1. Six Weeks Internship
Report On
Embedding Safety Culture at site by improving Lock-out
Tag-out Work instructions.
Submitted By: Atul Thakur
2. Indian Scenario
Indian confectionery market valued at INR 95 billion in 2012- 2013
Expected to touch INR 600 billion in 2016
Sugar confectionery hold market share of around 46%
Major Players- Nestle, Perfetti Van Melle, Mars India, Amul, Parle, ITC,
Candico.
In chocolate section – Cadbury holds market share of 65%
Nestle holds market share about 20%
Emerging Trend of gifting Confectionery products
Impulse buying
3. Company Profile
company was founded on April 1, 1891
Subsidiary of Mars Incorporated, acquired on April 28, 2008
Currently selling its products in 180 countries.
Maintains 140 factories in various countries including US, Mexico,
Australia, India, Canada, UK, Korea etc.
Mars Principles- Quality, Responsibility, Mutuality, Efficiency,
Freedom.
Associates are putting the Mars Principles in action every day to
make a difference
4. Major Products Of Company
Spearmint
Juicy Fruit
Altoids
Life Savers
Doublemint
Orbit
Winterfresh
Boomer
PimPom
Solano
Boomer Jelly On Top
5. ESH Department
Vision - “Protecting the Safety of People and Enhancing the Quality of
Life for our Associates, their families and communities”
Manager- Mr. Deepak Rai
Coordinator – Mr. Dinesh Gautam
The main objective of the department is to foster a safe and healthy work
environment.
Committed towards the goal of zero accident workplace.
6. Safety can be important for Moral, legal and financial reasons.
Moral obligation would involve the protection of employee’s health
Legal reasons to prevent Punitive and compensatory effects of laws that
protect worker’s safety and health
It reduce employee injury and illness related costs, including medical care,
sick leaves and disability benefit costs.
7. Lock-Out Tag-Out
Lockout/Tagout is a procedure used to ensure that machines, or
systems are isolated from their hazardous energy source.
This eliminates inadvertent activation while work is being performed
on the equipment, and protects other workers in that area.
Applicable to all the maintenance or servicing activities.
Types Of Energies- Electrical. Mechanical, Pneumatic, Hydraulic,
Steam, Chemical, Hot Water.
8. Six Steps Of Lock-Out Tag-Out
Preparation for shutdown
Shut down the equipment
Equipment isolation
Application of Lockout/Tagout devices
Release of stored energy
Verifying equipment isolation
10. Lock-Out Exception Permit
required for any adjusting or setting required to be done in running
machine by removing fixed guard / bypassing any interlocks or any
safety device.
Issued when problem is not identified in shutdown mode.
allows the associate to remove the fixed guard or bypass any interlock
guard and observe the problem when machine is running on inching
mode.
11. Requirement of LOTO SOPs
Total lines – Boomer, Boomer MP, Boomer JOT, Duet, Candy,
Gumbase, Dive, Airwaves.
Total no. of Machines or Equipment- 190 machines
Why need arises????
The observations of LOTO skill survey conducted at site was that :
Six steps of LOTO procedures were not clear .
As the SOPs are in English.
13. Lock-out Tag-out Survey
Conduct a survey as a part of training to analyze the knowledge of the
shop floor associates regarding LOTO procedure.
To know the problems faced by them during LOTO procedure.
And to check what they think about there safety in the organization
On the basis of my literature review I conclude that the main parameters
that effects safety during LOTO procedure are:
Knowledge about the equipment.
Procedure of energy isolation.
Availability of Lock & Tag.
Standard procedure of LOTO.
Safety Training.
14. Research Methodology
Objective: To find out that whether the Lock-Out Tag-Out work
Instructions improves safety culture in organization.
Sampling Frame: I considered the shop floor associates who are
working on different equipment and generally engage in maintenance
and servicing activities.
Target population and sample place: Shop floor associates of the
organization.
Sample Size: 40 Shop floor associates who work on different
equipment or machines taken as sample as being part of project based
assignment on Lock-Out Tag-Out instructions.
Sampling Method: I choose random sampling technique in different
lines to select my sample, to get data from the associates of different
lines.
Data Analysis: The data is analyzed by SPSS program.
15. Skill Survey Questionnaire
What is to be included in LOTO?
Safety is the top priority of the organization.
All the hazardous energies associated with equipment are well known.
LOTO is the best way to eliminate hazards during maintenance and servicing
(cleaning) activities.
New LOTO SOP helps you to understand 6 steps of LOTO procedure.
LOTO equipments are easily available.
Proper training is provided to you for the usage of LOTO equipment.
There is strict need that every person working on equipment during
maintenance or servicing activities should individually attach there lock and tag
on equipment.
You feel safe during minor intervention activities.
You feel safe after taking LOTO exception permit
LOTO falls under the Mars Zero Tolerance Policy.
Pre shift inspection is enough to ensure safety.
LOTO can be removed only after informing to all associates and removing all
the tools.
16. Findings
During preparation of LOTO SOPs
No system for verification of release of steam energy on Boomer
Mixers 1, 3, 5.
No system for verification of release of steam energy on JOT
Cooker 1, 3, 4.
There are still some pneumatic ball valves are used that requires additional
accessories during Lock-out Tag-out.
we replaces these valves with automatic pneumatic valves on Solano milk
tank, auto feeder, Duet Cooker & PimPom Metal detector
MCBs are used as electric switch in many machines that also requires
additional accessories during Lock-out Tag-out.
No system for verification on Carton Sealing Machines.
17. Recommendations
A system should be provided to verify release of steam energy on Boomer
Cooker 1, 3, 5, and JOT Cooker 1, 3, 4.
All the pneumatic ball valves should be replaced with the automatic
pneumatic valves to ensure safety of the associates.
MCB boards should be replaced by electric LOTO switches.
By that time MCB LOTOs should be provided to associates with proper
training of how to use this LOTO.
A system should be provided how to verify energy isolation on carton
sealing machines.
18. Finding
Lock-out Tag-out Survey
62.5% of the respondents said that LOTO equipments are not easily
available.
62.5% of the respondents said that they do not feel safe after taking
LOTO exception permit
Only 20% of the respondents able to explain the complete procedure
of group LOTO removal.
19. Recommendations
Al l the MCB boards and pneumatic ball valves should replaced by electric
LOTO switch and automatic pneumatic valve.
The associates do not having clarity about LOTO exception permit, proper
training is to be provided on LOTO exception permit.
Proper training should be provided to the associates on group LOTO
removal procedure.
