Safety first!
Hello, industry professionals! I am trying my best to give you some valuable inputs on industrial safety. I am very surprised that many people still have confusion about the meaning, significance and applications of industrial safety. This article is highly useful for the industry professionals for all kinds of industries including corrugation, offset printing & packaging, flexible packaging, paper packaging, paper mills and broadly applicable to most of the industries. But, some specific safety instructions, safety practices are required according to the nature of products, processes of a specific nature of industry like chemical, electrical or others etc. Regarding the corrugation industry some specific areas of safety is concerned as follows: The corrugation industry involves the production of corrugated cardboard sheets, boxes, and packaging materials. While it’s a vital sector, the processes entail several safety risks. Unfortunately, still, we are noticing number of fire and accidents in many corrugation factories due to lack of safety awareness, safety training, safety manual and insufficient arrangement of installing safety equipment like fire extinguishers, PPE, fire alarms and emergency exits, first aid kits, loose wiring, improper grounding, and exposed cables etc……
Here are some essential safety concerns in the corrugation industry:
Heat Stress and Fatigue
- High temperatures: Machines like corrugators generate significant heat, especially in poorly ventilated facilities.
- Long shifts: Workers on extended shifts may experience fatigue, increasing accident risks.
Mitigation:
- Improve ventilation and provide cooling systems.
- Schedule breaks and limit overtime hours.
Noise Pollution
- High-speed corrugators and cutting machines generate significant noise levels, leading to hearing damage.
Mitigation:
- Install noise-dampening materials or barriers.
- Provide ear protection (e.g., earplugs or earmuffs) to workers, supervisors and others.
. Machine-Related Hazards
- Moving parts: Corrugators, slitters, and stackers have fast-moving rollers and blades, increasing risks of entanglement or cuts.
- Inadequate guarding: Machines without proper guards can lead to severe injuries.
- Crushing hazards: Large sheets and pallets can trap or crush workers if improperly handled.
Mitigation:
- Install machine guards and interlocking devices.
- Ensure proper Lockout/Tagout (LOTO) procedures during maintenance.
- Train workers on safe operating procedures.
Fire Hazards
- Highly flammable materials: Cardboard, paper dust, and adhesives increase the risk of fires.
- Electrical faults: Poorly maintained equipment can spark fires.
Mitigation:
- Install fire alarms, extinguishers, and sprinkler systems.
- Regularly inspect electrical equipment.
- Maintain proper ventilation to reduce dust accumulation.
Ergonomic Risks
- Manual handling of heavy loads: Workers frequently lift or move large and bulky sheets or stacks.
- Repetitive strain injuries: Continuous packaging or stacking tasks can lead to musculoskeletal disorders.
Mitigation:
- Use lifting aids and conveyors to reduce manual handling.
- Implement ergonomic workstations and rotate tasks.
Slip, Trip, and Fall Hazards
- Spilled adhesives or water: Can cause slippery surfaces.
- Obstructions in walkways: Equipment, pallets, or waste material can block paths, increasing the risk of trips and falls.
Mitigation:
- Maintain clean and organized floors.
- Mark walkways and ensure proper housekeeping practices.
Electrical Hazards
- Loose wiring, improper grounding, and exposed cables can cause shocks or short circuits.
Mitigation:
- Ensure regular inspections and electrical safety training.
- Use insulated tools and protective equipment.
Chemical Exposure
- Adhesives and solvents: Some glues and solvents used in laminating or printing contain hazardous chemicals.
- Dust inhalation: Paper dust can cause respiratory problems over time.
Mitigation:
- Provide adequate ventilation and dust collection systems.
- Issue Personal Protective Equipment (PPE) like masks and gloves.
- Use low-toxicity adhesives where possible.
Note: Safety awareness programmes, safety training, implementation, safety audit are highly important to sustain it. Build a strong safety culture.
