles, Eye wash shower, etc.) are provided in each area

• State-of-the-art ESP units

• Dust Extraction systems

• Pneumatic conveying systems for all DE and ESP units

• Chemical dust suppression system

• Retrievable unloading spouts with water jacketting system

• Road vacuum cleaning machines

• Water sprinklers on roads, RM yards and Railway siding

• Concreting of major plant areas

• Covering waste mounds and sweet soil and plantation

22

DUST MANAGMENT

23

> 90 dB

Area-PCC

BL 1,,2,3, 89- 85 dB

Area

79 - 75 dB

Area 74-70 dB

Area

84 - 80 dB

Area

Norm : 90 dB for 8 hour exposure

time

KEY INITIATIVES (Noise Mapping at Plant area)

Focused Hazards : Noise

Identified Areas

Measures in place

TG

Enclosure at 18.5 MW TG, Display of Noise level and signage, SOP/Signage in place. PPEs.

PCC Blowers SOP in place

Crusher area

Enclosing the crusher platform with proper material

We are here

Tata Sponge Performance

TATA SPONGE PERFORMANACE-NOW

24

RESULT (Safety)

25

And the Journey Continues

End of Presentation

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