Industrial Safety
RajagiriTechThe course is designed to provide a comprehensive understanding of safety management principles, safety systems, machine guarding methods, hazard identification techniques, and various energy sources along with their applications in modern industrial contexts, while emphasizing the importance of safety in today’s evolving technological environment; it enables learners to evaluate and compare different hazard identification tools and select the most appropriate methods based on specific industrial needs, and also equips them with the necessary knowledge and skills to undertake project work and pursue research in related areas.
Syllabus
Module 1: Fundamentals of Industrial Safety and Risk Awareness
Need for safety, Safety and productivity, Definitions: Accident – Injury - Unsafe act - Unsafe Condition - Dangerous Occurrence - Reportable accidents. Theories of accident causation, Safety organization: objectives, types, functions.
Stakeholder Roles in Industrial Safety: management, supervisors, workmen, unions, government and voluntary agencies. Safety policy, Safety Officer - responsibilities, authority, Safety committee - need, types.
Introduction to Safety 4.0 and Industry 4.0 in safety, Digital transformation in safety systems, Role of Cyber-Physical Systems (CPS) in hazard prevention.
Module 2: Personal protection in work environment
Types of PPEs, Personal protective equipment: respiratory and non-respiratory equipment, Standards related to PPEs, Smart PPE, IoT-based safety monitoring systems.
Monitoring Safety Performance: Frequency rate - severity rate - incidence rate - activity rate. Housekeeping: Responsibility of management and employees - Advantages of good housekeeping - 5s of housekeeping. Work permit system: objectives - hot work and cold work permits. Typical industrial models and methodology, Entry into confined spaces.
Module 3: Construction Safety Hazards
Introduction to construction industry and safety issues in construction, Safety in various construction operations – Excavation and filling – Under-water works – Under-pinning & Shoring – Ladders & Scaffolds – Tunneling – Blasting – Demolition – Confined space – Temporary Structures, Safety Standards and code for high altitude working condition. Familiarization with relevant Indian Standards and the National Building Code provisions on construction safety. Sustainability and ESG in safety, Relevance of ergonomics in construction safety. Ergonomics Hazards - Musculoskeletal Disorders and Cumulative Trauma Disorders.
Module 4: Safety hazards in machines
Machinery safeguard: Point-of-Operation - Principle of machine guarding - types of guards and devices. Safety in turning and grinding, welding and cutting, Safety precautions of gas welding and arc welding. Material handling: Classification - safety considerations - manual and mechanical handling - Handling assessments and techniques – lifting – carrying – pulling – pushing - palletizing and stocking. Material handling equipment: operation & maintenance. Maintenance of common elements: wire rope - chains slings – hooks - clamps. Hearing Conservation Program in Production industries.
Industrial automation safety, Collaborative robots-cobots and human-robot interaction safety.
Module 5: Hazard identification and analysis
Hazard and risk, Types of hazards, Classification of Fire, Types of Fire extinguishers, fire explosion and toxic gas release, Structure of hazard identification and risk assessment, Identification of hazards, Inventory analysis, Fire and explosion hazard rating of process plants: The Dow Fire and Explosion Hazard Index - Preliminary hazard analysis - Hazard and Operability study (HAZOP) – methodology, criticality analysis, corrective action and follow-up. Control of Chemical Hazards, Hazardous properties of chemicals, Material Safety Data Sheets (MSDS), AI-assisted hazard identification.
Module 6: Introduction to Bureau of Indian Standards
Standard - need, aim and benefits of standards, types of standards, History of standardization – international level and national level, Introduction to Bureau of Indian Standards (BIS): objectives, roles and functions of BIS, Bureau of Indian Standards act, Purpose of standardization, Marking and certification of articles and processes, Importance of standards to industry, policy makers, trade, sustainability and innovation, Standardization in safety systems. International standards and frameworks: ISO 45001 (Occupational Health & Safety), OSHA regulations and global practices, Concept of Dark factory.