Now, coming to the main subject: Industrial Safety:
The Industrial safety is basically a management activity which is concerned with
reducing, controlling and eliminating hazards from the industries or industrial units or work places.
Ideally it refers to the policies, procedures, and practices implemented to ensure the health and well-being of employees and prevent accidents in workplaces like factories,
manufacturing units, and industrial plants. It aims to safeguard people, property, and the environment from hazards arising in industrial operations.
Evolution of Industrial Safety:
Early Industrial Revolution (18th – 19th Century)
- Unsafe Working Conditions: The Industrial Revolution observed rapid factory growth with minimal attention to workers safety.
- High Accident Rates: Factories, mines, and mills exposed workers to dangerous machinery, toxic substances, long working hours and unhealthy working environment.
- Child Labor: Children were often employed, working in hazardous environments without the safety measures and precautions.
- Lack of Regulations: There were no safety laws or compensation systems in place.
Emergence of Safety Regulations (Late 19th – Early 20th Century)
- Factory Acts: In countries like the UK and India, early laws (e.g., UK Factory Acts of the 1800s) started setting standards for working conditions for the workers.
- Workers’ Unions: Organized labour movements began pushing for safer workplaces and better wages.
- Accident Reporting: Employers started documenting accidents, leading to awareness about workplace hazards.
- Workers’ Compensation Laws: These emerged to provide injured workers with financial support and medical care properly.
Rise of Safety Organizations and Standards (20th Century)
- Formation of OSHA (1970): In the U.S., the Occupational Safety and Health Administration (OSHA) was created to enforce safety standards.
- National Safety Council (1913): Established in the U.S. to promote workplace safety awareness and reduce injuries.
- Development of Safety Equipment: Helmets, gloves, goggles, and other protective equipment became more common.
- Safety Science Advances: Industrial engineers began applying scientific methods to reduce workplace hazards.
Post-War Industrialization and Technological Advances (1945–1970s)
- Automated Systems: Increased use of automation reduced human involvement in hazardous tasks.
- Environmental Safety Focus: Industrial accidents, like oil spills and chemical disasters, led to regulations on environmental safety.
- Introduction of Fire Safety Codes: Fire alarms, sprinkler systems, and emergency exits became mandatory in factories and plants.
- Behavioural Safety Models: Psychological studies on human error contributed to better safety training.
Modern Safety Practices (1980s–Present)
- Introduction of ISO Standards: ISO 45001 set international benchmarks for occupational health and safety management.
- Digital Safety Tools: IoT (Internet of Things) devices and sensors help monitor risks in real-time.
- AI and Predictive Analytics: AI systems predict potential hazards, reducing accidents.
- Focus on Ergonomics: Industrial safety evolved to consider the comfort and well-being of employees, reducing strain-related injuries.
- Stricter Environmental Regulations: Industries are required to limit emissions, handle hazardous waste properly, and prevent spills.
OBJECTIVES OF INDUSTRIAL SAFETY:
- to prevent accidents in the plant by reducing the hazard to minimum.
- to eliminate accident caused work stoppage and lost production.
- to achieve lower workmen’s compensation, insurance rates and reduce all other direct and indirect costs of accidents.
- to prevent loss of life, permanent disability and the loss of income of worker by eliminating causes of accidents.
- to evaluate employee’s morale by promoting safe work place and good working condition.
- to educate all members of the organization in continuous state of safety mindness
- to make supervision competent and intensely safety minded.
A safety programmed includes mainly following four E’s.
- Engineering: i.e safety at the design, equipment installation stage.
- Education: i.e. education of employees in safe practices.
- Enlistment: it concerns the attitude of the employees and management to
wards the programmed and its purpose. Ti is necessary to arouse the
interest of employees in accident prevention and safety consciousness.
- Encouragement: i.e. to enforce adherence to safe rules and practices.
Safety Organization:
Definition: safety organization may be defined as organization taking in the work of
accident prevention which means that it has to remove unsafe physical conditions and
substitute safety practices in the place of unsafe practices.
Essential Elements: the basic elements regarding the safety organization are as under;
- management leadership
- assignment of responsibility
- maintenance of safe working conditions
- establishment of safety training
- an accident record system
- medical and first aid system.
- acceptance of personal responsibilities by employees.
Management attitude: Top management attitude towards accident prevention is
reflected in the attitude of the supervisory force. Similarly, the workers attitude is
dependent on the supervisor. Therefore, the success of a program for prevention of
accidents will mainly rest on the interest taken by the top management.
Assignment of responsibility: It is of a paramount importance that assignment of full
responsibility should be given to someone for safety activities. It is usual to entrust this
function to general manager, workers manager or personnel manager but if there is full
time safety officer then this function is entrusted to him and he is usually answerable to a
top ranking officer such as Director or General manager.
Supervisor: In fact, the supervisor is the key person in any safety program. To the worker, he is the management. It is again the supervisor who has intimated knowledge of the
temperament, attitude, sense of responsibility, physical characteristics, skill, training, etc
of the workers. In other words, he has immediate control over them. Therefore, the
supervisor is indispensable (that is not be set aside) in any safety scheme and workers
success would depend upon the interest and participation of the supervisor. To achieve
the results, management should adopt the method of policy of associating safety as part
of good production methods and to make it known that bad safety record or poor safety
procedure by itself will be as a bad performance by management.
IMPORTANCE OF INDUSTRIAL SAFETY
- EMPLOYEE WELFARE: IT ENSURES THE PHYSICAL AND MENTAL HEALTH OF WORKERS, PREVENTING ACCIDENTS AND INJURIES.
- INCREASED PRODUCTIVITY: SAFE ENVIRONMENTS REDUCE DOWNTIME CAUSED BY ACCIDENTS, ENHANCING PRODUCTIVITY.
- FINANCIAL SAVINGS: PREVENTS COSTS ASSOCIATED WITH MEDICAL EXPENSES, COMPENSATION, AND LEGAL LIABILITIES.
- REPUTATION AND COMPLIANCE: COMPANIES THAT ADHERE TO SAFETY REGULATIONS BUILD TRUST AND AVOID PENALTIES.
- ENVIRONMENTAL PROTECTION: INDUSTRIAL SAFETY MEASURES PROTECT THE ENVIRONMENT BY PREVENTING LEAKS, SPILLS, AND TOXIC EMISSIONS.
COMMON INDUSTRIAL HAZARDS
- PHYSICAL HAZARDS: MACHINERY, TOOLS, OR NOISE EXPOSURE.
- CHEMICAL HAZARDS: TOXIC GASES, FLAMMABLE LIQUIDS, AND CHEMICALS.
- ELECTRICAL HAZARDS: FAULTY WIRING, ELECTRICAL OVERLOADS, OR SHOCKS.
- ERGONOMIC HAZARDS: POOR WORKING POSTURES OR REPETITIVE TASKS.
- FIRE AND EXPLOSION HAZARDS: DUE TO FLAMMABLE MATERIALS AND FAULTY EQUIPMENT.
Key Components of Industrial Safety
- Safety Training: Employees should be regularly trained in safety protocols.
- Protective Equipment (PPE): Use of gloves, helmets, safety goggles, and masks.
- Safety Audits and Inspections: Regular inspections to identify and mitigate risks.
- Emergency Preparedness: Plans for evacuation and firefighting measures.
- Accident Reporting Systems: Quick reporting helps in identifying root causes.
Industrial Safety Laws and Standards:
- Occupational Safety and Health Administration (OSHA): Enforces safety standards in the U.S.
- Factories Act, 1948 (India): Ensures safety, health, and welfare of workers.
- ISO 45001: An international standard for occupational health and safety management systems.
- Environmental Protection Regulations: Prevent industrial pollution and chemical spills.
- Company-Specific Guidelines: Many organizations implement in-house safety policies.