| COURSE PLAN | |
| WEEK 1 | |
| Module 1_Session 1 | Need for safety, Safety and productivity, Definitions: Accident – Injury - Unsafe act - Unsafe Condition - Dangerous Occurrence - Reportable accidents |
| Module 1_Session 2 | Theories of accident causation |
| Module 1_Session 3 | Safety organization: objectives, types, functions, Safety committee - need, types |
| WEEK 2 | |
| Module 1_Session 4 | Stakeholder Roles in Industrial Safety: management, supervisors, workmen, unions, government and voluntary agencies |
| Module 1_Session 5 | Safety policy, Safety Officer - responsibilities, authority |
| Module 1_Session 6 | Introduction to Safety 4.0 and Industry 4.0 in safety, Digital transformation in safety systems, Role of Cyber-Physical Systems (CPS) in hazard prevention |
| WEEK 3 | |
| Module 2_Session 1 | Types of PPEs, Personal protective equipment: respiratory and non-respiratory equipment |
| Module 2_Session 2 | Standards related to PPEs, Smart PPE, IoT-based safety monitoring systems |
| Module 2_Session 3 | Monitoring Safety Performance: Frequency rate - severity rate - incidence rate - activity rate |
| Module 2_Session 4 | Housekeeping: Responsibility of management and employees - Advantages of good housekeeping - 5s of housekeeping |
| Module 2_Session 5 | Work permit system: objectives - hot work and cold work permits |
| Module 2_Session 6 | Typical industrial models and methodology, Entry into confined spaces |
| WEEK 4 | |
| Module 3_Session 1 | Introduction to construction industry and safety issues in construction |
| Module 3_Session 2 | Safety in various construction operations – Excavation and filling – Under-water works – Under-pinning & Shoring |
| Module 3_Session 3 | Ladders & Scaffolds – Tunneling – Blasting – Demolition – Confined space – Temporary Structures |
| Module 3_Session 4 | Safety Standards and code for high altitude working condition. Familiarization with relevant Indian Standards and the National Building Code provisions on construction safety |
| Module 3_Session 5 | Sustainability and ESG in safety |
| Module 3_Session 6 | Relevance of ergonomics in construction safety. Ergonomics Hazards - Musculoskeletal Disorders and Cumulative Trauma Disorders |
| WEEK 5 | |
| Module 4_Session 1 | Machinery safeguard: Point-of-Operation - Principle of machine guarding - types of guards and devices |
| Module 4_Session 2 | Safety in turning and grinding, welding and cutting, Safety precautions of gas welding and arc welding |
| Module 4_Session 3 | Material handling: Classification - safety considerations - manual and mechanical handling - Handling assessments and techniques – lifting – carrying – pulling – pushing - palletizing and stocking |
| Module 4_Session 4 | Material handling equipment: operation & maintenance. Maintenance of common elements: wire rope - chains slings – hooks - clamps |
| Module 4_Session 5 | Hearing Conservation Program in Production industries |
| Module 4_Session 6 | Industrial automation safety, Collaborative robots-cobots and human-robot interaction safety |
| WEEK 6 | |
| Module 5_Session 1 | Hazard and risk, Types of hazards, Classification of Fire, Types of Fire extinguishers, fire explosion and toxic gas release |
| Module 5_Session 2 | Structure of hazard identification and risk assessment, Identification of hazards, Inventory analysis |
| Module 5_Session 3 | Fire and explosion hazard rating of process plants: The Dow Fire and Explosion Hazard Index - Preliminary hazard analysis |
| WEEK 7 | |
| Module 5_Session 4 | Hazard and Operability study (HAZOP) – methodology, criticality analysis, corrective action and follow-up |
| Module 5_Session 5 | Control of Chemical Hazards, Hazardous properties of chemicals, Material Safety Data Sheets (MSDS) |
| Module 5_Session 6 | AI-assisted hazard identification |
| WEEK 8 | |
| Module 6_Session 1 | Standard - need, aim and benefits of standards, types of standards, History of standardization |
| Module 6_Session 2 | International level and national level, Introduction to Bureau of Indian Standards (BIS): objectives, roles and functions of BIS, Bureau of Indian Standards act |
| Module 6_Session 3 | Purpose of standardization, Marking and certification of articles and processes |
| Module 6_Session 4 | Importance of standards to industry, policy makers, trade, sustainability and innovation |
| Module 6_Session 5 | Standardization in safety systems. International standards and frameworks: ISO 45001 (Occupational Health & Safety), OSHA regulations and global practices |
| Module 6_Session 6 | Concept of Dark factory |
Course Instructor
Dr. Jeffin Johnson