Technologies Enhancing Industrial Safety:
- Sensors and Alarms: Alert workers to potential dangers like gas leaks.
- Robotics: Reduces human exposure to hazardous tasks.
- IoT and Wearables: Tracks employee health and safety conditions in real-time.
- Automation: Minimizes manual handling of dangerous materials.
- AI-Powered Safety Systems: Predict risks and help prevent accidents.
Challenges in Implementing Industrial Safety:
- High Costs: Safety equipment and technologies can be expensive.
- Lack of Awareness and training: Workers may not always follow safety practices.
- Resistance to Change: Employees and employers might resist adopting new protocols.
- Maintenance Issues: Safety equipment needs regular upkeep and active.
- Compliance Pressure: Companies must continuously adhere to changing regulations.
There are several case examples of safety failure (Inadequate safety culture) in India as well as many places in the world like Bhopal Gas Tragedy (1984) India, Chernobyl Disaster (1986) Chernobyl Nuclear Power Plant near the city of Pripyat in northern Ukraine, Rana Plaza Collapse (2013) in Bangladesh etc.
Various kinds of Safety Negligence in Industry
LACK OF SAFETY TRAINING
- EMPLOYEES MAY NOT RECEIVE PROPER EDUCATION ABOUT HANDLING MACHINERY, HAZARDOUS MATERIALS, OR EMERGENCY PROCEDURES.
- EXAMPLE: A WORKER OPERATING HEAVY EQUIPMENT WITHOUT PROPER INSTRUCTIONS, INCREASING THE RISK OF ACCIDENTS.
IMPROPER EQUIPMENT MAINTENANCE
- FAILURE TO PERFORM ROUTINE INSPECTIONS, REPAIRS, OR REPLACEMENTS OF FAULTY MACHINES.
- EXAMPLE: IGNORING A MALFUNCTION IN PRESSURE VALVES, LEADING TO POTENTIAL EXPLOSIONS. ABSENCE OF PROTOCOLS FOR EMERGENCIES OR FAILURE TO ENFORCE EXISTING SAFETY STANDARDS.
- EXAMPLE: LACK OF FIRE DRILLS OR EMERGENCY EXIT ROUTES IN THE FACILITY.
INADEQUATE SAFETY POLICIES AND PROCEDURES
Failure to Provide Protective Gear (PPE)
- Workers may not receive or be required to wear safety gear like helmets, gloves, masks, or goggles.
- Example: Workers exposed to toxic fumes without respirators
Overworking Employees
- Excessive workloads and overtime can cause fatigue, impairing judgment and reaction times.
- Example: Sleep-deprived machine operators are more prone to make dangerous mistakes.
Ignoring Safety Audits or Reports
- Disregarding identified hazards or recommendations for improvements.
- Example: Continuing operations after inspectors highlight faulty safety equipment.
Violation of Legal Standards
- Failure to comply with occupational safety and health regulations.
- Example: Operating without required safety certifications or ignoring OSHA (Occupational Safety and Health Administration) mandates.
CAUTION: Negligence of safety in industry can result in devastating consequences for workers, businesses, and society. Proactive measures, a strong safety culture, and strict enforcement of standards are essential to mitigate risks and ensure a safe working environment.
Future of Industrial Safety
- Major application of Robotics and Automation: Reducing human exposure to dangerous tasks.
- Wearable Technology: Devices that monitor health indicators and environmental conditions.
- Augmented Reality (AR) Training: Enhancing safety education with immersive, virtual training.
- Sustainability-Driven Safety: Focus on eco-friendly safety practices to prevent both workplace and environmental hazards.
Stay Safe and keep others Safe!!
About the Author: Surjya Ganguly: Owner of Print-Pack-Tech International, Principal Consultant, Technocrat, National C.S., Lead Auditor (IRCA-UK), Technology Commercialization and Transfer Specialist, Motivational Speaker, Author (Technology & Management), Industry Expert (Printing & Packaging Industry).